Installation Guide
DC Power Supply System, 16kW, 48VDC
351476.033
Outdoor 2.0m Fan Cooled Cabinet
1 Welcome
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 explicit written permission of Eltek Energy.
Copyright ©: Eltek Energy, Norway 2007
Power Distribution
Centre for
Communications
Equipment
35KS
Certificate no: 900005E
Certificate no: 900005Q
NS-EN ISO 14001:
1996 Certificate
No: 900005E
NS-EN ISO 9001:
1994 Certificate
No: 900005Q
This product is CE marked and complies with all current requirements for relevant
standards and directives.
This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).
EMC
EN61000-6-2 Industrial Environment
EN61000-6-3 Residential, Commercial and Light Industry
ETS 300386 Telecommunication Equipment
LVD
LVD73/23/EEC Low Voltage Directive
EN60950 Safety of Technology Equipment
UL60950,UL1801
“FP2 PRSB 16KW/48V OD fan 2.0m” has part no. CF1032.006.
351476.033
Issue 4, 2007 June
Published 2007-06-19
Mfm
2
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
1 Welcome
Table of Contents
1.
Welcome
4
About this Guide ............................................................................................................. 4
2.
System Description
4
Location of Components ~ General Arrangement.............................................. 5
External AC Fuses ~ Recommended Ratings ................................................................ 6
Mains Reconfiguration ~ AC Terminal Block .................................................................. 6
Terminals & Pin-out Location, GMT Fuses ..................................................................... 7
Alarm Relays & Digital Inputs.......................................................................................... 7
Terminals & Pin-out Location, Alarm Interface Card ................................................................8
Terminals & Pin-out Location, System Interface Card ..............................................................9
LVD Latching Contactors ................................................................................................ 9
Monitoring, Control and Signal Interface .......................................................... 10
System Monitoring ........................................................................................................ 10
Fan and Heater Operation................................................................................... 10
System Specification .......................................................................................... 11
3.
Installation
12
Safety Precautions ........................................................................................................ 12
General Safety Precautions .......................................................................................... 13
Electrical Safety ............................................................................................................ 13
Mechanical Safety ......................................................................................................... 14
Battery Safety ............................................................................................................... 14
Installing the Modules ......................................................................................... 15
Mounting or Removing Smartpack and Flatpack2 Modules ...................................................15
Mounting and Removing Blind Panels ....................................................................................16
Correct Rectifier Position in Power Shelves ...........................................................................16
System Installation.............................................................................................. 17
Site Preparation ............................................................................................................ 17
Mechanical Installation .................................................................................................. 17
Electrical Installation ..................................................................................................... 18
4.
Commissioning
23
Pre-Start Check ................................................................................................... 23
Commissioning Steps, Startup .......................................................................... 24
Startup and No-Load Adjustments ..........................................................................................24
Load Adjustments ...................................................................................................................25
5.
Maintenance
26
Replacement of Door Filter ........................................................................................... 27
Replacement of Fan Filter ............................................................................................. 27
6.
Forms, Schematics & Drawings
28
Installation Check List .......................................................................................................28
Commissioning Procedure .................................................................................................28
Maintenance Procedure......................................................................................................28
General Arrangement Drawing ..........................................................................................28
Cabinet’s Neoprene Mat Table, Drilling Template, Plinth’s fastening holes ....................28
Cabinet Clearance Drawing ...............................................................................................28
System Schematic Drawing ...............................................................................................28
Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m ........28
Load Distribution List........................................................................................................28
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3
1 Welcome
1. Welcome
The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m is a DC power supply for
telecom equipment suitable for outdoor fan cooled applications.
About this Guide
This booklet provides users of the Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m
with the required information to perform system installation, commissioning and
maintenance. The booklet also describes the system’s technical specifications, and
includes check lists, arrangement and schematic drawings.
Read also the generic documentation included in the system’s documentation set, Art.
No. 351476.003
2. System Description
The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m is a DC power supply system
based on the Flatpack2 2000W 48V rectifier.
The system contains AC termination blocks, DC distribution, Flatpack2 Power Rack,
Flatpack2 2000W rectifier modules and the Flatpack2 Smartpack control unit. The system
is designed for cable entry from top and the cabinet size is 770x820x2030 mm
(30.3x32.3x80”) (WxDxH).
4
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
Location of Components ~ General Arrangement
Battery DC (+) terminals
DC (+) Load Terminals
Bus bar, 35mm2, AWG 2
Common
positive bus bar,
2
70 mm , AWG 2/0
Battery DC (-) terminals
Bus bar, 35mm2, AWG 2
DC (-) Load Terminals
(BTS2 MCBs)
2
25mm , AWG 4, 70mm , AWG 2/0
(on top of each load breaker)
Terminals for
GMT 10A
Load
2
Fuses, 1.5mm , AWG 16
Smartpack controller
Alarm Terminals
2
and CON 4 (monitoring
terminals on the controller’s
rear panel)
1.5mm , 16AWG
(Front access)
AC Earth
Mains Protective Earth (PE)
Connection
(Cabinet main ground bar)
DC Earth
Telecom Earth (TE)
Connection
Smartpack
controller unit
DC Distribution
MCB Load, Alarm and
Signal Terminals
Flatpack2
rectifier modules
AC Mains
Terminals
AC Input & Earth
Terminals
AUX.AC MCB
(heater, AC socket, air-conditioner)
Figure 1 General
Arrangement Flatpack2
PS System, 16kW,
48VDC, OCab, FanC
2.0m
Door Filter Outlet
Fan Filter Inlet
Battery strings and fuses
in the lower part of the
cabinet
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
5
2 System Description
External AC Fuses ~ Recommended Ratings
The site’s AC supply quality is of great importance. In general, a site with better AC
supply quality (stable nominal voltage) may use smaller breakers.
Use the type of external AC fuses recommended in the table below.
External AC Fuses ~ Recommended Ratings
AC Mains Type
External Fuse Type
50A – C-char.
400VAC +N, 3 ph
100A – C-char.
230VAC, 1 ph
63A – C-char.
230VAC, 3 ph
70A.
208VAC, 1 ph
Note: An external AC breaker is required on all sites,
and it must be switched off under installation.
Mains Reconfiguration ~ AC Terminal Block
The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase & N.
To reconfigure the system’s AC mains feed, perform the following:
1. Switch OFF the AC supply fuses in external fuse boards
2. Connect the AC Mains wires to the AC terminal block, and mount the fish
plate(s) shipped with the cabinet, according to the type of AC mains to be
used, as shown in the actual example in this section
AC Mains
Cable
L1
L2
L3
N
Fish Plate
L1
L2
L3
N
AC Mains
Cable
AC Mains
wires
N
Wires
Links
AC Mains
wires
L2
L1
AC Mains
Cable
Fish Plate
L1
L2
L3
Fish Plate
L1
L2
L3
N
N
L1
L2
L3
N
N
AC Mains
wires
AC Mains
Terminal
Block
AC Mains
Terminal
Block
(To internal connections)
Flatpack2 DC Power System
Factory configured
AC Mains terminal block.
