Installation Manual

Compact C-Shelf System

Compact DC Power Family

Part. No. DO600000021 Doc. No. 2067838, Issue 10
Published 10-Sep-12
DISCLAIMER
Information in this document is believed to be accurate as of the date of publication and is subject to
change without notice. This document and the information contained herein do not represent either
a commitment or any guarantee on the part of Eltek regarding the reliability, fitness, or compatibility
of the products and procedures described.
While every reasonable effort is made to ensure the accuracy and completeness of this document,
Eltek assumes no responsibility or liability for any damages that may be directly or indirectly
attributed to the use of the information contained within or to any errors or omissions.
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 expressed
consent of Eltek.

Copyright © 2012 Eltek

1303 E Arapaho Rd
Richardson, TX 75081
USA

Phone: +1 (469) 330-9100

Fax: +1 (469) 330-9101

Technical Support
+1 (800) 435-4872
techsupport.us@eltek.com

www.eltek.com

Doc. No. 2067838, Issue 10, September 2012

Published 10 September 2012

2 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 Table of Contents
Safety and Recommended Practices .....................................................4
FCC Compliance Statement ................................................................................................ 5
1. Overview ..........................................................................................6
Rectifier Specifications ........................................................................................................ 6
AC Input Requirements......................................................................................................... 7
AC Feed Sizing ............................................................................................................................ 9
AC Connector Requirements ................................................................................................ 10
DC Output Requirements ................................................................................................... 10
DC Reference Ground ............................................................................................................. 11
DC Output Wire Sizing............................................................................................................. 11
DC Lug Requirements ............................................................................................................. 12
Torque Settings .................................................................................................................... 14
Required Tools ...................................................................................................................... 14
2. Installation.................................................................................... 13
Site Preparation .................................................................................................................... 13
Mechanical Mounting .......................................................................................................... 14
Controller Connections....................................................................................................... 15
AC Input Connections ......................................................................................................... 15
Dual Feed.................................................................................................................................... 15
Single Feed ................................................................................................................................ 16
Individual Feed .......................................................................................................................... 18
DC Output Connections ...................................................................................................... 20
Proper DC Cable Routing ....................................................................................................... 20
Circuit Breaker Installation ................................................................................................ 22
3. Test and Turn-Up .......................................................................... 23
Power up ................................................................................................................................. 23
4. Replacement Items ....................................................................... 24
Controller ................................................................................................................................ 24
Rectifiers ................................................................................................................................ 24
LVD and Shunt (Optional) ................................................................................................... 24
Rectifiers ................................................................................................................................ 26
5. Troubleshooting ........................................................................... 27
Short Circuit and Current Limit......................................................................................... 27
6. Installationsanleitung (German) .................................................. 28
7. Revision Table ............................................................................... 29

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 3
Safety and Recommended Practices
For use in restricted-access locations only.
Suitable for mounting on concrete or other non-combustible surface only.
The Compact C-shelf DC Power System operates on an AC voltage between 100 V and 240
V, 50–60 Hz, and produces a regulated DC output of 20–56 V (depending on rectifiers
deployed; see ). It is capable of delivering a maximum DC output of 160 A in an ambient
operating temperature range of –40°C up to +62°C.
WARNING: HAZARDOUS VOLTAGE AND ENERGY LEVELS CAN PRODUCE SERIOUS
SHOCKS AND BURNS. Only authorized, qualified, and trained personnel should
attempt to work on this equipment. The equipment is to be connected to supply mains by
a qualified personal in accordance with local and national codes (e.g. NEC, CEC, etc). Refer
to datasheets for full product specifications.
WARNING: For safety, the power supply is required to be reliably connected to
PROTECTIVE GROUND. Do not disconnect and reconnect I/O power connectors
during a lightning storm. Equipment meets GR-1089 Surge requirements and is intended
for deployments where an external Surge Protective Device (SPD) is not utilized.
Observe all local and national electrical, environmental, and workplace codes.
Each power shelf should be fed from a dedicated AC branch circuit of a terra neutral (TN)
power system.
The plug end of an AC line cord is considered to be the primary disconnection means, and
reasonable access must be given to the plug and receptacle area. The receptacle must be
fed with a breaker or fuse according to NEC requirements.
For hard-wired AC connections, a readily accessible disconnection device must be
incorporated in the building installation wiring. Select circuit breaker sizes according to
national and local electric codes.
CAUTION: All rectifiers employ internal double pole/neutral fusing. Fuses are not
field-replaceable.
The output of the power supply is not intended to be accessible due to energy hazard.
Use Underwriters Laboratories (UL)-listed, double-hole lugs for all DC connections to
prevent lug rotation and inadvertent contact with other circuits. Terminal strip
connections require only single-hole lugs.
Wire rated for 90°C is recommended for all DC connections. In practice, wires of a size
larger than the minimum safe wire size are selected for loop voltage drop considerations.
Alarm contacts are rated for a maximum voltage of 60 V, SELV (Safety Extra Low Voltage)
and a maximum continuous current of 0.5A. Connection and mounting torque requirements
are listed in Table 6.
Heat dissipation greater than the objectives listed in GR-63-CORE may occur. Additional
equipment room cooling may be required. To cope with high heat release, aisle spacing

4 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
may be increased and high heat-dissipating equipment may be located adjacent to
equipment generating less heat.
It is recommended practice to ensure that all circuit breakers (including those for DC
distribution) are in the OFF position during both installation and removal.
Eltek does not recommend shipping the power shelf with rectifiers installed. Rectifiers
should be shipped in separate boxes provided by Eltek.
Rack mounting must be performed in accordance with instruction provided by the
manufacturer to avoid potential hazards.

