Flatpack DC/DC 24/48 and 48/24 Converters

35

1550

.013

Operation Guide

Flatpack DC/DC 24/48

Flatpack DC/DC 48/24 and

1 Scope

Flatpack DC/DC 24/48 and DC/DC 48/24 Converter Modules Art. 351550.013, v3-2006-07 2

Information in these documents is subject to change without notice and does not represent a commitment on the part of Eltek Energy AS.

No part of these documents 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 2006 EMC Generic Immunity Standard EN50082-1 Residential, Commercial and Light Industry EN50082-2 Industrial Environment Generic Emission Standard EN50081-1 Residential, Commercial and Light Industry EN50081-2 Industrial Environment

LVD LVD73/23/EEC Low Voltage Directive

NS-EN ISO 9001:1994 Certificate no: 900005Q NS-EN ISO 14001:1996 Certificate no: 900005E. This product holds a CE mark and satisfies all requirements covering relevant standards and directives. Eltek Energy AS PO Box 2340 Strms, N-3003 Drammen Grterudveien 8, N-3036 Drammen Norway Tel: +47 32 20 32 00 Fax: +47 32 20 32 10 E-mail: [email protected] Internet: www.eltekenergy.com

Art. No.: 351550.013 Issue 3, 2006 July

Published 2006-07-31

mfm

Certificate no: 900005E Certificate no: 900005Q

1 Scope


Contents

1. Scope 4

2. System Precautions 4

3. Main Features 5 General.......................................................................................................................5 Features .....................................................................................................................5

4. Installation Procedures 6 Safety Precautions............................................................................................6 Handles and Locking Mechanism....................................................................7 Installation of Modules .....................................................................................8

Signal Connections ....................................................................................................9 Removal of Units...............................................................................................9

5. Operating Instructions 10 General.....................................................................................................................10 Front Panel LED Indications.....................................................................................10

System Operation Flatpack DC/DC Converters............................................11

6. Interface 12 Visual Interface................................................................................................12 User Interface ..................................................................................................12 Converter Alarm..............................................................................................14 Error State Table and Fault-Finding ..............................................................14 Replacement of Fans ......................................................................................16

7. Technical Specifications 17 Technical Specification Flatpack DC/DC 48/24.............................................17 Technical Specification Flatpack DC/DC 24/48.............................................18

1 Scope


1. Scope The Flatpack DC/DC 24/48 and the Flatpack DC/DC 48/24 Converter Modules are designed for stand-alone use, or for working in parallel, as part of a DC-DC rack system. The converters are hot pluggable and have a blocking diode on the output for true redundancy.

High frequency switch mode technology is used to minimise volume and weight and to obtain fast output voltage regulation. The module has soft start power up.

When working in parallel the converters provide active current sharing via CAN-bus. An internal blocking diode allows hot plug-in and isolates any faults in the converters output the DC bus.

This manual includes a specification of the environmental limits of the converters, with regards to temperature range, humidity and acoustic noise.

Elteks Part Name Description Flatpack DC/DC 48/24 Flatpack 48/24 DC/DC Converter Module

Flatpack DC/DC Converter Flatpack 24/48 DC/DC Converter Module

2. System Precautions Before you start using a Flatpack DC/DC converter, it is essential you read this manual first. The manual employs consistent visual cues to help you locate and interpret information easily.

Symbol Meaning

; A note following this symbol provides important or critical information. 9 A note following this symbol clarifies or emphasises a recommendation.

3 Main Features


3. Main Features

General The Flatpack DC/DC converters are designed for use in telecom systems.

The Flatpack DC/DC 24/48V and 48/24V converters are intended to receive power from a 24V or a 48V telecom rectifier system and to deliver a fixed output voltage (for exact output values, please see chapter 7 in this manual). The converters are hot pluggable and have blocking diodes on the output for true redundancy. Parallel operation is possible, with active current sharing via CAN-bus.

The converters are intended for stand-alone operation, but some control and information retrieval will be possible when connected to a control unit with CAN-bus. The typical application will be that the DC/DC converters are installed into a 24V or a 48V telecom rectifier system and communicate with this systems control unit.

In a typical application, the input side will have the negative leg connected to earth, and the output side will have the positive leg connected to earth. These connections will be made on system level. The converter design is independent of system earthing, i.e. with floating input and output and with isolated CAN-bus.

Modern, yet well-proven technology makes the Flatpack DC/DC 24/48 and the Flatpack DC/DC 48/24 compact and reliable modules. In addition, a wide range of features is integrated, as mentioned below.

Features Front LED indicators, current LED bar graph and output voltage

adjustment point for stand-alone control and monitoring. Information regarding the modules status will, at all times, be accessible from the front.