Υ Mains, TN
Three-phase & N, 400VAC
6
(To internal connections)
Flatpack2 DC Power System
Mains
One-phase, 230VAC/208VAC
AC Mains
Terminal
Block
(To internal connections)
Flatpack2 DC Power System
Δ Mains, IT
Three-phase, 230VAC/208VAC
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
Terminals & Pin-out Location, GMT Fuses
Pin 1
Pin 16
GMT fuses
Max. 10A each
F12
F5
F8
Figure 2
2
GMT fuse board (max. cable size 1.5mm , AWG 16)
The table below shows the pin-out location for the GMT load fuse card:
Pin Assignment for GMT Fuse
Pin
1
2
3
4
5
6
7
8
Signal
+
—
+
—
+
—
+
—
Function
GMT fuse 1 (F5)
GMT fuse 2 (F6)
GMT fuse 3 (F7)
GMT fuse 4 (F8)
Pin
9
10
11
12
13
14
15
16
Signal
+
—
+
—
+
—
+
—
Function
GMT fuse 5 (F9)
GMT fuse 6 (F10)
GMT fuse 7 (F11)
GMT fuse 8 (F12)
(fan fuse)
Alarm Relays & Digital Inputs
The alarm outputs in Flatpack2 systems use the Fail-Safe Operation Mode (relay coils
energized in the system’s normal operation mode). When the system is in alarm mode,
the alarm relay coils are de-energized.
The figure shows the position of the relay contacts when the relay coils are de-energized
(PS system in alarm mode)
Alarm Relays & Digital Inputs
Normal Mode
Relay X
(Energized coil)
NO
Com
NC
+
NO
Com
Relay X
(De-energized coil)
NC
Flatpack2 PS System
Alarm Mode
—
+
Alarm Relay Specification
Nominal switching capacity
30 VDC, 2A
Maximum switching power
60W (resistive load)
Maximum switching voltage
220 VDC
Maximum switching current
2A DC
—
Correct Use of Alarm Outputs (example)
Digital Input X
(Normal mode)
Digital Input X
(Activated)
+
Normal Mode
—
External Relay Y
(Energized coil)
+
Alarm Mode
—
External Relay Y
(De-energized coil)
Flatpack2 PS System
In order to implement monitored fail-safe
digital inputs circuits, the external relay coil
must be energized and the contacts closed
in the system’s normal mode of operation.
Correct Use of Digital Inputs (example)
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
7
2 System Description
Terminals & Pin-out Location, Alarm Interface Card
The Smartpack controller’s alarm and digital input monitoring signals are accessible from
the controller’s rear panel, on mini power connector CON1 (2 outputs & 2 inputs) and on
D-Sub connector CON2 (4 outputs & 4 inputs).
Using the Alarm Interface Card (Art. 105954) – located on top of the controller; see page
5 -- and two interface cables, you can make the signals on CON1 & 2 accessible at any
suitable location inside your system.
For detailed information about the card’s pin-out location and terminal block connections,
refer to the figures in this section.
Alarm Outputs & Digital Inputs
Voltage free relay outputs and Configurable monitoring digital inputs
Out
Digital Input 1
Digital Input 2
*X1:
+
−
+
−
Relay 1 NO
OVP & Door Alarm COM
NC
Terminals & Pin-out Location
CON2A
CON1A
CON1
Alarm Outputs & Digital
Inputs Card, Art. 105954
Battery Connections
Card, Art. 200576
CON2
Smartpack
CON1A
CON2A
*X1
1
Battery Connections
Card, Art. 200576
Relay 2
High Battery Alarm
To Smartpack,
CON1
System Connections
Card, Art. 200625
*X2
10
1
20
To Smartpack,
CON2
Alarm Outputs & Digital Inputs Card, Art. 105954
NO
COM
NC
1
2
3
4
5
6
7
8
9
10
Input Circuit 1
Input Circuit 2
Alarm Circuit 1
Alarm Circuit 2
*X2:
1
2
3
Digital Input 4
4
5
Digital Input 5
6
7
Digital Input 6
8
Relay 3 NO 9
Low Battery Alarm COM 10
NC 11
Relay 4 NO 12
Fuse Alarm COM 13
Load & Battery NC 14
Relay 5 NO 15
Battery Alarm: -10°C >Temp>50°C COM 16
& Rectifier Alarm NC 17
Relay 6 NO 18
Mains Alarm & COM 19
Mains Low & High Alarms NC 20
(Customer Connections)
Digital Input 3
+
−
+
−
+
−
+
−
(To and from
external equipment)
In
SIGNAL PIN-OUT
Input Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6
Alarm Circuit 3
Alarm Circuit 4
Alarm Circuit 5
(From external equipment)
1
(To external equipment)
FUNCTION
Card Art.105954
Alarm Circuit 6
2
1.5 mm , max.
wire section
The figure shows the position of the relay contacts when the relay coils are de-energized
(PS system in alarm mode. Factory Settings in bold).
8
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
Terminals & Pin-out Location, System Interface Card
Smartpack
JP1
3
2
1
JP2
JP1
Battery Connections
Card, Art. 200576
Pos. Distr.
Neg. Distr.
JP2
1
2
3
X*****
1
11
CON5A
7
13
15
6
12
9+, Neg.D.
11−,Pos.D.
1+/−
3+/−
2+/−
+
−
+
−
+
−
1
Power Input
2
3
Batt. Current 1
4
Batt. Fuse Fail 1
5
6
Load Fuse Fail 1
7
LVD1A
8 LVD Common
LVD1
9
LVD2A
10 LVD Common
LVD2
11
(To latching contactors
LVD1 & LVD2)
(Internal Connections)
Neg. Distr.
Pos. Distr.
JP1 and JP2 are used to configure the
system for Negative DC distribution (48 and
60V systems) or Positive DC distribution
(24V systems)
System Connections Card, Art. 200625
For Internal Use Only!
Alarm Outputs & Digital
Inputs Card, Art. 105954
10
JP2
CON5
System Connections
Battery Connections
Card, Art. 200576
Terminal Board, Art. 200625
(To Smartpack, CON5)
System Connections
Card, Art. 200625
CON5A
Flatpack2 systems are shipped from factory with the CON5 signals already connected.
Some of the Smartpack controller’s internal system signals are accessible on D-Sub
connector CON5, on the controller’s rear panel.
Using the System Interface Card (Art. 200625) and a standard 15 pins D-Sub cable, the
signals on CON5 may be accessible at any suitable location inside your system.
For detailed information about the card’s pin-out location and terminal block connections,
refer to the figures in this section.
In
Out
X:*****
Terminals & Pin-out Location
LVD Latching Contactors
Flatpack2 systems’ LVBD and LVLD1 functionality is implemented by the Smartpack
controlling magnetically latching contactors.
Latching Contactors, LVD1 & LVD2
A latching contactor changes state only when a
reversed pulse voltage is applied to its coil
OFF
ON
+ Pulse
+
PCB Art.
200625
LVD1A
X
X:*****
8
9
10
11
Bidirectional
diode
Latching
Contactor
LVD1
LVD Common
LVD2A
Y
X
X
Latching
Contactor
LVD2
—
Smartpack
Unit
Y
- Pulse
Warning! The bidirectional
diode must always be
mounted to avoid damaging the controller.
Y
Latching Contactor
LVD Common
Flatpack2 PS System (internal)
Correct Use of Latching Contactors (example)
The coil of latching contactors is not energized in any state. They change state from open
to close, or vice versa, when a reversed pulse is applied to the coil.
1
LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
9
2 System Description
Monitoring, Control and Signal Interface
The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m is available with basic
functionality for monitoring and control of the system, and is equipped with:
o Relay outputs, 6 pcs
o Digital inputs, 6 pcs
System Monitoring
The Smartpack Control Unit monitors and controls the entire rectifier system including
distribution and batteries, as well as other equipment on site. The unit also incorporates
a communication port for connecting computers via the USB interface.