FCC Compliance Statement

NOTE: The power system complies with Part 15 of Federal Communications
Commission (FCC) Rules. Its operation is subject to the following two conditions:
o The system may not cause harmful interference.
o The system must accept any interference received, including interference
that may cause undesired operation.
The system has been tested and found to comply with the limits for a Class B digital
device, pursuant to Part 15 of FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. The
system generates, uses, and radiates radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a
particular installation.
If the system causes harmful interference to radio or television reception, which can
be determined by turning the equipment off and on, the user is encouraged to try to
correct the interference by one or more of the following measures:
o Reorient or relocate the receiving antenna.
o Increase the separation between the system and the receiver.
o Connect the system to an outlet of a circuit different from that to which the
receiver is connected.
o Consult the dealer or an experienced radio/television technician for help.
WARNING: Changes or modifications to the system not expressly approved by
the party responsible for the compliance could void the user's authority to
operate the system.
ICES-003 CLASS B NOTICE : This Class B digital apparatus complies with Canadian
ICES-003. Cetappareilnumérique de la classe B estconforme à la norme NMB-003 du
Canada.

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 5
1. Overview
The Compact C-shelf is a DC power system has a mid-mount design for a standard
23” telecommunications racks. It can accommodate up to four Eltek V-series
rectifiers and output either 24Vdc or 48Vdc (depending on which rectifiers are
deployed).

Figure 1 - C Shelf

Rectifier Specifications
Rectifiers for the Compact power system are listed in Table 1 (high-efficiency
rectifiers) and Table 2 (standard rectifiers). Heat dissipation for Eltek rectifiers
is also listed. “Typical” is calculated at AC 240 V and typical DC voltage and
current values for the rectifier. “Maximum” is calculated at minimum AC input
and maximum DC output voltage.
NOTICE: A minimum of ¾”of space is required above and below Compact DC
Power Systems for airflow.
NOTICE: Values listed in the table are per rectifier rather than the sum of a
fully-populated shelf.
Table 1 – High Efficiency (“HE”) V-Series Rectifiers
Rectifier Part AC Input Operating Maximum AC Nominal DC Output DC Output Heat Dissipation Operating
Number Voltage Range (VAC) Current (A) Voltage (VDC) Current (A) (BTU/hr) / (W) Temperature Range
VBLANK-HE NA NA NA NA NA NA
V1000A1-HE 90-264 13.7 48 20 171 / 50 -40°C to +70°C
V1500A1-HE 180-264 10.1 48 30 276 / 81 -40°C to +70°C
V2000A1-HE 180-264 13.6 48 40 425 / 124 -40°C to +70°C

6 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 Table 2 - Standard V-Series Rectifiers
Rectifier Part AC Input Operating Maximum AC Nominal DC Output DC Output Heat Dissipation Operating
Number Voltage Range (VAC) Current (A) Voltage (VDC) Current (A) (BTU/hr) / (W) Temperature Range
VBLANK-VC NA NA NA NA NA NA
V0500A-VC 90-264 7.4 48 10 180 / 53 -40°C to +65°C
V0750A-VC 90-264 11.1 48 15 271 / 79 -40°C to +65°C
V1000A-VC 90-264 14.6 48 20 361 / 106 -40°C to +65°C
V1250A-VC 90-264 17.8 48 25 451 / 132 -40°C to +75°C
V1500A-VC 180-264 10.9 48 30 541 / 159 -40°C to +65°C
V2000A-VC 180-264 14.6 48 40 722 / 212 -40°C to +70°C
V2500A-VC 180-264 18.2 48 50 902 / 264 -40°C to +65°C
V1500B-VC 180-264 10.9 24 60 882 / 258 -40°C to +73°C

NOTICE: Heat dissipation greater than the objectives listed in GR-63-CORE

may occur. Additional equipment room cooling may be required. To cope with
high heat release, aisle spacing may be increased and high heat-dissipating
equipment may be located adjacent to equipment generating less heat.