Wide input voltage ranges Low voltage shutdown Temperature monitoring and automatic power limitation and shutdown at

high internal temperatures

True hot plug-in

4 Installation Procedures


4. Installation Procedures

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 module. As the modules incorporate large charged capacitors, it is dangerous to work inside them even if the DC 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.



Handles and Locking Mechanism The Flatpack DC/DC 24/48 and 48/24 converter modules are equipped with handles that serve two purposes:

1. To lock the module into position When the module is plugged into its slot, it is then locked into position using the handles on either side of the front panel. Once the module is in position the handles must be rotated into their housings and firmly pushed home; failure to do so will prevent the module from making proper contact.

Figure 1 Releasing the modules handles

2. To pull the module loose When both handles are released, use them to pull the module loose.

Figure 2 Module with released handles

5 Do not hold or hand-carry the module by its handles. 5 Use gentle force, when releasing the handles from their locked position

Handle in locked position

To unlock and release the handles, insert a small screwdriver into the holes in the upper corners of the modulesfront panel to release the spring mechanism. Do not use excessive force. The handle will release and pop out.



Installation of Modules

Figure 3 Connections accessible from the rear of Flatpack DC/DC 24/48 and DC/DC 48/24

Installation of Flatpack DC/DC 24/48 & 48/24 Converter Modules Step Comments OK

1. PLUG IN THE NEW UNIT

Insert a small screwdriver into the holes in the upper corners of the unit front panel and carefully rotate each lever downwards. Do not use excessive force The lever will release and pop out. Make sure that the levers are fully open and insert the unit into its slot in the system.

2. FASTEN THE MODULE Push the levers into their slots to lock the unit into position.

3. VERIFY THAT THE UNIT IS ON The green ON LED is lit and no alarm is activated.

4. MOUNT BLIND PANELS ON EMPTY UNIT POSITIONS

For safety reasons all vacant unit positions must be covered by blind panels

Output +ve

Output ve CAN busconnector

Input +ve

Input ve



Signal Connections

Figure 4 Signal connector as seen from the back of the unit

Plug no. / pin Name Comments A5 CanH Opto isolated B5 CanL Opto isolated C5 CanGnd Opto isolated C2 +5v Used for programming the C D1 P1 - Reset Used for programming the C C1 P2 - PTA0 - DIG1 Used for programming the C and output

voltage selection B1 P3 - IRQ - DIG2 Used for programming the C and output

voltage selection D2 Signal reference Used for programming the C and output

voltage selection A4 Shutdown + Opto isolated B4 Shutdown - Opto isolated C6 Module alarm C Alarm: common D6 Module alarm NO Alarm: Normally open B6 Module alarm NC Alarm: Normally closed A6 Module alarm NC critical Alarm: Normally closed via 2k2 resistor

Removal of Units Removal of Flatpack DC/DC 24/48 & 48/24 Converter Modules

Step Comments OK

UNLOCK THE LEVERS Insert a small screwdriver into the holes in the upper corners of the unit front panel and carefully rotate the lever downwards. Do not use excessive force The lever will release and pop out (see chapter Handles and Locking Mechanism, page 7 ).

PULL THE UNIT LOOSE Using both handles pull the unit forward to release it from the connector

SLIDE THE UNIT OUT Take hold of the unit and pull it out from its slot. Support the unit from below as it is being removed (If the unit has been in use for some time it may be hot!) Do not carry the unit by its levers.

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

5 Operating Instructions


5. Operating Instructions General

The Flatpack DC/DC 24/48 and 48/24 converter modules are designed for both stand-alone and parallel operation in a system.

When used as a stand-alone unit, the output voltage is adjusted on insertion to the back plane.

Front Panel LED Indications The front panel LEDs provide information regarding unit status and an LED bar graph shows how much current the unit is delivering (on a scale from 0 to 100%). A unit alarm signal provides an alarm, if there is any internal failure.

When operating in a system, local and remote monitoring can be achieved via the AEON monitoring & control unit. The unit is installed in a power shelf that provides parallel connection of several units and/or power shelves, either in 19, ETSI or 21 wide cabinets. Various DC distribution solutions provide connectivity for different amounts of load circuits and battery strings.

Figure 5 View showing front panel LED indicators in normal operation

Figure 6 View showing 4 units in normal operation (All green LEDs ON and equal number of bar graph LEDs ON)

Figure 7 View showing 4 units in asymmetric operation (All green LEDs ON and unequal number of bar graph LEDs ON)

The bar graphs show that the individual units are delivering different power outputs. This shows that the current sharing subsystem is inoperable, and may indicate a fault on the CAN-bus. It does not stop the system from delivering full load.