The Flatpack2 system can be operated and configured locally via the keypad on the
Smartpack unit, by selecting commands from set-up menus in a hierarchical menu
system.
Remote system monitoring and configuration may also be performed using PowerSuite -a Windows-based program that runs on a connected PC.
Following configuration tasks require the use of a PC:
o Installation settings
o System calibration
o Battery configuration
o Alarm setup
o Alarm log retrieval
o Site information
o Site specific configuration
Please, refer to the Smartpack controller’s User’s Guide --Art. No. 350003.013 – and to
the PowerSuite program’s online help (press function key F1) for detailed information
about system monitoring and functionality.
Fan and Heater Operation
The fan runs as soon as the temperature in the cabinet passes 25oC (77°F). Hysteresis is
1°C (1.8°F). The heater is controlled through a thermostat and it starts up at cabinet
temperature of 5°C (41°F).
10
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
System Specification
Technical Specification
Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m
Max. number of
8
rectifiers
AC INPUT
Voltage
1 phase 230VAC (max 3
rectifiers, 6kW)
3 phase 208VAC ( Δ )
3 phase 230VAC ( Δ )
3 phase 400VAC+N ( Y )
Frequency
45 to 66Hz
Maximum
See Flatpack2 48VDC datasheet
Current
(241115.001.DS3)
OVP
Live – surge arrestor
(Optional)
Neutral – spark gap
Class C, type II
In(8/20) – 40kA
MONITORING
Monitoring Unit
Smartpack
Local operation
Menu driven software via keypads
and LCD, USB or PC (PowerSuite)
Remote operation
PowerSuite via modem or Web
NMS via SNMP-agent
Alarm relays
6 relays are standard
Visual indications
Green LED – System ON
Amber LED – Minor Alarm
Red LED – Active alarm(s)
LCD – system status
Digital inputs
6 (for monitoring of external
equipment)
Current
Battery current
measurements
Rectifier current
Load current
Alarms
Load fuse alarm
Battery fuse alarm
Low Battery Voltage
High Battery Voltage
Temperature alarm
Door switch alarm
Mains detect alarm
OVP Alarm
DC OUTPUT
Voltage
Current
CONNECTIONS
Battery connections
Load MCB
connections
48VDC
Up to 16 KW – 340A
Battery cable, M8 bolts
Negative distribution, Negative load
cable, 70mm2 cable clamps
Common positive bus bar, 70mm2
cable clamps
Alarm connections
Plug-in wire connectors front access
DISTRIBUTION OPTIONS
No. of DC Load
Up to 4 x 3pole 150A
breakers
No. of Battery
Up to 4 x 150A MCBs mount next to
breakers
each battery shelf
No. of Aux. fuses
8 x 10A GMT type
Programmable LVD Standard: 1 LVBD (max. 300A)
OTHER SPECIFICATIONS
Isolation
3.0 KVAC – input and output
1.5 KVAC – input earth
1.0 KVDC – output earth
Operating temp
-40 to +50°C (-40 to +122°F) ***
Storage temp
-40 to +85°C (-40 to +185°F)
Dimensions
770 x 820 x 2030 mm (WxDxH) (30.3
x 32.3 x 79.9”)
Weight
Cabinet: 150 kg excl. optional plinth,
rectifiers and batteries
Flatpack2 rectifiers: 1.9 kg
per rectifier
Batteries: Max. 250 kg
per battery shelf
APPLICABLE STANDARDS
Electrical safety
EN 60950
UL 60950
EMC
ETSI EN 300 386 (telecommunication
network)
EN 61000-6-3 (emission, light
industry)
EN 61000-6-2 (immunity, industry)
Environment
ETSI EN 300 019-2
ETSI EN 300 132-2
2002/95/EC RoHS Compliant
*** Note that the cabinet’s operating temperature range does
not apply to batteries. Refer to the manual for used batteries.
Rectifier Input Voltages
Type
VAC
Note
Type
Nominal
230
High voltage
Range
185 – 275
Full output power
High voltage
Low voltage 1
0 – 85
Shutdown
High voltage
Low voltage 2
85 – 185
Linear between 850W and 2000W
High voltage
* Note: If the input voltage is > 300Vac the rectifier will go into self protective mode.
or battery connected, it will survive 420Vac.
VAC
Note
1
185 – 275
Full output power
1
275 –300
Full power, reduced power factor
2
300 – 350
Shutdown
3
350 – 420
Shutdown* (see note below)
At no load, the rectifier will survive 350Vac. With load
Specifications are subject to change without notice
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
11
3 Installation
3. Installation
This section describes how to install the Flatpack2 PS System, 16kW, 48VDC, OCab, FanC
2.0m.
Step-by-step procedures will guide you through the installation.
Read also the generic documentation included in the system’s documentation set, Art.
No. 351476.003
Safety Precautions
To be installed only in restricted access areas or the like, in accordance with
articles 110-16, 110-17, and 110-18 of the National Electrical Code,
ANSI/NFPA 70
For supply connectors use wires suitable for at least 75˚C (167˚F)
Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.
Use copper conductors only
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
CAUTION: Even though the product incorporates protection circuitry and
other safeguards, it can be damaged, perform poorly or have a reduced
lifecycle if it is exposed to incorrect treatment during transport, installation
or service.
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 power system. As the modules
incorporate large charged capacitors, it is dangerous to work inside the
system even if the mains 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
12
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
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3 Installation
General Safety Precautions
Please read and follow all safety instructions or warnings before installing or
maintaining the power system. Review any supporting documentation regarding the
power system and its components prior to installation.