AC Input Requirements
The Compact C-shelf has AC input architecture that supports single-, dual-,
and individual-feed options. The single- and dual-feed shelves are shipped
configured for dual-feed and can be converted single-feed. The AC terminal
block is located in the rear of the shelf.
Dual and Single Feed
N+1 DC Out

Rectifiers

1 2 3 4

Feed 1
AC In
Feed 2
Figure 2 - Dual Feed AC Wiring Architecture

A dual feed architecture is powers rectifier slots 1 and 3 on AC feed 1 and

rectifier slots 2 and 4 on AC feed 2. The ground wires should be
connected first; there are two ¼”-20 studs provided next to the terminal
block (see Figure 7). Connect each feed, sized according to specifications
in Table 3, onto the #8-32 screw on the rear terminal block. If AC cords

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 7
 from Eltek are not ordered, choose AC ring terminals from the list in Table
4. The AC terminal strip on the rear of the shelf accepts ring terminals
that are less than 0.5” in width. Two knockouts are provided for cable
entry to the AC block that each accept either an AC cord grip provided by
Eltek or a ¾” conduit. Shelves with DC circuit 5 have two knockouts that
each accept snap bushings provided by Eltek, and two more knockouts
for ½” conduit.
N+1 DC Out

Rectifiers

1 2 3 4

AC In Feed 1

Figure 3 - Single Feed AC Wiring Architecture

A single feed architecture is configured by installing the bus bars provided

onto the AC terminal strip. This configuration powers all four rectifier
slots on a single AC feed. The ground wire should be connected first;
there is a single, ¼”-20 stud provided next to the terminal block (see
Figure 8). The AC feed, sized according to specifications in Table 3,
connects to the top set of #8-32 screws on the rear terminal strip. There
is a set of small bus bars that power the second rectifier from the top AC
input terminal. If AC cords from Eltek are not ordered, choose AC ring
terminals from the list in Table 4. The AC terminal strip on the rear of the
shelf accepts ring terminals that are less than 0.5” in width. Two
knockouts for ¾” conduit are provided for cable entry to the AC block, and
AC cord grips are provided. Shelves with DC circuit 5 have two knockouts
that each accept snap bushings provided by Eltek, and two more
knockouts for ½” conduit.

8 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 Individual Feed
N+1 DC Out

Rectifiers

1 2 3 4

Feed 1
Feed 2
AC In
Feed 3
Feed 4
Figure 4 - Individual Feed AC Wiring Architecture

An individual feed architecture powers one rectifier on each AC feed.

Connect each feed, sized according to specifications in Table 3, onto the
#8-32 screws of the terminal strip. All grounds should be on ¼”-20 studs
as shown in Figure 9. Choose AC ring terminals from the list in Table 4.
The AC terminal strip on the rear of the shelf can accept ring terminals of
less than 0.5” width and a wire size of 10 AWG (6 mm2). There are two
knockouts for ¾” conduit (cord grips are provided) and one knockout for a
1” conduit (the cord grip can be ordered separately).

AC Feed Sizing
To size AC feeds properly, follow the specifications in Table 3. Failure to
size the AC breaker and wiring properly can result in annoying breaker
trips or even fire. If you anticipate growth, size the AC breaker and wiring
for the expected capacity. Always follow NEC (national electrical code)
rules and your local company practices when selecting AC wires and
protection devices.
AC requirements listed in Table 3 are based on the absolute minimum
input voltage at which the rectifiers will run. To calculate current draw for
a feed with multiple rectifiers, simply multiply the current draw value in
Table 3 by the number of rectifiers on the feed.

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 9
 Table 3 - Rectifier Worst-case Current Draw

Rectifier Part Number Minimum Input Voltage (VAC) Maximum Rated AC Current (A)
VBLANK-VC NA NA
VBLANK-HE NA NA
V0500A-VC 90 7.4
V0500A-VC 180 3.7
2
V1000A-VC 90 14.6
V1000A-VC 180 7.3
1
V1000A1-HE 90 13.7
1
V1000A1-HE 180 6.2
2
V1250A-VC 90 17.8
V1250A-VC 180 9.1
V1500A-VC 180 10.9
V1500A1-HE1 180 10.1
2
V2000A-VC 180 14.6
V2000A1-HE1,2 180 13.6
2
V2500A-VC 180 18.2
V1500B-VC 180 10.9
1
HE is the high-efficiency line of rectifiers
2
Select rectifiers based on 80% rule (current draw should not exceed 80% of terminal ampacity).

AC Connector Requirements
Part numbers that can be used for AC input connections are listed in
Table 4. Wire type should be considered when determining the type of lug
to use.
AMP ring
Wire size Burndy Lug terminal Description
2
AWG mm Part number Part number
14 2.5 321045 For ground connection on single, dual, or Individual feed
14 2.5 320565 For line connections on single, dual, or individual feed
12 4.0 323763 For ground connection on single, dual, or Individual feed
12 4.0 35605 For line connections on single, dual or individual feed
10 6.0 323763 For ground connection on single or dual feed
10 6.0 35605 For line connections on single or dual feed
8 10.0 YA8CL1BOX For ground connections on single or dual feed
8 10.0 YA8CLNT6 For line connections on single or dual feed
6 16.0 YA6CLBOX For ground connections on single feed
6 16.0 YA6CLNT6 For line connections on single feed

Table 4 - Lug Part Number for AC Input

DC Output Requirements
Distribution circuit 9 accepts UL-approved bullet-style breakers of up to 100 A
and GMT fuses of up to 15 A. Maximum load on breakers should not exceed
80A, and maximum load on GMT-style fuses should not exceed 10A. The shelf
is rated for a maximum total output of 160A.

