350005 013 UserGde Powerpack 3PhAC DC Rectifier Mod 2v0ev

350005.013

User's Guide

3Ph AC DC Rectifier Module480 VAC & 208 VAC Modules

DC Power Supply Systems

Powerpack

1 Welcome

2 User’s Guide Powerpack Rectifier Modules, 350005.013, 2v0ev-2006-12

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.

Certificate no: 900005E

Copyright ©: Eltek Valere, Norway 2007

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. The heatsink is not earthed, and can therefore contain hazardous voltages. See electric shock symbols

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

When the equipment is installed in USA or Canada, the installation has to comply with the NEC/CEC requirements, see page 12

CAUTION! Triple pole/neutral fusing. In 480 VAC systems, fuses F1, F2, F3 must only be replaced with Bussmann KTK-25, rated 600V, 25A

CAUTION! Triple pole/neutral fusing. In 208 VAC systems, fuses F1, F2, F3 must only be replaced with Bussmann JJN-50L, rated 300V, 50A

WARNING! For safety reasons (high leakage current and high touch current) you must always connect the AC earth wire (PE) to the terminals, before you connect the AC input cable(s).

The equipment is only to be installed in Restricted Access Locations (RAL). Access must be limited by the use of tool, i.e. lock and key

Please read the manual carefully before using the equipment 350005.013 Issue 2.0ev, 2006 Dec Published 2006-12-01 Mfm

1 Welcome

User’s Guide Powerpack Rectifier Modules, 350005.013, 2v0ev-2006-12 3

Table of Contents

1. Welcome 4

About this Guide ............................................................................................................. 4 System Diagram ⎯ Powerpack DC Power System ........................................................ 4

2. Powerpack Rectifier 5

Key Features ................................................................................................................... 5 Typical Applications ........................................................................................................ 5

3. Installation of Powerpack Rectifiers 6

Safety Precautions .......................................................................................................... 6 Mounting and Removing Rectifiers ..................................................................... 6 Connections ........................................................................................................... 7 CAN Bus Addressing (plug-and-play) ................................................................. 7

4. Operation 8

Front Panel Interface ............................................................................................. 8 LCD Display & Modes of Operation ................................................................................ 8 Front Keys ....................................................................................................................... 8 LED Indicators ................................................................................................................ 9 Operating Menu ─ User Options ..................................................................................... 9

5. Technical Specifications 10

Specifications Powerpack 480 VAC, 48 VDC, 11 kW ............................................................. 10 Specifications Powerpack 208 VAC, 48 VDC, 11 kW ............................................................. 11 NEC/CEC Requirements for Installations in USA and Canada .............................................. 12

1 Welcome


1. Welcome Congratulations on your purchase of the powerful Powerpack DC power supply system, which uses the new Powerpack modules ⎯ the powerful 3 phase AC DC rectifier modules with high power density.

About this Guide This booklet provides users of Powerpack DC power systems with the required information to install and operate the Powerpack rectifier modules. The booklet also presents the rectifier’s technical specifications, such as input voltage range, output power, operating temperature range, etc. Read also the general and site specific documentation that was delivered with your Powerpack DC power system.

System Diagram ⎯ Powerpack DC Power System The Powerpack rectifier module is the building block of Powerpack Power Supply systems, see Figure 1. The Smartpack controller monitors and controls the whole system, and serves as the local user interface between you and the system. The PowerSuite application enables you to configure and operate system from a personal computer.

Figure 1 Example of a typical Powerpack PS system for DC supply of telecom equipment

Powerpack Cabinetized

Fuse Alarm

Telecomequipment

DC Supply(48V)

AC Supply (three-phase)

Alarm Outputs NC-C-NODigital Inputs

Load Fuses & MCBs

Smartpack ctrl. unit

PowerSuiteApplication

USB cable

DC distribution

Analogue Inputs

AC Fuses, external 480VAC, 3Ph

L1

L2

L3 (PE)

Powerpackrectifiers CAN Bus

2 Powerpack Rectifier


2. Powerpack Rectifier The Powerpack rectifier module is a digitally controlled switch mode power supply.

The rectifier works in stand-alone mode or in parallel with other rectifiers, then communicating via CAN bus with the system’s Smartpack controller and other connected rectifiers. Powerpack DC power systems are implemented by mounting the rectifiers in 23” power shelves.

A wide range of features are implemented in the Powerpack rectifier, as mentioned below.

Key Features

Highest efficiency Rectifier technology utilizes soft switching and three-level boost and buck converters, making the module efficiency industry leading and compact in size.

Local module monitoring Display and push buttons enable easy local monitoring of the individual rectifier, as an addition to the Smartpack monitoring.