The enclosure must be installed, serviced, maintained, and operated by a qualified technician who is
familiar with electrical wiring, electrical equipment, and enclosure deployment techniques and best
practices for safety
The enclosure must remain locked at all times, except when authorized service personnel are present
Remove all conductive jewelry or personal equipment prior to servicing equipment, parts, connectors,
wiring, or batteries
Read and follow all installation, equipment grounding, usage, and service instructions included in this
manual
Use proper lifting techniques whenever handling the enclosure, equipment, parts, or batteries
Do not roll the cabinets on their sides
Do not store anything on top of the cabinet
Electrical Safety
Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical
connection or conductor is not energized. Check the circuit with a volt meter with respect to the
grounded portion of the enclosure (both AC and DC) prior to any installation or removal procedure
An external electrical service disconnect must be used that is properly sized as required by the NEC
and/or local codes
The supply neutral conductor must be bonded to earth ground at the disconnect panel
Do not work alone under hazardous conditions
A licensed electrician is required to install permanently wired equipment
Ensure that utility power is disabled before beginning installation or removal
Ensure no liquids or wet clothes contact internal components
Hazardous electrically live parts inside the enclosure are energized by batteries even when the AC input
power is disconnected. Make sure the power is removed via the battery disconnect breaker before
servicing any of the equipment
The internal equipment may be powered by AC circuits. Make sure power is removed via the appropriate
breaker before servicing any of the equipment
Prior to installation, verify that the AC input voltage to the enclosure and its equipment with respect to
voltage and frequency
Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage
requirements of the connected equipment loads
Prior to installation, verify that the enclosure’s utility service panel is equipped with a properly rated
circuit breaker for use with the equipment inside. Refer to the manufacturer’s recommendations
Prior to installation, contact local utilities, local building maintenance departments, and cable/piping
locating services to ensure that installation does not interfere with existing utilities or building
cables/piping
Fuses/circuit breakers may not be provided with the equipment. Refer to the documentation for the
proper hardware. Use only the parts specified in the documentation. Installing fuses or circuit breakers
not specified for use in this equipment may result in injury to service personnel or equipment damage
Where required for installations in the United States or Canada, use listed/certified compression
connectors to terminate listed/certified field-installed conductors. If the proper connector for the country
of installation is not provided, obtain the appropriate connectors and follow all manufacturer and local
requirements for proper connections
Torque the electrical connections to the values specified on labels or in the product documentation
The DC distribution is considered a Safety Extra Low Voltage (SEL V) with the return side connected to
the chassis (earth ground) inside the enclosure
The supply neutral conductor must be grounded at the external service supply disconnect panel
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
13
3 Installation
Do not use other methods for cable entry than what is specified in the documentation for this product
Ensure proper cable support is used to support the weight of cables and cable conduits that enter/exit
the cabinet
Do not drill new holes or use other methods for cable entry than what is described in the product
documentation
Mechanical Safety
Keep hands, hardware and tools clear of the fans. Fans are thermostatically controlled and will turn on
automatically as a function of temperature
Rectifiers can reach extreme temperatures under load and normal operation
Use caution around sheet metal components and sharp edges
Do not climb on the enclosure to access the cable entrance. Always use the proper ladder and safety
precautions as dictated by the site conditions
Battery Safety
Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove
all metallic objects from hands, wrists, and neck
Batteries contain dangerous voltages and current, as well as corrosive material. Battery maintenance,
service, and replacement must be performed by authorized personnel only
Never use non-insulated tools or other conductive materials when installing, maintaining, servicing, or
replacing batteries
Use special caution when connecting or adjusting battery cables. An improperly connected battery cable
can result in arcing, fire, or possibly an explosion
A battery showing signs of cracks, swelling or leaking must be replaced immediately by authorized
personnel using a battery of identical type and make
Do not smoke or introduce sparks in the vicinity of a battery
Follow the battery manufacturer’s approved transportation and storage instructions
Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may
have developed in your body
Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects or
other reproductive harm. Battery post terminals and related accessories contain lean and lead
compounds. Wash hands after handling
If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your
company’s approved chemical exposure procedures
Neutralize any spilled battery emission with a special solution contained in an approved spill kit or with a
solution of 1 lb bicarbonate of soda to 1 gallon of water. Report a chemical spill using your company’s
spill reporting procedures and seek medical attention, if necessary
Each individual battery should have at least 0.25 inches of space between it and surrounding surfaces,
or per the battery manufacturer’s specification to allow for convective cooling
Battery cables must be dressed to avoid damage to the conductors. Damage or stress can be caused by
routing around sharp edges or in areas where wires could get pinched
Follow battery manufacturer’s approved instructions to set all battery related parameters accordingly
14
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
Installing the Modules
Device
hazard
CAUTION:
- The modules may be warm, but do not hand-carry them by their handles
- Open the handles before inserting them into the power shelves (hot-pluggable)
The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing
Mounting or Removing Smartpack and Flatpack2 Modules
Note that cables are plugged to the Smartpack’s rear panel. When mounting the
controller, you must plug the cables before step 2. When removing it, unplug the cables
during step 2.
Smartpack
controller
Hole to release the
handle’s spring
mechanism
Flatpack2
rectifier
Handle in locked position
Handle in
unlocked position
1. Unlock the handles by
inserting a screwdriver into the holes to release the spring mechanism
2. Insert or remove the module by
sliding it fully into the power shelf, so that the module makes proper contact
(for Smartpack, plug cables first)
or
using both handles to pull the module loose. Support from underneath before
the unit is completely free. Unplug the cables, when removing the Smartpack
module
3. Lock the handles by
pushing the handles up into their housings (locked position). Then, the module
will be securely locked in the shelf, or ready for transport
Electric
shock
4. Mount blind panels in
unused module locations
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
15
3 Installation
Mounting and Removing Blind Panels
Screwdriver to
release the locking
tabs
Blind panel’s upper
locking tabs
To remove blind panels, carry out the following:
1. Release the panel’s upper left and right corners by
inserting a small screwdriver into the panel’s upper left gap and carefully press
down and out to release the locking tabs. Repeat on the upper right gap.
2. Remove the blind panel by
using you hand to pull the panel loose
To mount blind panels, carry out the following:
1. Insert the panel’s upper edge by
pressing gently so that its upper locking tabs engage
2. Lock the panel’s lower edge by
pressing with your hand so that the blind panel’s lower tabs lock into position.
Correct Rectifier Position in Power Shelves
Flatpack2 DC power systems are normally shipped from factory with empty power
shelves. The rectifier modules are shipped in separate packaging, and you have to
install the modules in the correct position in the power shelves, with respect to their
ID number (or CAN bus address). Do not relocate already pre-installed rectifiers.
Follow the scheme below to install the Flatpack2 rectifier modules:
o
Insert & hot-plug the rectifiers in the indicated power shelf positions,
one module at a time, allowing a 2s delay between them and starting with ID
number 1, 2, 3, and so on. (indifferent after ID# 6)
Correct Rectifier Position in the Power Shelves
Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
and
Δ Mains
Three-phase, 230VAC
Υ Mains
Three-phase & N, 400VAC
Flatpack2
rectifier
Smartpack
controller
Position 1
Position 9
16
01
04
03
06
-----
-----
02
05
Position 4
---
---
Position 8
---
-----
---
Phase 1
Phase 2
Phase 3
ID number
(Assigned CAN
bus address)
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
System Installation
Check off in the Installation Check List, that you find in the last section of this folder.
Site Preparation
Refer also to chapter “Location of Components ~ General Arrangement” on page 5.
Step - Site Preparation
1. Organize the
installation site
Action
Power is OFF!
o Check min. clearances for cabinet access:
front access, 100 cm, top access, 60 cm,
rear clearance 100 cm *
See page 36
OK
* Note, The minimum rear clearance is only
needed if Flexi kit 2 will be installed
o
2.
Prepare the
installation tools
3.
Prepare AC Supply: AC
input cable(s) and
fuses
The floor construction must be capable of
supporting the equipment, refer to System
Specification, page 11
Check that insulated tools suitable for telecom
installations are used
Check the AC supply is the correct type, and that
the external AC fuses and AC input cable(s) are
suitably rated. Refer to page 6
Mechanical Installation
Step - Mechanical Installation
4. Remove packaging
and check equipment
5.
Use the Neoprene Mat
Action
Power is OFF!
CAUTION: Do not step nor walk on the cabinet’s
roof.
o Check you have received all the parts,
correct cabinet, documentation, batteries (if
applicable), etc
o Inspect the equipment for physical damage
(report any damages)
o Leave rectifier modules in their packaging or
in the selves, if factory installed.
(commissioning task)
Note: Only to be used when the cabinet is placed
directly on concrete floor and a cabinet plinth is
not mounted.
o Use the attached neoprene mat between the
cabinet and the concrete floor. See Table 1,
page 35 for specifications
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
OK
17
3 Installation
Step - Mechanical Installation
6. Position and fasten
the cabinet
Action
Power is OFF!