10 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 A B C D
1 2 20 Optional
LVD and/or
Shunt

Rectifiers 2 Circuit Breaker 20 GMT Fuse 2 Circuit Breaker

Connections Connections Connections
Double ¼" Studs #6-32 Screws Double ¼" Studs

Extra return for

DC reference
ground

Figure 5 - DC Wiring Diagram (Circuit 9)

Circuit 9 systems have twenty GMT fuse and four circuit breaker positions,
with breakers C and D connected through an optional battery LVD contactor as
shown in Figure 5. GMT fuse connections are made on compression screws.
The maximum wire size for fuse connections is 12 AWG (4 mm2). Circuit
breaker connections are made with double-hole lugs on ¼”-20 studs with 5/8”
centers. The maximum tongue width for breaker connections is 0.68” and a
wire size of 2 AWG (35 mm2). Breaker positions A-D in Figure 5 correspond to
positions A-D in Figure 12. Select the lug and wire size based on specifications
in section Table 5. An extra return connection is available for the DC reference
ground; this connection has double ¼”-20 studs with 5/8” centers.

DC Reference Ground
The power system is a fully floating system. This means that the return
bus bar is not tied to the chassis or an earth ground. An external
reference or earth ground may be connected to any return connection or
to the “DC reference ground” connection. The DC reference ground
attachment point is internally wired to all fuse, circuit breaker, and bulk
return connections. Follow your company’s guidelines for sizing and
attaching a reference ground.

DC Output Wire Sizing

There are two main considerations for sizing a DC wire: ampacity and
voltage drop. Ampacity refers to the safe current-carrying capacity of a
wire as specified by the National Fire Protection Association (NFPA), which
publishes the National Electrical Code (NEC). Voltage drop is the amount

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 11
 of voltage loss in a length of wire due to ohmic resistance of the
conductor. A DC wire may be sized for either ampacity or voltage drop,
depending on loop length and conductor heating. In general, for ampacity
considerations, wires of loop length less than 50 feet are selected, and
for voltage drop considerations, wires of loop length more than 50 feet
are selected. The NEC provides ampacity values for various wire sizes,
wire bundles, and insulation temperature–rated wires. Always follow
NEC rules and your local company practices when selecting DC wires
and protection devices.
The size of wires for DC circuit breakers must be based on the breaker
size rating. The size of wires for DC GMT fuses must be based on the GMT
fuse size rating. The selection of unprotected DC output wires is based on
the total rectifier capacity of the shelf.

DC Lug Requirements
Table 5 lists lug part numbers from Burndy that can be used for circuit
breaker or bulk output connections. These part numbers are of lugs used
with the flex conductor cable. Wire type should be considered when
determining the type of lug to use. Follow your company practices when
determining the exact part numbers of lug and ring terminals required.
Table 5- Breaker Lug Part Numbers
Wire size Burndy Lug Description
AWG mm2 Part number
10 6 YAV102TC14 Double hole lug with 1/4" holes and 5/8" centers
8 10 YA8CL2TC14 Double hole lug with 1/4" holes and 5/8" centers
6 16 YAV6C-L2TC14-FX Double hole lug with 1/4" holes and 5/8" centers
4 25 YAV4C-L2TC14-FX Double hole lug with 1/4" holes and 5/8" centers
2 35 YAV2C-L2NT14-FX Double hole lug with 1/4" holes and 5/8" centers

Circuit 9 uses compression screws and, therefore, does not require ring
terminals for GMT fuse connections.

12 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
2. Installation
Before installing the power system the following safety requirements should be
considered.
o Elevated Operating Ambient: If installed in a closed or multi-unit rack
assembly, the operating ambient temperature of the rack environment may
be greater than room ambient. Therefore, consideration should be given to
installing the equipment in an environment compatible with the maximum
ambient temperature (Tma) specified by the manufacturer.
o Reduced Air Flow: Installation of the equipment in a rack should be such
that the amount of air flow required for safe operation of the equipment is
not compromised.
o Mechanical Loading: Mounting of the equipment in the rack should be such
that a hazardous condition is not achieved due to uneven mechanical
loading.
o Circuit Overloading: Consideration should be given to the connection of the
equipment to the supply circuit and the effect that overloading of the
circuits might have on over-current protection and supply wiring.
Appropriate consideration of equipment nameplate ratings should be used
when addressing this concern.
o Reliable Earthing: Reliable earthing of rack-mounted equipment should be
maintained. Particular attention should be given to supply connections
other than direct connections to the branch circuit (e.g. use of power
strips).

Site Preparation
Before unpacking the DC power system, note any physical package damage
that could indicate potential damage to the contents. After removing the
system from boxes and packing material, inspect for any shipping or other
damage. Contact sales or technical support immediately if you notice any
damage.
Have all tools, wires, cables, and hardware within easy reach. To the extent
possible, ensure a clean (free of debris, dust, and foreign material) work
environment. Care should be taken during the installation process to prevent
exposure of the equipment to wire clippings. If possible, rectifiers should
remain sealed in their shipping boxes until the shelf wiring is complete. Ensure
that all AC and DC power sources are off and disconnected.