Heat management Front-to-back air flow — with chassis integrated heat-sinks and chimney — gives the module the best reliable working environment.

CAN bus networked The Powerpack rectifier is connected in a CAN bus network for communication with the controller and other rectifiers.

Unique connection A real plug & play connection system: reducing time-to-install related cost. User-friendly handles lock the module to the power shelf.

Global approvals Powerpack is CE marked, UL recognized and NEBS certified for world wide installation.

Typical Applications Powerpack based systems are designed for supplying high quality DC power to equipment in medium and large telecom systems, IT power systems and similar applications.

Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost efficient and compact DC power systems. Powerpack rectifiers deliver an industry leading space saving power density of 650W per liter. Broadband and network access Increasing network speed demands flexible and expandable DC power solutions. The Powerpack rectifier is your key building block for future needs.

3 Installation of Powerpack Rectifiers


3. Installation of Powerpack Rectifiers Safety Precautions

Get acquantied with the satety precautions on page 2, before installing or handling the equipment1.

Mounting and Removing Rectifiers The Powerpack rectifiers incorporate handles that serve both to lock the modules into position and to pull them out of their housings.

Mounting the Powerpack rectifier (not hot-pluggable)

1. Turn OFF the switch on the left side of the module’s front panel

2. Unscrew and open the handles by pulling them out of their housings

3. Remove plastic cover and insert the module fully into the power shelf. The cover protecting the terminals is located in the power shelf’s back panel

4. Lock and screw the handles by pushing the handles flat with the front panel (locked position), and securing them with the screws. Do not turn ON the switch until you are ready for electrical installation

Removing the Powerpack rectifier

1. Turn OFF the switch on the left side of the module’s front panel

2. Unscrew and open the handles by pulling them out of their housings

3. Remove the module and snap the plastic cover use both handles to pull the module loose from the connectors; support from underneath. Snap the cover tightly, to protect the power shelf’s terminals

Figure 2 Powerpack rectifiers’s locking mechanism

1 For installations in the USA and Canada, refer to the NEC/CEC requirements, page 12.

Device hazard

CAUTION: The rectifiers are heavy and may be warm; hand-carry them by their handles. Before inserting or removing the modules from the power shelves, turn off the switch on the rectifier’s front (not hot-pluggable) and open both handles.

WARNING: Mount blind panels in unused module locations. Electricshock

Unscrew to openthe handle

Switch in OFFposition

Screw to secure the handle

Handle in locked position

Powerpack rectifier

Rectifier with open handles

Protective plastic covers on back panel

Locking knobs recessed

3 Installation of Powerpack Rectifiers


Connections All connections are implemented by inserting the Powerpack module fully into the power shelf, thus plugging the rectifier to the connectors on the self’s back panel.

Figure 3 Powerpack module’s rear plug-in connections to power shelf’s back panel

For details about other power shelf signals, system connections, etc., please read your system’s standard and specific documentation, or contact your dealer or Eltek Valere representative.

CAN Bus Addressing (plug-and-play) When a Powerpack rectifier is plugged in the power shelf, and its switch turned ON the first time, the Smartpack controller automatically assigns the rectifier with the next available ID number (CAN bus address). The rectifier will retain its ID (and serial number), even after removing and reinserting it in the power shelf. The rectifiers’ IDs are assigned from 1 and upwards. When a module is plugged in, the Smartpack controller automatically increases the number of communicating rectifiers in the CAN network.

DC Output Blades

-48V (-)0V (+)

L1L2

L3(PE) CAN-L, CAN-H

and Alarm Signals

AC Input and BusConnections

in 480 VAC Systems

Location of AC Input and Bus Connections in 208 VAC Systems

Power Shelf back panel connections

Powerpack Rectifier rear plug-in connectors

DC OutputModule 0V (+)

DC OutputModule -48V (-

AC Input and Bus Connectorin 480 VAC Systems

Location of AC Input and Bus Connector in 208 VAC Systems

Devicehazard

WARNING: Always connect the AC earth wire (PE) to the terminals, before you connect the AC input cable(s).

CAUTION: The Powerpack system must be connected to AC earth (PE). Electric shock

4 Operation


4. Operation This chapter describes the Powerpack rectifier’s keys and indicators, and how to operate the rectifier locally from the front panel.

Front Panel Interface

The Powerpack rectifier’s front panel consists of two functional areas: the presentation area (LCD display and LED lamps) and the control area (keys). For information about the handles, read page 6.

