Installation and Operation Guide

Flatpack 125A System

1503287
Revision 1
May 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 express written permission of
ELTEK ASA.
Copyright ©: ELTEK Energy 2004

Corporate Headquarters:
ELTEK Energy AS
P.O. Box 2340 Strømsø
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

 Contents

1 INTRODUCTION ...............................................................................................................................................4

2 GENERAL INFORMATION.............................................................................................................................5
2.1 DIMENSIONS AND WEIGHT .............................................................................................................................6
2.2 TOTAL DC CURRENT......................................................................................................................................6
2.3 LIST OF TOOLS REQUIRED ..............................................................................................................................6
2.4 UNPACKING THE SYSTEM ...............................................................................................................................7
2.5 MECHANICAL MOUNTING ..............................................................................................................................7
2.6 ENVIRONMENTAL INFORMATION ...................................................................................................................7
2.7 SYSTEM OVERVIEWS ......................................................................................................................................8
3 AC CONNECTIONS...........................................................................................................................................9
3.1 AC SERVICE WIRING OPTIONS.......................................................................................................................9
3.1.1 AC Input Current and Wiring Ratings ....................................................................................................9
3.2 INSTALLING AC FEED CONNECTIONS ..........................................................................................................10
3.2.1 AC Input Connection.............................................................................................................................10
3.2.2 Input Termination Details.....................................................................................................................11
3.2.3 Completion of AC Wiring......................................................................................................................11
4 DC CONNECTIONS.........................................................................................................................................12
4.1.1 General .................................................................................................................................................12
5 ALARM AND CONTROL WIRING ..............................................................................................................13
5.1 MCU INTERFACE PCB CONNECTOR ARRANGEMENT .................................................................................13
5.1.2 Control and Alarm Electrical Specifications ........................................................................................16
5.1.3 Control and Alarm Terminations..........................................................................................................16
6 SYSTEM MONITORING ................................................................................................................................16

7 FINAL CONNECTION CHECK.....................................................................................................................17

TABLE 5 – DC POWER WIRE SIZING GUIDE .............................................................................................................................................12

TABLE 6 – ALARM RELAY SPECIFICATIONS ...........................................................................................................................................16
TABLE 7 – HARDWARE TORQUE SPECIFICATIONS................................................................................................................................17

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Introduction

1 Introduction
Eltek Energy is a world leader in the development of new power supply systems, designed to meet the rapid growth
within the field of telecommunication, as well as the increasingly stringent reliability requirements.

With the introduction of microelectronics in electronic equipment, energy distribution and telecommunication and
data systems technology require a guaranteed, uninterruptible power supply and to meet this demand, Eltek Energy
make in-depth investments in all types of scientific research, technical development, and experimental
mathematical modeling of thermal characteristics of components and systems.

The ultimate in reliability is secured through innovative new technologies and topologies, which reduces the size of
the power blocks and extend the operating range, thereby increasing efficiency and reducing costs. Eltek Energy
invests heavily in research and development - with highly qualified engineers and research scientists working with
the most advanced development platforms available, we are able to offer tailor-made solutions - a key factor for
penetrating new markets.

A modern power supply system must fulfill various international standards and regulations while, at the same time,
meeting market requirements. Increased awareness of Electromagnetic Compatibility (EMC), especially in Europe,
has resulted in Eltek’s investment in an EMC test laboratory. This laboratory not only ensures that products comply
with relevant standards, it is also utilized throughout product development. The EMC test laboratory forms part of
Eltek’s extensive in-house test facility.

Electronic equipment for data and telecommunications require supply voltages generated from the AC mains, as
well as from battery-assisted DC voltage. Intensive development work has produced power supply systems
designed to meet both present and future power requirements, and the development of control and alarm modules
make our power supply systems a market leader. Programmed functions monitor operating conditions, load and
battery. Should problems be detected, the operator will be notified immediately, either via the telephone network,
or via Ethernet. Shutdowns can thus be avoided for critical applications.