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 13
 Torque Settings
Table 6 shows recommended torque settings for all mechanical and electrical
connections according to the screw or nut size.
Table 6 - Recommended Torque Settings
Screw or Nut Size Torque Torque
(in-lb) (ft-lb)
#4-40 3.9-4.7 --
#6-32 7.6-9 --
#8-32 15-18 --
#10-32 21-31.2 --
#12-24 36-42 --
1/4"-20 -- 4.25-11
5/16"-18 -- 8.33-21
3/8"-16 -- 15-38
1/2"-13 -- 41.6-85
5/8"-11 -- 71-175
Fuse Terminal 7.6-9.0

Required Tools
The power system is designed to be installed with a minimum number of
commonly available tools.
o #1 and #2 Phillips screwdrivers
o Torque wrench
o 5/16” and 7/16” box wrenches, sockets, and nut drivers
o Wire and cable strippers
o Wire and cable crimpers

Mechanical Mounting
The system is intended for normal operations and should be installed in a
standard 23” telecommunications rack. Eltek recommends that one person
hold the shelf in position on the rack while another person secures it to the
rack with the #12-24 screws provided. See Table 6 for recommended torque
settings. A minimum gap of ¾”is required above and below the system for
proper airflow.

14 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 Mounting
brackets

Keyhole

4
3
2 Distribution
1 door

Insert the controller here Figure 6 - Shelf Front View

Controller Connections
Any BC-series controller is compatible with the power system. Install the
controller into the controller slot, which is on the left side of the shelf (see
Figure 6). Only gentle force is required to fully install the controller module. If
the controller does not mate with the backplane, simply withdraw the chassis,
realign, and try again. Excessive force can bend or break the pins of the
connector, permanently damaging the controller. For more information about
installing peripheral connections, refer to the Installation and Operation manual
that is shipped with the controller unit. System controllers are sold separately.

AC Input Connections
There are two AC input feed configurations available: dual and individual. A
dual-feed AC box can be modified for single-feed by following the instructions
in the section “Single Feed”, beginning on page 16.
Remove knockouts and install a conduit or cord grip before connecting AC
wiring. There are two knockouts for ¾” conduit (provided) and one knockout
for a 1” conduit (available for order separately).

Dual Feed
Make these connections with single-hole ring terminals on #8-32 screws,
and follow torque settings listed in Table 6.
To install AC 110 V:
1. Always make ground connections first. Ground leads should be
longer than the AC lines. Make the ground connections with single-
hole lugs onto the ¼”-20 stud labeled with the ground symbol, and
follow torque settings listed in Table 6.
2. Connect the first line/hot to Line 1, labeled on the AC terminal
block (Figure 7).

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 15
 3. Connect the neutral to the slot labeled Line 1/N1.
4. For the second feed, connect line/hot to the slot labeled Line 2.
5. Connect the neutral to the slot labeled Line 2/N2.
To install AC 208/220 V:
1. Always make ground connections first. Ground leads should be
longer than the AC lines. Make the ground connections with single-
hole lugs onto the ¼”-20 stud labeled with the ground symbol, and
follow torque settings listed in Table 6.
2. Connect the first line/hot to Line 1, labeled on the AC terminal
block (Figure 7).
3. Connect the second line/hot to the slot labeled Line 1/N1.
4. For the second feed, connect line/hot to the slot labeled Line 2.
5. Connect the second line/hot to the slot labeled Line 2/N2.
Screws (#8-32) Ground
(1/4”-20 stud)

Line 1

Line 1/N1
2 - Knockouts
(3/4” conduit)
Line 2

Line 2/N2

Figure 7 - AC Terminal Block Connections (Dual Feed)

Single Feed
To convert a dual feed box to single feed, install the terminal straps
provided. The straps are small bus bars (part numbers B0247011513 and
B0247011512) that, when installed, allow all rectifier slots to be fed by a
single AC input.
WARNING: AC breaker and wire sizing must be adjusted for a single AC
input feed.
WARNING: Once the bus bar straps are added only one AC feed can be
connected to the power shelf. DO NOT attempt to connect a second feed
in parallel.

16 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 To install the AC straps:
CAUTION: Ensure that AC power is removed from the system before
following these instructions.
1. Remove the cover to the AC section. The AC section may look
similar but not identical to the photos below, which depict the AC
section of a K-series shelf.
2. Remove four terminal block screws.
3. Insert B0247011512 from screw labeled “Line 1” (top screw) to
“Line 2” (third screw from the top).
4. Secure bus bar using the screws removed in step 2.

5. Insert B0247011513 from screw labeled “Line 1/N” (second screw

from the top) to “Line2/N2” (bottom screw).
6. Secure bus bar using the screws removed in step 2.

7. Follow directions for single feed AC installation per the installation

and operation manual provided with the shelf.
8. Torque all screws to 18 in-lbs.
9. Replace cover over AC section before activating AC breakers.