Bar graph showing % power output

ON / Alarm LED (Green in normal operation)

Shorter bar graph indicates the module outputs lower power

5 Operating Instructions


Figure 8 View showing Warning LED illuminated

When the warning LED is lit one of the following warnings has occurred:

LED bar graph (10 green LEDs) shows the output current on a scale from 0 to100%, each LED representing 10% output current. The unit delivers more than 23A, when all LEDs are lit, when the unit is in current limit operation the warning LED will be illuminated.

Single fan failure High temperature derating activated

Figure 9 View showing Alarm (red) Led illuminated

Status (red) indicates one of the following fault conditions:

DC input voltage out of range High temperature shutdown

Unit shutdown due to high internal temperature Fan Failure

Both fans has been stopped, or failed Internal malfunction

Internal failure Over voltage shutdown

The output voltage has been above safe level

The internal alarm relay is made failsafe, i.e. the relay coil is energized, when there is no alarm. The alarm relay is energized when the green LED, and only the green LED is lit.

System Operation Flatpack DC/DC Converters In a system configuration, the units are mounted in dedicated power shelves that provide parallel DC connection, DC feed and signal interconnection via a communication bus to the AEON unit.

The modules exhibit active load sharing when connected in parallel. Current sharing has the advantage that the MTBF will be equally distributed throughout the system.

Warning yellow LED ON

Alarm red LED ON

6 Interface


6. Interface

Visual Interface INDICATORS TYPE OF ALARM Red/Green LED Red: Module alarm

Green: Power OK Yellow LED Module warning:

Single fan failure High temperature / derating activated Current limit

Module alarm: DC input voltage out of range No output voltage Over voltage shutdown Both fans failed High temperature shutdown

Bar graph Output current, 2.3A per segment

User Interface Voltage adjustment: The module will read two digital inputs:

DIG1 and DIG2, (shorted to signal ref. = 0, open = 1). The output voltage will be set according to the table:

OUTPUT VOLTAGE DIG1 DIG2 48Vdc 0 1 53,5Vdc 1 0 55Vdc 1 1 56Vdc 0 0

Shutdown: Shutdown is possible both from an opto-isolated digital

input and via the CAN bus. Alarms: The alarm relay shall be activated by both Module

failure and Module warning Detailed alarm info shall be available on the CAN bus.

Information: When communicating with a CAN-based Eltek control module, it shall be possible to retrieve detailed module information according to the generic Eltek CAN-bus protocol (to be determined).

6 Interface


The following production data is stored in the module, and can be retrieved on demand:

INFORMATION LIMITATIONS Main Board Serial Num Unit Serial Num Main Board HW Revision

Maximum 6 characters. Character set: 0-9, A-D and period.

Main Board Article No. Maximum 16 characters. Character set: 0-9, A-D and period.

Unit HW Revision Maximum 6 characters. Character set: 0-9, A-D and period.

Unit Article No. Maximum 16 characters. Character set: 0-9, A-D and period.

Main Board Tested By Up to 4 ASCII characters Main Board Tested Date Unit Tested By Up to 4 ASCII characters Unit Tested Date Burn In By Up to 4 ASCII characters Burn In Date

In addition, the following information can be retrieved on demand

Converter type Version number SW Manufacturer (part of serial number) Hour counter Max. current Max. temperature Current limit operation High temperature derating /warning High temperature failure Internal temperature Output current Output voltage Fan failure alarm OVP alarm Low input voltage alarm High input voltage alarm Module failure SW download:

It is possible to download new software via the signal connector. Addressing :

Automatic (Plug and Play)

6 Interface


Converter Alarm If the Flatpack DC/DC converters operating environment (input voltage or temperature) is outside limits, or if the units have suffered an internal component failure, the Flatpack DC/DC converters will give an alarm via a common internal alarm relay. Also, the red alarm LED in the front panel will be lit.

Some of these alarms are automatically reset as soon as the source of the alarm is no longer present. The following circumstances may cause such an alarm:

Input voltage below limit (auto-recovery when input voltage is high enough)

High temperature shutdown

Other alarms are caused by more severe circumstances and a manual reset, or repair of the module might be necessary. The following circumstances will cause damage that will require repair of the module:

Input fuse(s) blown due to component failure. Fan failure. One or both fans have been stopped or failed Loss of internal supply voltage(s) due to internal component failure

The following circumstance can be manually reset on site

Over voltage shutdown. The unit will automatically shut itself down if its output is above the OVS limit. Unplug the rectifier from the system, let it discharge until all the bar-graph LEDs are dark and the warning LED should now be dark. If the alarm is still activated when the rectifier is re-installed it probably has an internal fault and needs repairing

Error State Table and Fault-Finding A summary of operating and failure modes of the module is given in table 1 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