Eltek’s software expertise is constantly expanding the remote communication capabilities of our systems, using
standard network protocols such as SNMP and HTTP.

Eltek Energy AS accepts no responsibility for any damage or injury to the system, site or personnel caused by
drawings, instructions or procedures not prepared by Eltek Energy.

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 General Information

2 General Information
This manual provides detailed instructions for installing the Flatpack® FP1UD AM, 1U 125A power system.

Flatpack Power Systems are made up of Power Shelves for plug-in rectifier modules, a DC distribution that
includes a monitoring and control unit and optional batteries.

The power shelves include the necessary amount of rectifiers needed in the system. The DC distribution may
include fuses, circuit breakers, and load and/or battery disconnect contactors, as well as a Monitoring & Control
Unit.

This document contains information about the Flatpack FP1UD AM-125A DC system. It includes information
about alarm connections, DC connections and optional equipment, together with a description on how to install the
distribution.

Flatpack FP1UD AM-125A is a 1U high, front access, DC distribution unit designed for mounting into 19” rack
cabinets. All load and battery connections are available at the rear of the unit. Alarm output connections are located
on the rear of the unit, on the far right side as viewed from the rear, behind the monitoring unit. Box-clamp
terminals are provided for the AC mains input connections, in a compartment in the left rear corner (rear view) of
the rectifier power rack. An optional removable rear cover prevents accidental contact with the mains wiring after
installation.

The system can be mounted into customer equipment racks or it can be supplied in Eltek’s own racks. The unit can
be flush-mounted or mid-mounted. Extenders are available for installation into ETSI standard or 23” racks.

The FP1UD AM-125A DC System contains the LVD contactors and all interconnecting bus work, and the Flatpack
Monitor and Control Unit (MCU). All DC electrical interconnections are bolted copper bus bar connections for
maximum reliability and minimum voltage drop.

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General Information

2.1 Dimensions and Weight

Total system height at maximum build-out with Flatpack® rectifiers. A maximum of two power racks can be
supplied. This system is then 3U (5.25” or 133.3mm) tall. The system is designed for flush or NEBS (mid)
mounting in 19”and 23” EIA, or 21” (ETSI) equipment racks.

Overall system depth is 11.6” (295mm). Mid mounting: horizontal protrusion is 5 inches (127mm) from the front of
the equipment rack rail and 6.5 inches (165mm) behind the front rack mounting surface.

The fully equipped (1 LVD contactor) 1U distribution system (core section) alone weighs approximately 12.3 lbs
(5.6 kg). Models with no LVD contactors weigh slightly less.

2.2 Total DC Current

The Flatpack® 1U Distribution supports up to four Flatpack® rectifiers for up to 120 amperes of total charge current.
Shunt and conductor ratings allow a maximum of 125A battery discharge (load) current.

2.3 List of Tools Required

Caution: Use of fully insulated tools is required when working with any powered AC
or DC circuits. Never work alone. If insulated tools are not available, do not apply AC
power or make any battery connections.

The following tools are required for the installation:

Standard wrench and/or socket set (1/4” to 1”)

Torque wrench (see Table 3 for required range)

Small flat blade screwdriver or awl (3/32” maximum width)

Standard and Phillips tip screwdrivers

Wire cutters / strippers

Hoist with lifting straps (optional)

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 General Information

2.4 Unpacking the System

Rectifiers are shipped separately in their own cartons.

Depending on ordering options, the MCU system controller may also be packed separately, or it may be pre-
installed in the 1U distribution panel.

The assembled system should be lifted by two persons in order to maintain control over the assembly while moving
and/or mounting in the host cabinet.

After unpacking the system, inspect the assembly for damaged or missing components. Report any problems to
Eltek Energy’s Customer Care department.

Once the system has been unpacked and inspected, then secure the system into the final mounting location in the
host cabinet prior to making electrical connections.