Figure 4 Powerpack rectifier’s front keys and indicators

LCD Display & Modes of Operation The graphic display is an important part of the power supply system’s user interface. The display is in Status Mode (displays the system’s status) or in Menu Mode (displays the menu structure). Depending on the display’s mode, the upper line shows the output current or menu options, while the lower line displays output voltage, alarms, or information about which key to press. Notice that if no keys are pressed within 30 seconds, the display will automatically switch from Menu Mode and to back to Status Mode.

Front Keys You can control the Powerpack rectifier via a network of software menus accessed with the module’s front keys.

o Press on the key to change from Status Mode to Menu Mode.

o Press the or keys to scroll up or down and navigate to find menu options (function or parameter).

o Press then the key to select the function.

You can also control the Powerpack rectifier via the control panel on the system’s Smartpack controller. All rectifiers communicate with the system’s controller via the CAN bus.

Power LED Lamp (green)

Warning LED Lamp (yellow)

Alarm LED Lamp (red)

Graphical Display16 character x 2 lines LCD display

”Up” arrow key

”Down” arrow key ”Enter” key

Upper lineOutput voltage or

menu optionsLower line

Load current, alarms, orkeys to press

Screw to secure handle

4 Operation


LED Indicators The Powerpack rectifier has the following LED indications:

• “Power” (green) indicates that the power supply is ON or OFF • Warning (yellow) indicates an abnormal situation (minor alarm) • Alarm (red) indicates an alarm situation (major alarm)

The following events will activate the Powerpack rectifier’s front LEDs:

LED Status Description

Power (green)

ON Rectifier is powered

Flashing Smartpack controller accessing information on the rectifier OFF Mains are unavailable Warning (yellow)

ON

Rectifier is in Derating Mode (reduced output power) due to high internal temperature, or low input voltage

The remote Battery Current Limit is activated Rectifier in stand-alone mode (or loss of communication

with the Smartpack controller OFF No abnormal situation is present Alarm (red)

ON

Rectifier is in Shut-down Mode due to low mains, or high internal temperature, or high output voltage

Internal rectifier failure (malfunction) Fan failure (single or double fan malfunction) Low output voltage CAN bus failure

OFF No alarm situation is present Refer also to chapter “Technical Specifications”, page 10.

Operating Menu ─ User Options

The Powerpack’s functionality is accessed via a network of software menus and submenus, enabling you to configure and control the power supply. While in Status Mode, press the key to switch to Menu Mode (Level 1); Press the key again to select the User Options.

User menu <UserOption> OutVolt

OutCurr

NomVolt

Module Info CurrLim

Temp 1

Temp 2

InVolt 1

InVolt 2

InVolt 3

Product No

Serial No

SW Info 1

SW Info 2

Level 2 Level 3

5 Technical Specifications


Applicable Standards Electrical safety IEC 60950-1

UL 60950-1

EMC ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) NEBS Telcordia GR-1089 CORE

Harmonics EN 61000-3-2

Environment ETSI EN 300 019-2 (-1. -2, -3) ETSI EN 300 132-2 NEBS Telcordia GR-63 CORE Zone 4

Specifications are subject to change without notice. 241246.000.DS3 v.02

5. Technical Specifications

Specifications Powerpack 480 VAC, 48 VDC, 11 kW

DC Output Voltage 53.5 VDC (adj. range: 43-58.5 VDC)

Output Power 11 kW at nominal input Derating below 430 VAC

Maximum Current 230 Amps at 48 VDC and nominal input

Current Sharing ±3% from true average current between modules

Static voltage regulation

±0.5% at 0-100% load

Dynamic voltage regulation

±3.5% for 10-90% or 90-10% load variation, regulation time < 10ms

Hold up time > 20ms; output voltage > 44 VDC at full load

Ripple and Noise < 100 mV peak to peak, 30 MHz bandwidth

< 2.0 mVrms psophometric

Output Protection Over-voltage shutdown (level adjustable)

Overload and Short circuit proof High temperature protection

Other Specifications Efficiency Typical 92%

Isolation 3.0 kVAC – input / output 1.5 kVAC – input / earth 1.0 kVDC – output / earth

Rectifier Alarms o Low mains alarm o High mains alarm o Low output voltage alarm o Over voltage shutdown alarm o Current limit alarm o Current sharing alarm o Fan Alarm o Temperature alarm o Rectifier failure alarm

Visual indications Green LED: ON, no faults Red LED: rectifier failure Yellow LED blinking: no communication Yellow LED solid: derating power

User interface LCD and 3 push buttons ON/OFF switch

Operating temp -10 to +70°C (-40 to +158°F) Derating above +55°C (+131°F)

Storage temp -25 to +85°C (-13 to +185°F)