Note: If Flexi kit 2 will be installed, ensure a
minimum clearance of 1m between the cabinet rear
wall and any obstacle. See also Figure 7, page 36
OK
Drill holes on the floor or support beams,
See Figure 5, page 35 and
Perform Alt. A OR Alt. B
Alt. A: Cabinet Plinth Option NOT Used
o Bolt the cabinet to the ground or support
beams
Alt. B: Cabinet Plinth Option Used
o Fasten the plinth to the ground or support
beams using M10 bolts. See Figure 6, page
35
o Bolt the cabinet to the plinth, using the “2m
Cabinet-to-Plinth Fastening Holes”. See
Figure 6, page 35
o Start (if applicable) mounting them on the
lower shelf first, and continue upwards.
Use the battery kits, if supplied
Do not terminate the battery cables yet!
o
7.
Mount the batteries on
the shelves
Do not remove Condensation Stopper yet!
The condensation stopper (yellow plastic) prevents
humidity from entering the cabinet and must
therefore not be removed until the system is
powered up during commissioning. Humidity before
powering up the system may cause serious damage
to the system.
The condensation stopper is attached to the filter on
the inside of the door.
Electrical Installation
Refer also to chapter “Location of Components ~ General Arrangement” on page 5.
Step - Electrical Installation
8. Make the system
completely voltage free
9.
Open the cabinet’s roof
Action
Power is OFF!OK
Switch OFF or remove ALL load fuses (F1, Fx),
battery fuses (Fb1, Fbx) and external AC supply
fuses
The cabinet roof is locked with 2 screws in the
front, from inside the door opening.
o Open these screws and lift up the roof
o Secure the roof during installation with the
rod on the right side under the roof
..
18
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
Step - Electrical Installation
10. Insert the cables
Marcon 25 multigate
Action
Power is OFF!OK
Cable (all phases in one cable) max 6mm2 each
Single phase cable (one cable per phase) max
35mm2
CAUTION: Do not use the metal blind plates as
cable entry plates.
o Use a screw driver to puncture the
appropriate grommet(s) of the Marcon 25
multigate. Do not use a knife!
The cut must be smaller than the cable
diameter. The pictures show how to cut the
.
grommets.
Note! Other optional cable
entry solutions are available
for larger size cables and/or
cable conduit.
Please contact you local
representative for details
if the cable entry solution
provided is not sufficient
for your needs.
o
Push cable(s) through the grommet(s):
o
Then pull the cable(s) back out of the
grommet, approx. 10mm. This will lock the
cable in the grommet and ensure full IP
protection
Ensure that the fixing screws of all Marcon
25 multigate cable entry plates and metal
blind plates are properly tightened
o
Note! Ensure that any blind plates that are
refitted to the cabinet are mounted with the
gasket joint (spline) facing downwards.
Gasket joint/spline must face downwards when plate is
mounted back to cabinet
11. AC Connections
o
Check AC configuration: The AC
terminals are correct configured to the
external AC supply
o
Connect the AC Earth wire (PE) to the
terminals AC Earth (PE)
- Terminal AC Earth (PE) is mechanically
connected to cabinet chassis. Refer to page
5
o
Connect the AC input cable(s) to the
terminals. Cable and terminal block
labelling are to correspond. Read pages 5
and 6.
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
19
3 Installation
Step - Electrical Installation
12. AC Socket Connection
Action
Power is OFF!OK
The system is prepared for an AC socket, located
to the right side of the cabinet. This AC outlet is
intended for optional equipment. Due to the many
different socket types all over the world, no socket
is delivered with the system.
o
o
o
20
Turn OFF the AC breaker. Connect the
cables L, N and PE (not part of the cabinet)
to the preferred socket type and mount the
socket to the bracket.
Mount the cables from AC socket to the AC
breaker.
Turn ON the AC Breaker
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
Step - Electrical Installation
13. DC Connections
Load Circuits
3-pole link for CBI MCB
2-pole link for CBI MCB
14. DC Connections
Alarm & Signal Circuits
2
Action
Power is OFF!OK
o Terminate DC Earth (TE)
- Terminals DC Earth (TE) is mechanically
connected to cabinet chassis. Refer to page
5.
- The Common Positive Bus bar is internally
cabled to DC Earth (TE); thus the positive
output of the rectifiers is connected to
ground (TE), and the negative output
represents the –48VDC supply voltage.
Refer to Figure 1 General Arrangement
Flatpack2 PS System, 16kW, 48VDC, OCab,
FanC 2.0m, on page 5.
The Common DC Output Rail is to be
connected to TE at only one place.
- If required, you can remove the internal
cable that connects the positive bus bar to
local TE.
o
Terminate DC Load Circuits
The kit includes two copper links. One for
100 A (two pins) and one for 150 A (three
pins). If the load current is larger than 50 A
use the two pin copper link. Then the 3rd
hole in the breaker cannot be used.
If the load current is larger than 100 A, use
the three pin copper link. Insert the chosen
copper link on to the top of the MCB.
- Connect the orange alarm wire to the
copper links with a screw, if the links are
used.
- Connect the positive cable(s), max 70 mm
sq (AWG 2/0), to the common positive bus
bar on the top of the power core. 2
- Connect the negative (-48V) cables, max
25 mm sq each (AWG 3), to the top of the
MCBs or the copper links.
o
Terminate GMT Fuse Load Circuits
Connect the adequate cables, 1.5 mm sq
(AWG 16), to the GMT fuse card according
to the table on page 7
Terminate Alarm Circuit cables to the relay
output terminals.
Refer to chapter “Terminals & Pin-out
Location, Alarm Interface Card” on page 8.
o
The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
21
3 Installation
Step - Electrical Installation
15. DC Connections
Battery Cables
Action
Power is OFF!OK
The positive and negative (-48V) battery cables
are connected from factory to the common positive
bus bar and to the battery MCBs (does not apply
for additional battery string kits).
The battery temperature sense cable is also pre
wired to CON4, and temporally fixed to the
cabinet’s wall.
22
o
o
Connect all battery inter-cell links
Connect the loose end of the battery cables
to the battery terminals; blue cable to the
negative terminal and black cable to the
positive terminal.
o
Place the temperature sensor, located at
the end of the battery temperature sense
cable, on top of the topmost battery string
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
4 Commissioning
4. Commissioning
The commissioning of Flatpack2 PS System consists of following stages:
I. Perform a pre-start check before the PS system is switched ON
II. Switch ON the system with disconnected load; adjust output voltage
III. Adjust the nominal output voltage with connected batteries and load
I
Power is
OFF!
Pre-Start Check
Check off in the Commissioning Procedure, that you find in the last section of this
folder. If you have just finished the system installation successfully and filled in the
Installation Check List, jump over the Pre-Start Check and continue with stage II.
Before you switch ON the Flatpack2 PS system, verify the following:
Device
hazard
1. System installation is completed
o Ensure a correctly performed system installation, with correct polarity on
all connections, has been carried out (Installation Check List filled in)
o All cabling and copper bars are securely terminated and supported
o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
2. Battery and load fuses are disconnected
o Verify that all battery and load MCBs/ fuses are switched OFF or removed
3. AC input cable(s) and AC Earth wire (PE) are terminated
o Make sure that the AC input cable(s) are connected to correctly configured
AC terminals
o Verify that the AC input cable(s) and external AC fuses are sized and rated
as specified
o Check that AC Earth (PE) is terminated, and electrically connected to
chassis (Link 1)
4. Site specific parameters and settings are known
o Read the system specific drawings and documentation
5. AC supply and all MCBs, fuses are switched OFF
o Make sure that all external AC fuses and internal MCBs/ fuses are switched
OFF
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
23
4 Commissioning
Commissioning Steps, Startup
Check off in the Commissioning Procedure, that you find in the last section of this
folder. After the ”Pre-start Check” is performed, you can begin with stage II.