2.5 Mechanical Mounting

The system is designed to mount in an EIA standard equipment cabinet having 1.75” rack unit spacing and EIA
standard mounting hole spacing.

Typically, #12 SAE hardware is used to retain the system assembly within the host cabinet; in some cases #10 SAE
hardware may also be used. Under no circumstances should hardware smaller than #10 SAE be used to mount the
system into the cabinet rack rails.

Use of paint penetrating rack mounting screws is recommended to ensure adequate ground bonding between system
components. At least two such screws should be used at each component mounting position (one in each side
bracket).

Caution: All mounting bracket hole locations must be populated in order to ensure
structural integrity of the system within the host cabinet.

2.6 Environmental Information

The system is designed to operate in the following environment:

• Operating ambient temperature: -40 to +65 degrees C (MCU controller / LCD display –10 to +55 degrees C).

• Storage ambient temperature: -40 to +85 degrees C.

• Relative Humidity: 0-95%, non-condensing

• Elevation: -200 to 5000 feet (-61 to 1524 meters). Between 5000 feet (1524 m) and 13000 feet (3962 m), the
ambient temperature is derated by 2°C (3.6°F) per 1000 feet (302 m) as the altitude increases.

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General Information

2.7 System Overviews

Distribution
and Control

AC Input Power rack

Terminals 1

Power rack
2

AC Alarm &
Wire way DC Bus Bar Control
Cover Cover Figure 1 – Rear View, DCD 125A System Connections
Breaker/fuse
Connections
Cover

Breaker/Fuse
MCU Cover removed
System Controller

Rectifier Figure 2 – Front Perspective Assembly View

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 AC Connections

3 AC Connections
The electrical installation will be detailed in sections. The AC input wiring will be detailed first, followed
by the DC wiring.

3.1 AC Service Wiring Options

AC input power is connected to the rear of the rectifier racks. Wiring entry points are sized for ½” (trade
size) conduit, EMT, or protective bushings / grommets.

AC connections are made directly to the AC mains input terminal blocks on the rectifier power racks. AC
wiring access and entry is from the rear of the assembly. An entry point for EMT (conduit) is provided at
the side of the assembly. Depending on installer preference and installation requirements, wiring may be
either routed through the entry hole provided, or individual AC line cords may be connected directly to the
AC input terminals and anchored to a (customer-supplied) wire management and support system.

3.1.1 AC Input Current and Wiring Ratings

The Flatpack 700 rectifier is a constant power device, operating over an input range of 85 to 300VAC.
From 85 to 99V input, output power is limited to 600 watts. From 99V to 312V input, output power is
limited to 700 watts. Each power rack accepts up to two (2) rectifiers.

The Flatpack 1500 rectifier is a constant power device, operating over an input range of 85 to 275VAC.
From 85 to 150V input, output power is limited to 600 watts. From 150V to 185V input, output power is
limited to 1130 watts. From 185V to 275V input, output power is limited to 1500 watts. Each power rack
accepts up to two (2) rectifiers.

Maximum low-line input current per rectifier is approximately 9 amperes for the Flatpack 1500 and 7.5
amp for the Flatpack 700. For the Flatpack 1500 a 20 ampere service feeder / circuit breaker does not
provide sufficient margin, and cannot be used to feed two (2) rectifiers at some line voltages. The next
higher standard service feeder rating is 30 amperes. It is acceptable to utilize a 25 ampere circuit if local
codes permit this configuration, otherwise a 30 ampere rated circuit must be used in the indicated
configurations. For the Flatpack 700 a 20 ampere service feeder / circuit breaker can be used to provide
power to one power rack (two rectifiers).

All wiring calculations are based on the 1999 National Electric Code, tables 310-16 and C4. The wire
selection is based on the use of copper wire with 90°C rated insulation installed in a design ambient
temperature of 65°C.

Use of wire sizes other than factory recommendations must take into consideration the wire insulation
ratings, maximum ambient temperature, and type of wire enclosure.