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 17
 Make AC line connections with single-hole ring terminals on #8-32 screws,
and follow torque settings listed in Table 6.
To install AC 110 V:
1. Always make ground connections first. Ground leads should be
longer than the AC lines. Make the ground connections with single-
hole lugs onto the ¼”-20 stud labeled with the ground symbol, and
follow torque settings listed in Table 6.
2. Connect the line/hot to Line 1, labeled on the AC terminal block
(Figure 8).
3. Connect the neutral to the slot labeled Line 1/N1.
To install AC 208/220 V:
1. Always make ground connections first. Ground leads should be
longer than the AC lines. Make the ground connections with single-
hole lugs onto the ¼”-20 stud labeled with the ground symbol, and
follow torque settings listed in Table 6.
2. Connect the first line/hot to Line 1, labeled on the AC terminal
block (Figure 8).
3. Connect the second line/hot to the slot labeled Line 1/N1.
Screws (#8-32) Ground (¼”-20 stud)

Line 1

Line 1/N1

Knockout
(3/4” conduit)

Figure 8 - AC Terminal Block Connections (Single Feed)

Individual Feed
Make AC line connections with single-hole ring terminals on #8-32 screws,
and follow torque settings listed inTable 6.

18 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 To install AC 110 V:
1. Always make ground connections first. Ground leads should be
longer than the AC lines. Make the ground connections with single-
hole lugs onto the ¼”-20 stud labeled with the ground symbol, and
follow torque settings listed in Table 6.
2. Connect each line/hot to Line 1 (L1), rectifier 1 (R1), labeled on the
AC terminal block (Figure 9).
3. Connect the neutral to the slot labeled Line 2/N (L2), rectifier 1
(R1).
4. Repeat the procedure for each remaining rectifier.
To install AC 208/220 V:
1. Always make ground connections first. Ground leads should be
longer than the AC lines. Make the ground connections with single-
hole lugs onto the ¼”-20 stud labeled with the ground symbol, and
follow torque settings listed in Table 6.
2. Connect the line/hot to Line 1 (L1), rectifier 1 (R1), labeled on the
AC terminal block (Figure 9).
3. Connect the second line/hot to the slot labeled Line 2/N (L2),
rectifier 1 (R1).
4. Repeat the procedure for each remaining rectifier.
Line 2/N Line 1

Rectifier 1 Ground

Rectifier 2

Rectifier 3

Rectifier 4

Ground

Figure 9 - AC Connections (Individual Feed)

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 19
 DC Output Connections
WARNING: It is very important to verify polarity of all shelf connections, as well
as of batteries, before connecting batteries to the shelf. A wrong connection
can cause the system not to work properly, can damage the shelf, and may
cause bodily harm. For continued protection against fire, replace a fuse with
another of only same type and rating. Indicating fuses have exposed live
parts. Use caution when replacing or servicing them.
CAUTION: Circuit breakers (both load and battery) should be in the “OFF”
position when installed in the system.
NOTE: Use the distribution label card, located on the door of the distribution
section, to document fuse and breaker locations.

Proper DC Cable Routing

Figure 10 shows the proper cable routing for circuit breaker connections.
All circuit breaker cables should be routed through the cable openings to
the left, when looking at the rear of the shelf, of the connection points.
NOTE: Routing the cables in any other manner may harm the personnel or
the system.

Cable routing
openings

DC cables

Figure 10 - Proper Cable Routing for Circuit Breaker Connections

Circuit 9 contains four circuit breaker and twenty GMT fuse connections. All DC
output connections are accessible from the rear (Figure 12), whereas
circuit breakers and fuses are accessible from the front (Figure 11).

20 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 Circuit breakers GMT fuses

Figure 11 - Front Circuit Breaker and Fuse Positions (Circuit 9)

Circuit breaker Load breaker Primary GMT Secondary GMT

return connections connections connections

Do not use
Battery breaker connections DC
(through optional LVD) reference
d
Figure 12 - Rear DC Connections (Circuit 9)

Make GMT output and return connections by using the compression

screws on the GMT terminal strips accessible from the rear (Figure 12).
Select wire size according to specifications in the section “DC Output
Requirements” on page 10. GMT cables should be routed straight down
through the cable holes just below the GMT terminal block. Torque these
M3 screws to 4.5 in-lbs. Install fuses into appropriate slots in the GMT
fuse block shown in Figure 11.
For load output and return circuit breaker connections (positions A and B),
connect lugs to the double ¼” -20 studs with 5/8” centers, accessible
from the rear, as shown in Figure 12. Circuit breakers can be found behind
the distribution door on the right side of the system when viewing it from
the front (Figure 11). Size wires and lugs according to specifications in
the section “DC Output Requirements” on page 10. Breaker cables should
be routed through the cable holes on the left side of the shelf when
viewing it from the rear (Figure 10). DO NOT connect an equipment load
to LVD-protected output connections.

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 21
 For battery output and return circuit breaker connections (positions C and
D), connect lugs to the double ¼”-20 studs with 5/8” centers, accessible
from the rear, as shown in Figure 12. Circuit breakers can be found behind
the distribution door on the right side of the system when viewing it from
the front (Figure 11). Breaker cables should be routed through the cable
holes on the left side of the shelf when viewing it from the rear (Figure
10). If no LVD is installed, all circuit breaker connections can be used for
either load or battery connections.
Connect a DC reference ground to the extra return connection next to the
GMT connections shown in Figure 12. This connection has double ¼”-20
studs with 5/8” centers.

