FLATPACK

Rev.5 September 2002

Updated versions may be available

Flatpack 1500

The rectifier module in the new Eltek Medium Range Systems

Power Density
SMPS 1000 SI 1000W, convection cooled SMPS 1000 SI vs. Flatpack 1500 Flatpack 1500 1400W, fan cooled

Power density Power density 230 VAC: 0.26 W/cm3 4.23 W/inch3
W x D x H= 66.8 x 220 x 264 (mm)
2.63 x 8.66 x 10.39 (inches)

230 VAC: 0.648 W/cm3 10.58 W/inch3 120 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)

Flatpack 1500

Key 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 Power

1600
1400 Output Power (W) 1200 1000 800 600 400 200 150 185

85
0 0 50 100 150 200 250 300

312
350

Input Voltage (VAC)

Power Derate with Respect to Temperature (230VAC Input)

1600

Maximum Available Power (Watts)

1400 1200

1000 800

600 400

200 0 60 65 70 75 80 85 90 95 100

Ambient Temperature (degC)

Comment: Measured on a stand-alone rectifier module

Flatpack 1500 (48V)

MODULE DATA
Input voltage: 0-85 VAC 85-150 VAC 150-185 VAC 185-300 VAC > 275 VAC > 300 VAC 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 no output 500 W at 48 VDC 1100 W at 48 VDC 1400 W at 48-59 VDC reduced power factor disconnection from mains and automatic reconnect

Hold-up time: > 10ms Ambient temp: -40C to 70C (-40F to +158F) (Power limiting may occur > 40C (104F)) Dimensions: Approvals: 214 x 243 x 41.5mm (8.8 x 9.8 x 1.64) (WxDxH) IEC/EN 60950, UL 1950 IEC/EN 60215, BS3192 FCC 68, GR-1089-CORE

Flatpack 1500 (48V)

LED bargraph 10 green LEDs indicate output current from 0 Amps to 29 Amps

2 fans

Alarm LED Internal rectifier failure

Power LED Rectifier On No fault

Flatpack 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 mounting

Flatpack MCU Monitoring & Control Unit (1U) Flatpack DCD 125A 125A DC Distribution (1U)

2 Flatpack 1500 rectifiers in a 1U high power shelf

19 horizontal mounting

The capacity is increased by adding more power shelves

19 horizontal mounting

Two rectifiers mounted in a 1U Power Shelf

19 horizontal mounting

1U Power Shelf rear view

Mains input terminals

DC output terminals

RJ45 connectors for internal system communication

19 horizontal mounting with 3U distribution

The distribution on top will vary in size, depending on maximum current and the number of circuit breakers/fuses required

19 horizontal mounting with 3U distribution

Mains input

Load MCBs

Battery MCBs

Sample Flatpack Distribution Option

Common positive bar

Alarm outputs max 2.5 mm2

DC output on top of MCBs. Max 25 mm2

19 horizontal mounting with 3U distribution

Mains input

Load MCBs

Battery Fuses

19 horizontal mounting with 3U distribution

Front Side

Top
Rear

19 horizontal mounting with 3U distribution

Mains input

Load MCBs

Load Fuses Battery Fuses

Sample Flatpack in Cabinet Application

Intermediate PRS Solution

A 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 Solution

Implement Flatpack 1500 rectifiers into existing Power Rack Systems

7 kW
AL 175 NT

16.8 kW

Flatpack 1500

Intermediate PRS Solution

Highly competitive systems can be made by replacing SMPS 1000 with Flatpack 1500 in standard PRS 700 Advantages 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 disconnect Functionality which is not included Digital inputs for monitoring of external equipment Individual control of two contactors Single/several rectifier alarms

Future Flatpack Systems

New 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 Solutions

19 horizontal mounting

Power Tower

Different distribution units for different needs

1U Power Shelf

Highlights Flatpack MCU

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)

Remote Monitoring & Control

Options 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)