GREEN LED ON

ALARM (RED) AND WARNING (YELLOW) OFF

ANY NUMBER OF BAR GRAPH LEDS ON

Normal operation No fault

ALL LEDS OFF Normal disconnect Input is disconnected from power source

6 Interface


SYMPTOM POSSIBLE ERROR HOW TO FAULT-FIND, RECOVER OR RESTART

LOW OUTPUT VOLTAGE

De-rating due to high internal temperature

To verify temperature de-rating: Determine the maximum rectifier current of the system. Read the measured rectifier current in the display of the monitoring units. If the value shown by the monitoring unit is less than the maximum rectifier current, the rectifier(s) have most likely de-rated the output power due to high temperature.

Module alarm:

Loss of input voltage

Observe the system. If all modules act equal, most likely errors are:

Line input voltage failure. The modules may have entered input voltage low protect mode. Check all system line input voltage fuses or circuit breakers. Measure line voltage, and check that it is not below the limit. See specifications

Internal shutdown:

Over voltage protection

If modules act differently, the most likely errors are:

Over voltage protection. Each unit monitors its own voltage and shuts down if an internal error makes the output voltage go above the legal level.

Remove the rectifier from the system and let it rest for one minute, and then reconnect it. If the green LED lights up and the alarm LED is OFF, the rectifier has assumed normal operation. If rectifier goes back to failure condition it should be removed for repair.

High temperature shutdown

Observe the ambient temperature. At temperatures above the specified limit, the rectifier may shut down to avoid internal damage.

Fan failure, both fans

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.

ALARM LED (RED) ON

ALL OTHER LED'S OFF

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

GREEN LED AND WARNING LED (YELLOW) ON, LED BAR GRAPH SHOWS MAX. READING

Overload Observe the system. If all modules act equal, most likely errors are:

Normal operation - current limit

To verify that the module is OK: Reduce load and verify that the yellow LED goes off

Fan failure, single fan

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.

WARNING LED (YELLOW) ON, LED BAR GRAPH SHOWS LESS THAN MAX. READING

High temperature derating activated

Observe the ambient temperature. At temperatures above the specified limit, the rectifier may derate to avoid internal damage.

6 Interface


Replacement of Fans The Flatpack DC/DC modules incorporate two fans that are located in the front of the converters. This procedure describes how to replace fans in the event of failure.

REMOVE THE CONVERTERS TOP COVER

Unscrew the screws on the sides, top and back of the converter. Remove the top cover and the front panel

REPLACE DAMAGED FAN(S) Note the orientation of the fan(s), unscrew and remove them Plug in the new fan(s) and fasten them in the same orientation.

ASSEMBLE THE FRONT PANEL AND COVER

Fit the plastic front panel into the bottom cover Fit the top cover and ensure that the plastic front fits into all the slots making sure that the front is not mounted up side down. Fasten the chassis screws on the sides, the top and back.

7 Technical Specifications


7. Technical Specifications Technical Specification Flatpack DC/DC 48/24

INPUT

Input Voltage range

40.0-60 VDC

Maximum Current 32 Amps at 40.0 VDC input Protection Soft start

Internal fuse Automatic shutdown for input voltages < 40 VDC and > 62 VDC

OUTPUT Output Voltage 24-28 VDC Output Power 1100 W at 27.5 VDC Output Current 40 Amps at 24 VDC Current Share 2 Amps Static Voltage Regulation

0.5% from 0 to full load

Dynamic Voltage Regulation

4.0% for 10-90% or 90-10% load variation

Ripple and Noise



Technical Specification Flatpack DC/DC 24/48

INPUT

Input Voltage range

19.8-32 VDC

Maximum Current 73 Amps at 19.8 VDC input Protection Soft start

Internal fuse Automatic shutdown for input voltages < 19.5 VDC and > 30 VDC

OUTPUT Output Voltage 55 VDC

(43-59 VDC adjustable) Output Power 1250 W Output Current 23 Amps Current Share 1 Amp Static Voltage Regulation

0.5% from 0 to full load

Dynamic Voltage Regulation

1.0% for 10-90% or 90-10% load variation

Ripple and Noise

www.eltekenergy.com

ELTEK Energy P-O- BOX 2340 Stms N-3003 DRAMMEN NORWAY Phone: +47 32203200 Telefax: +47 32203210 Internet: http://www.eltekenergy.com e-mail: [email protected]

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 Ltd. +769 22651108 Europe Eltek Energy UK Ltd. +44 1442 219355 +44 1442 245894 Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175

Flatpack DC/DC 24/48 and 48/24 Converters

Documents

Transcript of Flatpack DC/DC 24/48 and 48/24 Converters