Eltek Energy is not responsible for any hazards resulting from incorrect wire size determinations. Contact
the factory if assistance is required in determining alternative wire sizing.

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AC Connections

3.2 Installing AC Feed Connections

Caution: Before proceeding, verify that all AC circuit breakers feeding the
system are in the OFF position. Never work alone.

3.2.1 AC Input Connection

Remove the rear AC wire way cover, if supplied, to gain access to the rectifier power rack input terminals.
See Figure 1. A #2 Philips screwdriver is required to remove the screws retaining the cover. Do not
remove the DC bus bar cover.

3.2.1.1 One Feed per Rectifier

In this arrangement, each power rack requires two separate AC feeds, and a maximum of six (6) each, 15-
ampere 120 VAC or 208/220/240 VAC single-phase service feeds are required. #14 AWG wire is
recommended and up to #10 AWG may be used. See Figure 3 for connector arrangement and Figure 4 for
termination procedure. The optional shorting jumpers shown in Figure 3 are not installed in this
configuration.

3.2.1.2 One Feed per Power Rack (two rectifiers per feed)
In this arrangement, each power rack requires a single AC feed, and a maximum of three (3) each, 30-
ampere 120 or 208/220/240 VAC single-phase service feeds are required. #12 AWG wire is recommended
and up to #10 AWG may be used. See Figure 3 for connector arrangement and Figure 4 for procedure.
Note that the red jumpers connect the two rectifiers’ individual feeds together for a single AC power feed
per rectifier power rack. These jumpers are shipped attached to the rectifier power racks for on-site
installation. Remove the jumpers from their packaging and install as shown in Figure 3.

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 AC Connections

3.2.2 Input Termination Details

OPTIONAL
SHORTING JUMPERS

POSITION #1 POSITION #6
PE / GROUND NO CONNECTION

POSITION #5
LINE 2 / NEUTRAL,
POSITION #2
RECTIFIER 1
LINE 1, RECTIFIER 2
Figure 3 – Power Rack AC wiring arrangement POSITION #4
POSITION #3 LINE 2 / NEUTRAL,
LINE 1, RECTIFIER 1 RECTIFIER 2

Note that Rectifier 1 is on the left side as viewed from the front of the system.

Caution: Incorrect shorting jumper installation may result in equipment damage or

personal injury due to an electrical short circuit. If use of jumpers is required, verify
locations are exactly as shown prior to applying AC power.

Step 1: Insert tool into Step 2: Push up on tool

opening above wire to release tension clamp
entry

Step 3: Insert wire into

lower opening, then
release and remove tool
Figure 4 – AC wiring installation procedure

3.2.3 Completion of AC Wiring

After connecting and termination of all AC feeds in accordance with the procedures outlined
above, replace any protective covers previously removed before continuing to the next section.
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Alarm and Control Wiring

4 DC Connections
4.1.1 General
125A Flatpack systems with the 1U 125A distribution are typically configured at the factory for the
required DC power level. In most cases, this will be the maximum number of rectifier power racks
supported by the 125A distribution.

A protective sheet metal rear cover, which encloses the external DC bus bars between rectifier power
racks, is provided on the rear of the assembly. It is not necessary to remove this cover during
installation of the equipment.

A protective sheet metal front cover, which prevents accidental contact with the circuit breakers, is
supplied with the equipment. Remove this cover, to gain access to the distribution devices.

DC Power Wire Sizes

Based on 0.5 Volt Drop for Based on 0.75 Volt Drop for
DC Current, Amps
100 Loop Feet 100 Loop Feet
50 One #1/0 AWG One #1 AWG
75 One #3/0 AWG One #1/0 AWG
125 Two #1/0 AWG or one 250 MCM One #3/0 AWG
Table 1 – DC Power Wire Sizing Guide

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 Alarm and Control Wiring

5 Alarm and Control Wiring

All alarm wiring is accessible from the rear of the system. Connections are to CON3, CON4, and CON5.
These are removable connectors. Each terminal accepts wire in the range of #22 AWG to #14 AWG.