Circuit Breaker Installation

CAUTION: Circuit breakers (both load and battery) should be in the
“OFF” position when installed in the system.
Circuit breakers (sold separately) are UL-approved bullet-nose style and install
into the breaker connection points shown in Figure 11. Follow national, local,
and company codes for sizing and installation. If circuit breakers supplied by
Eltek are not used, the system requires agency-approved breakers with
isolated auxiliary output connections. In addition, alarm contacts should short-
circuit between the NC (normally closed) and C (common) connections in a
tripped state.

Figure 13 - DC Circuit Breaker

22 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
3. Test and Turn-Up
Power up
1. After all input and output connections have been secured and checked,
activate all input breakers.
2. When input breakers are on, install each rectifier sequentially by sliding
the rectifier into position and closing the latch as shown in Figure 14.
Rectifier latches must be open for installation. Attempting to install
rectifiers with latches closed can result in mechanical damage to the
rectifiers and the shelf. Rectifier fans will start in high-speed mode and
reduce their speed according to the ambient and plant conditions within
10 seconds. As each rectifier is installed, the controller automatically
identifies the new rectifier and reconfigures the system.
3. Activate all DC breakers in the system. Leaving DC breakers in the off
position may cause a distribution alarm on the controller. In addition, if
the system contains an LVD contactor there may be a system alarm for
a short period of time until the LVD closes.
4. After all rectifiers have been installed, and if there are no alarms, the
controller will display “System OK.” (If there are alarms, refer to Section
5for troubleshooting assistance.) At this time, make any adjustments to
the default controller settings by following the instructions in the
Installation and Operation manual that is shipped with the controller.
5. If no changes are necessary, the installation is complete.
NOTE: There will be an LVD alarm initially (if the optional LVD is installed), but it will
clear after the pre-programmed LVD reconnect time (typically 20 seconds) has
elapsed. If there are no alarms, make any adjustments to the default controller
settings by following the instructions in the Installation and Operation manual that
is shipped with the controller.

Figure 14 - Rectifier Insertion

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 23
4. Replacement Items
The controller, LVD and shunt (optional), and rectifiers are designed as modular,
field-replaceable units. The following sections outline the procedure to replace
these items.

Controller
To replace a controller module:
1. Unlatch the display by using the release on the backside of the
faceplate, and remove it. The display is connected to the controller
module by a ribbon cable (do not disconnect it).
2. Pull the controller module out of the shelf.
3. Align the replacement controller module and carefully insert it into the
shelf. If it does not seat properly, partially withdraw the body and try
again until it mates with the connector in the rear of the shelf.
CAUTION: Using excessive force may permanently damage the
communication pins or the housing on the back of the controller.
Once properly seated, the controller turns on if the shelf is powered.
4. Install the display by hooking the bottom of the faceplate into the shelf
and rocking the top back until the release snaps in place.
For settings and operation of a BC-series controller, see the controller
operation manual provided with the controller unit.

Rectifiers
In the event that a rectifier needs to be removed:
1. Press the latch button on the front of the unit, and pull the handle until
the unit slides out of the slot.
2. With the latch open, (Figure 14), slide the replacement unit into the open
slot until it connects with the backplane.
3. After the rectifier is inserted, close the latch by pressing it.
The rectifier will power up and the controller will configure it automatically. No
further setup is required.

LVD and Shunt (Optional)

It is necessary to use an insulated ratchet and socket for removing an LVD and
shunt (referred to as just LVD) from a live system. Failure to use insulated

24 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
 tools and take precautions while removing the LVD screws can result in serious
bodily harm and damage to the shelf.
To replace the LVD, perform the following steps:
1. Remove circuit breakers from all LVD-protected positions.
2. Remove the two connection screws as shown in Figure 15 by using an
insulated ratchet with a ¼ inch socket. Caution must be taken not to
short-circuit the connection screws to the shelf chassis.
3. Grasp and pull the LVD plate as shown inFigure 16, until it unlatches
from the backplane.
4. To reinstall a new LVD, align the slots and pins as shown inFigure 17
and push the assembly until the front edge lines up with the front
surface of the chassis. Replace the LVD screws removed in step 2.

Figure 15 - Removal of the LVD Screw

Figure 16 - Removal of the LVD Plate

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 25
 LVD alignment pins

Top of the
distribution
section

LVD plate

Figure 17 - Alignment of the LVD Plate with Pins

Rectifiers
To replace a rectifier, perform the following steps:
1. Press the latch button on the front of the rectifier that needs to be
removed, and pull the handle until the unit slides out of the slot.
2. Open the latch of the new rectifier, and slide the rectifier into the open
slot until it connects with the backplane. (See Figure 14.)
3. After the rectifier is inserted, close the latch by pressing it. The
rectifier will power up and the controller will configure it automatically.
No further setup procedure is required.