During the stage, you will switch ON the Flatpack2 PSS — while the batteries and
load are disconnected ⎯ then measure the output voltage, and adjust it if required.
Carry out the following:
II
Power is
ON!
Device
hazard
Startup and No-Load Adjustments
1. Disconnect all rectifier modules, without removing them (keep original location)
o Read how to install modules, on page 15. Also, read about the correct
rectifier position on page 16, and then,
o If Flatpack2 rectifier modules are installed, unlock the handles and pull the
modules partially out (fan housing visible), but do NOT physically remove
them from the power shelves
o If Flatpack2 rectifier modules are not yet mounted, release their handles
and insert them partially into the correct position in the shelves
2. Remove the Condensation Stopper
o Remove the Condensation Stopper placed in front of both filters, inside the
door and in front of the fan. Read more about the Condensation Stopper on
page 18
3. Switch ON the system
o Switch ON the AC input supply (external AC fuses) to the PS cabinet
4. Measure and verify that the AC input voltage is correct
o Measure the AC input voltage at the cabinet’s mains connection box
o Verify the AC voltage is within range
5. Mount all Flatpack2 rectifier modules in the power shelves (keep original location)
o Push all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s
delay ⎯ to plug them in the same shelf location. Lock their handles. Refer
also to page 15
o Mount blanking panels over unused positions
6. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON
o Verify correct operation, by monitoring the modules’ LED lamps and
display: No alarms are present on rectifiers; The Smartpack displays fuse
alarms
7. Connect a PC to the PS system (to facilitate operation)
o Plug a standard USB A-B cable between the PC and the Smartpack
controller
o Start PowerSuite on the PC by selecting:
Start > All Programs > Eltek > PowerSuite
o On the toolbar, click the “Connect” button to establish connection
8. Measure and adjust DC output voltage
o Read the DC output voltage on the controller’s display
o With a multi-meter, measure the DC output voltage at the most accessible
point, e.g. between the common DC rail and the lower connection of one of
the priority load MCBs
o If required, adjust the voltage using the controller’s front keys or via
PowerSuite
24
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
4 Commissioning
9. Verify the alarm relays are working correctly (alarm relay test)
o Run the alarm relay test using the controller’s front keys or via PowerSuite
(select the menu Go > Output Test)
10.Make sure the System Setup is in accordance with configuration
o Verify system settings using the controller’s front keys or via PowerSuite
o Use the opportunity to enter site related information, number of used AC
phases, type of batteries, etc.
III
Load Adjustments
Now, you can begin with stage III, where you will adjust again the output voltage
to the battery voltage, and connect the batteries and the load.
Carry out the following:
Power is
ON!
11.Adjust DC output voltage to equal measured battery voltage
o Measure the battery voltage is within range (check connections have
correct polarity)
o Adjust DC output voltage — using the controller’s front keys or via
Device
PowerSuite— to equal the measured battery voltage.
hazard
(Important adjustment to avoid arcing when connecting the batteries)
12.Unplug all rectifiers but one, and connect the battery fuses /MCBs
(CAUTION: Have only one rectifier connected, when switching ON the battery
fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity
connections, etc.)
o Disconnect all rectifiers but one, by unlocking the handles and pulling them
partially out (fan housing visible). Do NOT physically remove them from
the power shelves
o Switch ON all battery fuses or MCBs
Device
hazard
13.Adjust DC output voltage again to equal the nominal battery voltage
o Adjust DC output voltage — using the controller’s front keys or via
PowerSuite — to equal the nominal battery voltage (or the nominal load
voltage, when not using batteries)
14.Plug in again all rectifiers, and verify the rectifiers’ current sharing
o Connect all rectifiers again by pushing them firmly inwards ⎯ Repeat step
4, in stage II
o Wait for about 2 min., and check — using the PowerSuite application —that
each of the rectifiers delivers the same output current. A deviation of 1A is
acceptable.
15.Connect the load breakers and verify that no alarms are displayed
o Switch ON all load MCBs/ fuses
o Verify correct operation: rectifiers and controller display no alarms
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
25
5 Maintenance
5. Maintenance
You can carry out the DC power system maintenance, by following the steps in the
Maintenance Procedure that you find in the last section of this manual.
This chapter describes how to perform filter maintenance.
WARNING: You are operating in a live system. Precaution must be taken when changing
filter in front of the fan.
Lower Door Filter (Fan Filter) Locations:
Car park/road side: City roof top: Non central:
Pollution degrees:
Low
1 year
2 years
3-4 years
Medium
1 year
2 years
3-4 years
High
6 months
1 year
2 years
* Note! The filter replacement intervals listed in the above table are only guidelines.
Shorter intervals may be required, depending on the level of air pollution on site.
Eltek recommend bi-monthly site checks during the first year of operation, to establish
actual filter replacement intervals for each individual site
Upper Door Filter
Locations:
Pollution degrees: Car park/road side: City roof top: Non central:
Low
4 year
8 years
12 years
Medium
4 year
8 years
12 years
High
2 years
4 year
8 years
* Note! The filter replacement intervals listed in the above table are only guidelines.
Shorter intervals may be required, depending on the level of air pollution on site.
Eltek recommend bi-monthly site checks during the first year of operation, to establish
actual filter replacement intervals for each individual site
Filter frame’s
fastening screws
Door Filter, Outlet
(The filter’s rough side facing
inwards)
Open fan filter door
Filter frame’s
fastening screws
Fan Filter Door
Fastening knobs for
fan filter door
Fan Filter, Inlet
(The filter’s smooth side
facing inwards)
Figure 3
26
Location of the cabinet’s door filter and fan filter
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
5 Maintenance
Replacement of Door Filter
Step
Action
1.
Refer to “Figure 3 Location of the cabinet’s door filter and fan
filter”, on page 26.
Remove
filter
OK
o Remove the Air baffle plate(s) that cover the filter grid on the
inside of the cabinet door (plates not shown in Figure 3).
o Remove the filter grid
by loosening the screws around it. Pull the grid towards you
when loose
2.
Exchange
filter
o Exchange the old filter with a new.
Make sure that the rough side of the filter faces the inside
of the cabinet
3.
Mount the
frame
o Mount the grid to the door again, fastening the screws around
it
o Mount the Air baffle plate(s) back on again and tighten the
screws
Replacement of Fan Filter
Step
1.
Disconnect
the fan
2.
Open the Fan
Filter Door
Comments
OK
o Remove the fan fuse,
located at the GMT fuse card (fuse 8). Refer to “Terminals &
Pin-out Location, GMT Fuses” on page 7
Refer to “Figure 3 Location of the cabinet’s door filter and fan
filter”, on page 26.
o Open the fan filter door
by turning the two knobs on the door (upper and lower right
side)
3.
Remove the
filter grid
o Remove the filter grid
by loosening the screws around it. Pull the grid towards you
when loose
4.
Exchange the
filter
o Exchange the old filter with a new. Make sure that the
smooth side of the filter faces the inside of the cabinet
5.
Mount the
grid
Close the Fan
Filter door
Connect the
fan
o Mount the grid again, fastening the screws around it
6.