5.1 MCU Interface PCB Connector Arrangement

Standard functionality (6 relays) version only is available on this product. Note that CON5 numbering is
reversed from that of CON3 and CON4. The DCD-3FM-200A common equipment section includes a
label with the connection information as shown below.

5.1.1.1 Customer Connections

CON2 CON3 CON4 CON5

PIN11 PIN20 PIN1 PIN18

PIN1 PIN10

CON4 PIN ASSIGNMENT (for basic PCB version part no. 100350)
PIN DESCRIPTION
1 Digital Input 1 (When shorted to AGND (PIN2), the input will be de-activated)
2 AGND
3 Digital Input 2 (When shorted to AGND (PIN4), the input will be de-activated)
4 AGND
5 Digital Input 3 (When shorted to AGND (PIN6), the input will be de-activated)
6 AGND
7 Digital Input 4 (When shorted to AGND (PIN8), the input will be de-activated)
8 AGND
9 Symmetry Alarm 2 (Digital input referred to AGND (PIN9). For use together with external symmetry alarm PCB(`s).
10 AGND
11 Symmetry Alarm 1 (+) (Analog measurement between PIN11 and PIN12)
12 Symmetry Alarm 1 (-) (Analog measurement between PIN11 and PIN12)
13 Symmetry Alarm 3 (+) (Analog measurement between PIN13 and PIN14)
14 Symmetry Alarm 3 (-) (Analog measurement between PIN13 and PIN14)
15 AUX. power output (+) (20Vdc/ 200mA (21V ±5%) Intended for powering a modem)
16 AUX. power output (-) (20Vdc/ 200mA (21V ±5%) Intended for powering a modem)
17 Not in use
18 Temperature sensor (+) (For connection of temperature probe)
19 Temperature sensor (-) (For connection of temperature probe)
20 Temperature sensor (cable screen)

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Alarm and Control Wiring

CON5 PIN ASSIGNMENT (for basic PCB version part no. 100350)
PIN DESCRIPTION PIN DESCRIPTION
1 Alarm relay 6 NC (Alarm relay output) 10 Alarm relay 3 NC (Alarm relay output)
2 Alarm relay 6 NO (Alarm relay output) 11 Alarm relay 3 NO (Alarm relay output)
3 Alarm relay 6 C (Alarm relay output) 12 Alarm relay 3 C (Alarm relay output)
4 Alarm relay 5 NC (Alarm relay output) 13 Alarm relay 2 NC (Alarm relay output)
5 Alarm relay 5 NO (Alarm relay output) 14 Alarm relay 2 NO (Alarm relay output)
6 Alarm relay 5 C (Alarm relay output) 15 Alarm relay 2 C (Alarm relay output)
7 Alarm relay 4 NC (Alarm relay output) 16 Alarm relay 1 NC (Alarm relay output)
8 Alarm relay 4 NO (Alarm relay output) 17 Alarm relay 1 NO (Alarm relay output)
9 Alarm relay 4 C (Alarm relay output) 18 Alarm relay 1 C (Alarm relay output)

5.1.1.2 Internal System Connections

CON 6 JP1

CON 2 CON 3

Figure 5 – Interface PCB Detail

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 Alarm and Control Wiring

The connectors CON2 and CON3 have the same pin assignment. CON6 is only mounted on the extended
version PCB (not supplied with this model). CON3 is used for rectifier and power shelf communication.
All three connectors are only used for internal system wiring, which has been done at the factory. These
connectors are not involved in the system installation and commissioning process. The tables below show
the pin assignment for CON2 and CON6.