Cooling Fans (front to back airflow) ball bearing

Fan Speed Temperature regulated

MTBF > 200, 000 hours Telcordia Issue I, method III (a) at 20°C ambient

Acoustic Noise < 72dBA

Humidity Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing

Dimensions 23” x 2U x 500 mm (wxhxd)

Weight 18.5 kg (40.8 lbs)

AC Input Voltage Nominal: 430 – 530 VAC 3ph

Tolerances: 260-550 VAC 3ph

Frequency 45 to 66Hz

Maximum Current

16.5 Arms maximum at nominal input and full load

Power Factor > 0.99 at 50% load or more @480VAC

Total Harmonic distortion

(THD)

< 5% at 50% load or more @480VAC

Input Protection Varistors for transient protection Mains fuse in all lines



Applicable Standards Electrical safety IEC 60950-1

UL 60950-1

EMC ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) NEBS Telcordia GR-1089 CORE

Harmonics EN 61000-3-2

Environment ETSI EN 300 019-2 (-1. -2, -3) ETSI EN 300 132-2 NEBS Telcordia GR-63 CORE Zone 4

Specifications are subject to change without notice. 241246.100.DS3 v.01

Specifications Powerpack 208 VAC, 48 VDC, 11 kW

AC Input Voltage Nominal: 185 – 250 VAC 3ph

Tolerances: 180 – 264 VAC 3ph

Frequency 45 to 66Hz

Maximum Current 38.5 Arms maximum at nominal input and full load

Power Factor > 0.99 at 50% load or more @208VAC

Total Harmonic distortion (THD)

< 5% at 50% load or more @208VAC

Input Protection Varistors for transient protection Mains fuse in all lines

DC Output Voltage 53.5 VDC (adj. range: 43-58.5 VDC)

Output Power 11 kW at nominal input

Maximum Current 230 Amps at 48 VDC and nominal input

Current Sharing ±3% from true average current between modules

Static voltage regulation

±0.5% at 0-100% load

Dynamic voltage regulation

±3.5% for 10-90% or 90-10% load variation, regulation time < 10ms

Hold up time > 20ms; output voltage > 44 VDC at full load

Ripple and Noise < 100 mV peak to peak, 30 MHz bandwidth

< 2.0 mV rms psophometric

Output Protection Over voltage shutdown (level adjustable)

Overload and Short circuit proof High temperature protection

Other Specifications Efficiency Typical 92%

Isolation 3.0 kVAC – input / output 1.5 kVAC – input / earth 1.0 kVDC – output / earth

Rectifier Alarms o Low mains alarm o High mains alarm o Low output voltage alarm o Over voltage shutdown alarm o Current limit alarm o Current sharing alarm o Fan Alarm o Temperature alarm o Rectifier failure alarm

Visual indications Green LED: ON, no faults Red LED: rectifier failure Yellow LED blinking: no communication Yellow LED solid: derating power

User interface LCD and 3 push buttons ON/OFF switch

Operating temp -10 to +70°C (-40 to +158°F) Derating above +55°C (+131°F)

Storage temp -25 to +85°C (-13 to +185°F)

Cooling Fans (front to back airflow) ball bearing

Fan Speed Temperature regulated

MTBF > 200, 000 hours Telcordia Issue I, method III (a) at 20°C ambient

Acoustic Noise < 72dBA

Humidity Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing

Dimensions 23” x 2U x 500 mm (wxhxd)

Weight 18.5 kg (40.8 lbs)



NEC/CEC Requirements for Installations in USA and Canada When the equipment is installed in USA or Canada, the installation has to comply with the NEC/CEC requirements, such as:

Security • The Powerpack module is only to be installed in Restricted Access Locations

(RAL)

AC Mains Input • Power Cables

o Minimum size of AC input cables: 6mm2 (8 AWG), 600V o Input cables are to be crimped on terminals, that should be pushed

into the tube in the plug until it enters the front area of the plug

• Input Circuit Breakers o Input circuit breakers should be:

- In 480 VAC systems: 30A, 600V, Breaker Characteristic curve C - In 208 VAC systems: 60A, 300V, Breaker Characteristic curve C

o Short circuit breaking current, minimum 6kA

• Terminal Blocks o If the modules are not installed in a power system, the input

terminal block should be of minimum 10mm2 (6 AWG), 600V

• Earth Connection o The Powerpack module/system must always be connected to earth.

Module Installation

• The internal switch in the front of the module must always be turned OFF before the module is removed or installed in the power shelf.







www.eltekvalere.com Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Eltek ValereGråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway

Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

Copyright © Eltek Valere 2007This document may be changed without notice

Art. No. 350005.013, Issue 2.0ev, 2006 DecPublished 2006-12-01

Documents

350005 013 UserGde Powerpack 3PhAC DC Rectifier Mod 2v0ev