26 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
5. Troubleshooting
In case of an alarm from the controller, verify the following (for details, refer to the
Controller Installation and Operation manual):
o All AC and DC connections are secured properly.
o All rectifiers are installed and seated properly.
o The controller is installed and seated properly.
Follow these instructions for different scenarios:
o AC OK off, DC OK off, ALM on or off, and display blank: Verify that proper
AC voltage has been supplied to the rectifiers being used. Refer to Error!
Reference source not found. for AC input voltage requirements. Reseat
the rectifiers, and if problems continue, replace the rectifiers.
o AC OK on, DC OK off, ALM LED on, and display blank: Check DC output
connections for short circuits. Reseat rectifiers, and if problems continue,
replace the rectifiers.
o AC OK on, DC OK on, and display blank: For details about troubleshooting in
this scenario, refer to the Controller Installation and Operation manual.

Short Circuit and Current Limit

Figure 18 represents the behavior of the output voltage in relation to the
output current as load requirements exceed the ILimitsetpoint. ILimit can be
adjusted up to +105% of the rated current of the rectifier. The system output
voltage will remain constant up to ILimit at which point it will drop quickly to 0
V, as shown in Figure 18. If the output voltage of a V rectifier drops below 12 V
for more than 5 seconds, the system will shut down. The system will
automatically restart after 60 seconds, and will continue to restart and shut
down until the short circuit is cleared.
VRated

Rectifier
Voltage
VShutdown

Current ILimit

Figure 18 - Current Limit Graph

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 27
6. Installationsanleitung (German)
Eingangsspannung (Voltage):
Netzteile fuer Netzteile fuer
(100 V – 240 V) (200 V – 240 V)
V500A V2000A
V750A V2500A
V1000A
V1250A
Eingangsstrom (Current): 15 A
Eingangsleistung (Watts): 3000
Nennfrequenz (Frequency): 50/60 Hz
Modellnummer (Model No.): CCxx-xxx
AbmessungensindnurzurReferenz (Dimensions are for reference only.):
o Depth: 12”/30.8 cm (front access with front wire)
o Depth: 15”/38.1 cm (front access with rear wire)
o Height: 3.45”/87.6 cm
o Width: 21.45” (std. 23”)/54.5 cm or 17.45” (std. 19”)/44.3 cm
Max. Umgebungstemperatur: V2000A rectifier, full power: 65 °C/Vollast (Max
operation temperature) V1500B, N+1 configuration: 70 °C
Ausgangsspannungen und –stöme 54 V, max 240 A (output voltage and current)
o Das Gerätdarfnur in RäumenmitbeschränktemZutrittaufgestelltwerden.
(Nurausgebildetes Personal) Restricted access locations only.
o Das GerätmußmindestensmiteinerAnschlußleitung 4 x mm oder 5 x mm
versehensein. (Minimum wire sizes)
o Das Gerät hat keineneigenenAusschalter, esmußdahermiteinemEin- und
AusschalterimVersorgungskreisversehensein. No mains ON/OFF switch is
provided; disconnection means must be provided in the end-installation.
o Das Gerät hat keinBrandschutzgehäuseesdarfdahernur auf
nichtbrennbarenUntergrundaufgestelltwerden. (Beton, Metallusw.) The unit
must be installed on non-combustible flooring.
o BeimAufstellen des Gerätesistdarafzuachten das alleAnforderungengemäß
EN60950 eingehaltenwerden. Installation must comply with EN60950.

28 Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10, September 2012
7. Revision Table
Revision Release Description CO
1 10/01/02 First release NA
2 12/01/02 Added alarm cable color tables NA
3 07/07/03 Page numbers added to TOC; 12V and 24V NA
rectifier info added; alarm matrix added;
alarm menus updated
4 10/01/03 Table 5 (recommended DC wiring) NA
expanded; single- and dual-feed AC input
descriptions separated; DC output
connections expanded; controller settings
expanded; Version 5 controller menu added
5 02/02/05 Reformatted; architecture diagrams, NA
rectifier tables, wire size and breaker tables
updated; lug table added; system photos
added; individual feed AC architecture
added; BC controller features added
6 05/04/07 Document number added to front cover; NA
German instructions added; controller
details removed; rectifier spec tables added
7 07/27/09 Reformatted; all but circuit 9 removed from 090727UE
DC descriptions; AC strap description and
installation added for dual to single feed
architecture; cord grip information added
8 09/01/09 Corrected AC strap description to reflect 090901UA
single-feed as the standard and dual-feed
as the option.
9 04/12/20 Breaker caution added regarding actuator in 100223UK
OFF position during installation. AC strap 100223UL
description reverted to dual-to-single feed
architecture from revision 7
9.1 08/10/11 Revised Table 5 to show only lugs that can 110712UA
be used with DC output landings
10 09/10/12 Updated branding. Figures 10 and 12 120808UA
updated to be polarity-generic. Rectifier
tables updated to include high-efficiency
models.

Installation Manual Compact C-Shelf System ~Doc. No. 2067838, Issue 10,September 2012 29
 Doc. No. 2067838, Issue 10
Published 10-Sep-12

www.eltek.com
US Office: International:
Eltek, Inc. Eltek AS
1303 E. Arapaho Rd, Richardson, TX. 75081, USA Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway
Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101 Phone: +47 32 20 32 00 Fax: +47 32 20 32 10