CON2 PIN ASSIGNMENT

Pin no. Name Description Classification
1 Batt curr + Current measurement, battery A/I
2 Batt curr - Current measurement, battery A/I
3 Rect curr + Current measurement, rectifier A/I
4 Rect curr - Current measurement, rectifier A/I
5 Power + Power for Flatpack Monitoring/Control Unit O
6 Power - Power for Flatpack Monitoring/Control Unit O
7 Vdc+ Voltage measurement, dc bus voltage A/I
8 Signal ref/Vdc- Voltage measurement, dc bus voltage A/I
9 DI Batt fuse Battery fuse state D/I
10 Load fuse Load fuse detection D/I
11 LVD1 Contactor control O
12 LVD2 Contactor control O

CON6 can be used to get an alarm via voltage free change over contacts, if the battery/load disconnect
contactor(s) fail to change state, or remains mechanically locked in any state. The contactors must be
equipped with alarm switch(es). CON6 is only used to improve the connectivity to external equipment.
The alarm signal(s) from the alarm switch(es) are connected to CON6 so they can be obtained on CON4
for easy connection to external monitoring equipment.
The same alarm(s) can be transmitted to a remote/local management station via software in Flatpack
MCU, if the signal(s) are connected directly to any of the programmable digital input(s) on CON4. See
“Flatpack MCU Operation Guide” for detailed information about digital inputs and how they are
programmed in software.

CON6 PIN ASSIGNMENT

Pin no. Name Description
1 LVD1 status For internal wiring to alarm switch on LVD1. Obtained on CON4 for external connection
2 LVD1 status For internal wiring to alarm switch on LVD1. Obtained on CON4 for external connection
3 LVD2 status For internal wiring to alarm switch on LVD2. Obtained on CON4 for external connection
4 LVD2 status For internal wiring to alarm switch on LVD2. Obtained on CON4 for external connection

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 Alarm and Control Wiring

5.1.2 Control and Alarm Electrical Specifications

Note: CON5 / Power Out is limited to ~400mA and is intended for connection of optional Eltek DC
powered monitoring equipment only. Do not use CON5 for any other type of connections, or to power
any equipment not supplied by Eltek Energy.

See “Flatpack MCU Operation Guide” for detailed information about digital inputs and how they are
programmed in software.

5.1.2.1 Alarm relay specification

Nominal switching capacity 2A/30V DC
Maximum switching power 60W (resistive load)
Maximum switching voltage 220V DC
Maximum switching current 2A DC
Table 2 – Alarm Relay Specifications

5.1.3 Control and Alarm Terminations

Strip approximately 3/8” (1cm) of insulation from each wire and insert it in the connector’s tension clamp
to terminate each wire.

A small flat blade screwdriver, awl, or similar tool, maximum 3/32” (2mm) wide, is required to release the
tension while inserting the wire. The tool opening in the connector is 0.100” (2.5mm) wide. Insert the tool
into the connector to release the clamp tension. Insert the wire and then release and remove the tool. See
Figure 6 for example.

Figure 6 – Tension Clamp, Tool Insertion Detail

6 System Monitoring
The Flatpack system can be monitored locally or from a remote location via the Flatpack MCU Monitoring &
Control Unit. The Flatpack MCU monitors and controls the entire rectifier system including distribution and
batteries, as well as other equipment on site.

Please refer to the Flatpack MCU Operation Guide, for detailed information about system monitoring and control.

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 System Monitoring and Final Connection Check

7 Final Connection Check

Observe all of the connections have been properly installed. Compare to the appropriate drawings provided with the
system to be certain all is complete. Once this has been verified, tighten all attaching hardware to the following
torque specifications.

Hardware Size Torque

¼ - 20 NC 4.25 - 11.0 Ft. Lb.
3/8 – 16 NC 15 - 38 Ft. Lb.
Table 3 – Hardware Torque Specifications

This completes the Flatpack 1U 125A System Installation and

Operation Guide. Consult the MCU Controller and Flatpack
Rectifier Operation Guides for startup information.

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ELTEK Energy
P-O- BOX 2340 Strømsø
3003 DRAMMEN
NORWAY

Phone: +47 32 203 200

Telefax: +47 32 203 210
Internet: http://www.eltekenergy.com
E-mail: eltek@eltek.no