7.
o Close the fan filter door, and turn the knobs closed
o Replace the fan fuse, and verify that the system is
operating normally
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
27
6 Forms, Schematics & Drawings
6. Forms, Schematics & Drawings
This section includes following forms and schematic drawings:
Installation Check List
Commissioning Procedure
Maintenance Procedure
General Arrangement Drawing
Cabinet’s Neoprene Mat Table, Drilling Template, Plinth’s fastening holes
Cabinet Clearance Drawing
System Schematic Drawing
Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m
Load Distribution List
28
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
INSTALLATION CHECK LIST
System Data
Flatpack2 PS System
Flatpack2 Power Supply System, type:
Article No.:
Site, name:
Serial No.:
Software, version No.:
AC Input Voltage, measured:
Battery Type:
Rectifiers, type & number of:
Battery Capacity:
Installation carried out by, name:
Site Preparations
Power is OFF!
CARRY OUT FOLLOWING:
OK
1. Organize the installation site
EMC
regard
2. Prepare the installation tools
3. Prepare AC Supply: AC input cable(s) and fuses
Mechanical Installation
CARRY OUT FOLLOWING:
Power is OFF!
OK
4. Remove packaging and check equipment
5. Use the Neoprene Mat
Device
hazard
6. Position and fasten the cabinet
7. Mount the batteries on the shelves
o
o
Do not terminate the battery cables yet!
Do not remove the Condensation Stopper!
Electrical Installation
Power is OFF!
CARRY OUT FOLLOWING:
Electric
shock
OK
8. Make the system completely voltage free
9. Open the cabinet’s roof
10. Insert the cables
11. AC Connections
o
o
o
Check AC configuration: The AC terminals are correct configured to the external AC supply
Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
12. AC Socket Connection
13. DC Connections ⎯ Load Circuits
Electric
shock
o
o
o
Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place
For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB
Terminate the GMT load circuits
14. DC Connections ⎯ Alarm & Signal Circuits
15. DC Connections ⎯ Battery Cables
Careful! Use correct polarity.
For each battery shelf,
o
Mount 3 intercell links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks)
o
Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-)
o
Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the
end of the cable) to a suitable place in the middle of the installed battery bank
Approval
Responsible of installation, sign.:
Date:
Approved by customer, sign.:
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
29
30
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
COMMISSIONING PROCEDURE
System Data
Supplier’s Order No.:
Flatpack2 PS System
Flatpack2 Power Supply System, type:
Article No.:
Site, name:
I
Serial No.:
Software, version No.:
AC Input Voltage, measured:
Battery Type:
Battery Capacity:
Commissioning carried out by, name:
Pre-Start Check
Power is OFF!
CHECK FOLLOWING:
1.
Device
hazard
Rectifiers, type & number of:
OK
Flatpack2 system installation is completed;
The Flatpack2 Installation Check List is filled in.
All cabling is securely terminated with correct polarity
2. All battery and load MCBs/ fuses are disconnected
3. AC input cable(s) and AC earth wire (PE) are terminated
4. Site specific parameters and settings are known
5. AC supply and all MCBs/ fuses are switched OFF
II
Device
hazard
Start-up, No-Load & Load Adjustments
CARRY OUT FOLLOWING:
Power is ON!
OK
1. Disconnect all rectifier modules, without removing them (keep original location)
2. Remove the Condensation Stopper
3. Switch ON the system (external AC fuses ON)
4. AC input voltage is correct;
Measure and verify
5. Insert all Flatpack2 rectifiers in their original locations in the power shelves
6. The Smartpack and all rectifier modules are working, LEDs are ON;
7. Connect a PC to the PS system
Verify
Install the PowerSuite software, if required
8. DC output voltage;
Measure and adjust
9. Alarm relay test;
III
Device
hazard
Verify all alarm relays are working correctly
10. System Setup is in accordance with configuration
Enter site spec. info in PowerSuite
11. Adjust DC output voltage to equal measured battery voltage
Check correct polarity!
12. Unplug all rectifiers but one, and connect all battery fuses/ MCBs
13. Adjust DC output voltage to equal nominal battery or load voltage
14. Plug in again all rectifiers, and verify the rectifiers’ current sharing
15. Connect all load MCBs/ fuses, and verify no alarms are displayed
Approval
Responsible of commissioning, sign.:
Date:
Approved by customer, sign.:
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
31
32
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
MAINTENANCE PROCEDURE
System Data
Flatpack2 PS System
Flatpack2 Power Supply System, type:
Article No.:
Site, name:
Electric
shock
Serial No.:
Software, version No.:
AC Input Voltage, measured:
Battery Type:
Rectifiers, type & number of:
Battery Capacity:
Maintenance carried out by, name:
WARNING: Maintenance work on live equipment is only to be performed by authorized and
qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.
System Inspection
Power is ON!
CARRY OUT FOLLOWING:
OK
1. Site specific parameters and settings are known.
User manuals and site specific connection & arrangement drawings are available.
2. The battery bank has been fully charged in advance.
At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration
3. The equipment and door filters are free from damage, dust or dirt; verify.
Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt. Perform filter maintenance.
4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.
5. The Smartpack & all rectifier modules are ON, no alarm present; verify.
Otherwise, correct and put the PS system in normal mode of operation.
6. All rectifier’s functionality & Smartpack’s keys and display work OK; verify
Correct possible abnormalities before continuing.
7. Connect the PS system to a PC (install the PowerSuite application if required)
The PowerSuite program in the PC enables system configuration from the PC.
8. Rectifiers’ load current sharing; verify.
Use the PowerSuite PC application to check all rectifiers output the same amount of current (±1A)
9. Display the stored log of Alarm Messages.
Using the keypad on the Smartpack controller or from the PC.
System Adjustment
CARRY OUT FOLLOWING:
OK
1. DC Output Voltage Calibration; ensure correct display readings.
If measured DC output voltage at the load terminals deviates more than ±1% from the display reading, calibrate the
output voltage from the Smartpack’s keypad or the PC.
2. Load & Battery Current Calibration; verify correct display readings.
Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery
current. If the calculated total values deviate more than ±1% from the display readings, calibrate the current from the
PC (calibration value>50% of system’s max. capacity)
3. DC Output Voltage Adjustment; measure and adjust.
Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery manufacturer.
(Voltage measurements to be done at the DC rail, with little load current)
4. Alarm Relay Test; verify all alarm relays are working correctly.
From the Smartpack’s keypad or PC use the Relay Test function; verify activation of external equipment
5. Battery bank control; measure and verify battery specifications.
Follow the recommendations of the actual battery manufacturer.
Approval
Responsible of maintenance control, sign.:
Date:
Approved by customer, sign.:
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
33
770.0000
Door Switch
41U
DC Distribution
Cabinet main ground bar
AC Earth (PE) and DC
Earth (TE) connection
Smartpack
controller
On cabinet’s side wall
Flatpack2
rectifiers
35U
AC Mains Terminals
AUX.AC MCB
(heater, AC socket,
air-conditioner)
29U
1944.4200
Battery MCB
FB4*
21U
Battery MCB
FB3*
14U
Battery MCB
FB2*
7U
Battery MCB
FB1
* Optional
Figure 4
General Arrangement Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m
Doc, 24nnnn.yy, XvX
34
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
Feature
Cabinet’s Neoprene Mat Specifications
Value
Test Standard
Shore hardness A
Tensile strength
Elongation at rupture
Density
Mass per unit area
Compression stress at 30% deformation
Operational temperature
Flammability
Table 1
65±5
0,45 N/mm²
45%
730 kg/m³
730g/m²/mm
0,75 N/mm²
-40 to +155°C
Class B 2din 4102
DIN 53 505
DIN 53 571
DIN 53 571
DIN 53 577
Neoprene Mat Specifications
FRONT
620 mm
Figure 5 Drilling Template, top
view of the cabinet’s bottom plate. For
cabinet fastening directly to the floor or
to a plinth
620 mm
Front
Note: The mat is only to be used when the cabinet is placed directly on concrete floor and a cabinet
plinth is not mounted.
