Flatpack Introduction

FLATPACK

Rev.5 September 2002

Updated versions may be availableFlatpack 1500 The rectifier module in the new Eltek Medium Range Systems

Power DensityPower density230 VAC:0.648 W/cm310.58 W/inch3120 VAC:0.278 W/cm3 4.53 W/inch3

W x D x H=214 x 243 x 41.5 (mm)8.43 x 9.57 x 1.64 (inches)SMPS 1000 SI1000W, convection cooledFlatpack 15001400W, fan cooled

SMPS 1000 SI vs. Flatpack 1500

Power density230 VAC:0.26 W/cm34.23 W/inch3

W x D x H=66.8 x 220 x 264 (mm)2.63 x 8.66 x 10.39 (inches)

Flatpack 1500Key parameters: Maximum output power 1400 W Global input range: 85 300 VAC Automatic disconnect at input voltages > 300 VAC Wide temperature range: -40C to +70C (-40F to +158F) Compact and flexible (1U high/2 rectifiers in 19 width) Vertical or Horizontal mounting Hot swap (output diode) Fan cooled Cost efficient Automatic de-rating of output power at low input voltage and/or high ambient temperatures Easy and quick mounting and removal

Flatpack 1500 Input Voltage vs. Output Power3121851508502004006008001000120014001600050100150200250300350Input Voltage (VAC)Output Power (W)020040060080010001200140016006065707580859095100Ambient Temperature (degC)Maximum Available Power (Watts)Power Derate with Respect to Temperature (230VAC Input)Comment: Measured on a stand-alone rectifier moduleFlatpack 1500 (48V)MODULE DATA Input voltage:0-85 VAC no output85-150 VAC 500 W at 48 VDC150-185 VAC 1100 W at 48 VDC185-300 VAC 1400 W at 48-59 VDC> 275 VAC - reduced power factor> 300 VAC - disconnection from mains and automatic reconnect Power Factor:> 0.99 Efficiency:> 90% Output power:1400 W from 48V to 59V (230 VAC input)(de-rated in lower input range) Output current: 29 Amps at 48V Ripple/noise:< 100mVp-p < 0.96mV psophometric noise Hold-up time:> 10ms Ambient temp: -40C to 70C (-40F to +158F)(Power limiting may occur > 40C (104F)) Dimensions:214 x 243 x 41.5mm (8.8 x 9.8 x 1.64) (WxDxH) Approvals:IEC/EN 60950, UL 1950 IEC/EN 60215, BS3192 FCC 68, GR-1089-CORE

Flatpack 1500 (48V)

Alarm LEDInternal rectifier failurePower LEDRectifier On No fault2 fansLED bargraph10 green LEDs indicate output current from 0 Amps to 29 AmpsFlatpack 2U Power System

19 horizontal mounting 1U high building blocks: 44.45mm (1.75) Allows optimal utilisation of rack height The 1U Power Shelf accommodates 2 Flatpack rectifiers The 1U DC-distribution and monitoring unit is mounted on top

Flatpack 1U System Components for 19 rack mountingFlatpack MCU Monitoring & Control Unit (1U)Flatpack DCD 125A125A DC Distribution (1U)2 Flatpack 1500 rectifiers in a 1U high power shelf

The capacity is increased by adding more power shelves

19 horizontal mounting19 horizontal mountingTwo rectifiers mounted in a 1U Power Shelf

19 horizontal mounting

1U Power Shelf rear viewMains input terminalsRJ45 connectors for internal system communicationDC output terminals19 horizontal mounting with 3U distributionThe distribution on top will vary in size, depending on maximum current and the number of circuit breakers/fuses required19 horizontal mounting with 3U distribution Mains input Load MCBs Battery MCBs

Sample Flatpack Distribution Option

Common positive bar DC output on top of MCBs. Max 25 mm2Alarm outputsmax 2.5 mm219 horizontal mounting with 3U distribution Mains input Load MCBs Battery Fuses

19 horizontal mounting with 3U distributionFrontTop

RearSide19 horizontal mounting with 3U distribution Mains input Load MCBs Load Fuses Battery Fuses

Sample Flatpack in Cabinet Application

Intermediate PRS SolutionA comprehensive amount of PRS 700 system solutions have been made to fulfill many different customer and regional requirements. Compared with today's system solutions the Flatpack 1500 has the following improvements:

Improved operating temperature range (some old system designs may experience power de-ration at temperatures < 40C (104F))

Improved power density (convection cooled rectifiers require a lot of open space above and underneath to achieve a good airflow)

Wider input voltage range (De-rated output power at input voltages below 205 VAC and no high voltage disconnect)

New important features are added when replacing the SMPS 1000 with the Flatpack 1500 rectifier. A large range of existing system designs with various distribution solutions can be used.

Intermediate PRS SolutionAL 175 NTFlatpack 15007 kW16.8 kW

Implement Flatpack 1500 rectifiers into existing Power Rack Systems

Intermediate PRS SolutionHighly competitive systems can be made by replacing SMPS 1000 with Flatpack 1500 in standard PRS 700

Current system solutions are made highly competitive Short development time and short time to market More than twice the power density of a standard PRS 700 Utilizes existing distribution, monitoring and cabinet solutions Wider operating temperature range Wider input voltage range with high voltage disconnectAdvantagesFunctionality which is not included Digital inputs for monitoring of external equipment Individual control of two contactors Single/several rectifier alarmsFuture Flatpack SystemsNew cabinet designs based on the Flatpack 1500 rectifier, various rack mountable distribution units and the Flatpack MCU will be made. The main improvements will be: Increased flexibility (the systems can be designed with a building block approach)

Improved monitoring & control features using the Flatpack MCU

Reduced cost as more parts of the system can be manufactured in high volumes

Increased power density (the system designs will be even more compact, since the height of the monitoring unit including interface PCB is only 1U as opposed to today's 5U)

The rectifiers can be mounted vertically to achieve even higher power density in ETSI cabinets (15.4 kW in only 5U height)Future Flatpack Systems

A common MPSU solution

Future Flatpack Systems

Future Flatpack Systems

Outdoor Cabinets

Flatpack SolutionsPower Tower19 horizontal mountingDifferent distribution units for different needs1U Power Shelf

Front panel LCD and keypad for on-site service RS-232 for PC connection or remote monitoring & control via modem / SNMP Up to 11 configurable alarm relay outputs for traditional remote monitoring 4 configurable digital inputs for monitoring of other equipment on site Battery monitoring and testing (manual & automatic) Temperature Compensated Charging for increased battery lifetime Hot Plug-In Password protected operator access levels Alarm/event log with time and date Windows based software for easy access and configuration (WinPower Silver)

Highlights Flatpack MCU

Remote Monitoring & ControlOptions for remote monitoring & control Potential free relays (6 or 11 form C contacts) Modem with call-back functionality SNMP direct connection to TCP/IP network connection using micro-wave WinPower Silver through TCP/IP Web browser (future option)