FLATPACK

Rev.5
September 2002


Updated versions may be available
Flatpack 1500
The rectifier module in the new Eltek Medium Range Systems
Power Density
Power density
230 VAC: 0.648 W/cm
3

10.58 W/inch
3

120 VAC: 0.278 W/cm
3

4.53 W/inch
3


W x D x H= 214 x 243 x 41.5 (mm)
8.43 x 9.57 x 1.64 (inches)
SMPS 1000 SI
1000W, convection
cooled
Flatpack 1500
1400W, fan cooled
SMPS 1000 SI
vs. Flatpack 1500
Power density
230 VAC: 0.26 W/cm
3

4.23 W/inch
3


W x D x H= 66.8 x 220 x 264 (mm)
2.63 x 8.66 x 10.39 (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
312
185
150
85
0
200
400
600
800
1000
1200
1400
1600
0 50 100 150 200 250 300 350
Input Voltage (VAC)
O
u
t
p
u
t

P
o
w
e
r

(
W
)

0
200
400
600
800
1000
1200
1400
1600
60 65 70 75 80 85 90 95 100
Ambient Temperature (degC)
M
a
x
i
m
u
m

A
v
a
i
l
a
b
l
e

P
o
w
e
r

(
W
a
t
t
s
)

Power Derate with Respect to
Temperature (230VAC Input)
Comment: Measured on a stand-alone rectifier module
Flatpack 1500 (48V)
MODULE DATA
Input voltage: 0-85 VAC no output
85-150 VAC 500 W at 48 VDC
150-185 VAC 1100 W at 48 VDC
185-300 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 LED
Internal
rectifier failure
Power LED
Rectifier On
No fault
2 fans
LED bargraph
10 green LEDs indicate output
current from 0 Amps to 29 Amps
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
The capacity is increased by adding more power shelves
19 horizontal mounting
19 horizontal mounting
Two rectifiers mounted in a 1U Power Shelf
19 horizontal mounting
1U Power Shelf rear view
Mains
input
terminals
RJ45 connectors
for internal
system
communication
DC
output
terminals
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
DC output on
top of MCBs.
Max 25 mm
2
Alarm
outputs
max 2.5 mm
2
19 horizontal mounting
with 3U distribution

Mains input Load MCBs Battery Fuses
19 horizontal mounting
with 3U distribution
Front
Top
Rear
Side
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
AL 175 NT
Flatpack 1500
7 kW 16.8 kW
Implement Flatpack 1500 rectifiers into existing Power Rack Systems
Intermediate PRS Solution
Highly 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 disconnect
Advantages
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
Power Tower
19 horizontal mounting
Different distribution units
for different needs
1U 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 & 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)