75 mm
75 mm
75 mm
75 mm
120 mm
575 mm
125 mm
120 mm
575 mm
125 mm
2m Cabinet-to-Plinth Fastening Hole (4x)
One hole in each corner
1.3m Cabinet-to-Plinth Fastening Hole (4x)
One hole in each corner
2m
Cabinet-to-Plinth
Fastening Holes
Figure 6
Plinth-to-Floor Fastening Hole (4x)
One hole in each corner
Cabinet’s plinth, top and 3D view. Cabinet’s and plinth’s fastening holes
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
35
Figure 7
Cabinet Clearance, side and top view
Doc No. 14990 - 109, 23.02.07
36
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
System Schematic Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m
4
*OPTION
N
PS 1
PS 2
Relay
62950-734
11
14 11
A2 A1
+
-
PE
T
Battery Heater*
A1 A2
Door Switch
3
1
2
JP2
3
Load Fuse Fail 1
LVD 1A
LVD Common
LVD 2A
LVD Common
Battery Fuse Fail
Battery Current
Power Input
+
+
+
-
1
2
3
4
5
6
7
8
9
10
11
*X1
Con 2A*
Ext. Alarm I/O Connections
Con 1A*
Alarm I/O Connections
3
4
5
6
7
8
9
10
Relay 6
Relay 5
Relay 4
Relay 3
Digital Input 6
Digital Input 5
Digital Input 4
Digital Input 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
LTE EQUIPMENT*
NO
COM
NC
+
+
+
+
NO
COM
NC
NO
COM
NC
NO
COM
NC
*X2
Ext. Alarm I/O Connections
Relay 2
Relay 1
Digital Input 2
+
NO
COM
NC
NO
COM
NC
Alarm Outputs and Alarm I/O Connections
Digital Inputs
+ 1
Digital Input 1
2
105954
2
JP1
POS. DIST.
NA when Web/SNMP (ENET) kit installed in Smartpack
26
10
NEG. DIST.
1
NEG. DIST.
*X5
System Connection
J1
Red
351476.033, v4-2007-06
LTE Customer connections*
2
-
TERM 1
TERM 2
TERM 3
+
J1
Yellow
Brown
White
Temp
sensor
62950-421
Zener diode 5,6V
62950 - 731
AC socket*
8
8
8
8
Con 5A*
System Connections
SH1
TERM 1
TERM 2
TERM 3
Yellow
Blue
Red
FAN
62950-420
Brown
PE
Con8, pin 9-16
Con8, pin 1-8
-
+
Backwiring FP2
Low Current 2AC
4 rectifier positions
105581
Smartpack Power
- /CAN bus
interconnections
PE CON13
L1 CON9
L1 CON11
L2 CON10
L2 CON12
Con8, pin 9-16
Con8, pin 1-8
-
+
Backwiring FP2
Low Current 2AC
4 rectifier positions
105581
Smartpack Power
- /CAN bus
interconnections
PE CON13
L1 CON9
L1 CON11
L2 CON10
L2 CON12
15
System Connection Board
200625
-F13
*
-F5 GMT
POS. DIST.
-F14
OVP kit
-F15
Star (400Vac)
3-phase
L1 L2 L3 N
-F16
AC terminal
connections
-F17
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
-F18
Y
X
LVBD
8
8
10
8/26
9/15
15
15
DC Earth (TE)
Optional Web/SNMP (ENET) connection.
Replaces ”Ext. Alarm I/O Connections”
2:
9
Customer
connections
- F4*
- F3*
- F2
- F1
- FB4*
- FB3*
- FB2*
- FB1
0V
Customer connections
The Schematic/Connection Drawing shows the position of the
relay contacts when the Power System is in its alarm mode of
operation (relay coils are then de-energized). The relay outputs
are preprogrammed from factory (Factory Settings).
Optional 9 pin D-sub RS232 connection.
Can be mounted in front or on rear side of
Smartpack. Replaces ”Ext. Battery Connections”
when mounted on the rear side of Smartpack
1:
CAN port
CAN port
CON1
Alarm I/O Connections
CON2
Ext. Alarm I/O Connections
2: Optional: Web/SNMP (ENET)
1: Optional: RS232
USB
Front connections
USB 2.0 type B port
(PC connection)
Smartpack
monitoring and
control unit
CON3
Ext. Battery connections
1: Optional: RS 232
CON4
Battery connections
CON5
System Connections
Rear connections
-
+
16
F12 15
14
F11 13
12
F10 11
F9 10
9
F8 8
7
F7 6
5
4
F6 3
2
F5 1
CU-bar common +
Load
Alarm
-F19
203929
-F20
GMT Load circuits 48Vdc
Battery Strings
Circuits -48Vdc
Figure 8
Load circuits -48Vdc
Load
Alarm
Diode
Matrix
101526
1
2
Diode
Matrix
101526
9
1
2
9
White
Doc, 2020335, 4v0
37
Customer connections
Note! The values in this table are default factory settings. The settings of a Smartpack controller in
an installed system may be different from the above settings, depending on the system’s final
configuration of optional kits, number/type of batteries, alarm setup and/or any other changes done
to the system and/or the Smartpack controller after the system was shipped from the factory.
38
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
LOAD DISTRIBUTION LIST
System Data
Flatpack2 PSS, type:
Article No.:
Site, name:
FUSE
ID
Form xxx-gb-v1-C01_351476-033_instgde_fp2-pss-16kw-48vdc-ocab-fanc-2m0.doc_ts/mfm_2007-06-19
F1
F2
F3*
F4*
F5
F6
F7
F8
F9
F10
F11
F12
F13*
F14*
F15*
F16*
F17*
F18*
F19*
F20*
FUSE TYPE
BTS
MCB
GMT
FUSE
LTE
MCB
RATING
LOAD DESCRIPTION
AMPERE
CABLE
SIZE
mm2
CABLE
SIZE
AWG
X
X
X
10
X
10
X
10
X
10
X
10
X
10
X
10
X
10
10
10
10
10
10
10
10
10
*Optional fuses/breakers.
F3 & F4 are only fitted if optional BTS breaker kit(s) are installed in the cabinet.
F13-F20 are only fitted if optional LTE kit is installed in the cabinet
Breakers F1, F2 and GMT fuses F5-F12 are always part of cabinet
LTE MCB`s
(Optional)
BTS MCB`s
For details, see installation manual
for LTE kit (351480.033)
For details, see chapter
“Location of Components General
arrangement”
GMT FUSES
For details, see chapter
“Terminals and pin-out location
GMT fuse”
Eltek Energy AS
Tel. +47 32 20 32 00
Internet: www.eltekenergy.com
E-Mail: eltek@eltekenergy.com
ELTEK Energy
P-O- BOX 2340 StØmsØ
N-3003 DRAMMEN
NORWAY
Phone:
Telefax:
Internet:
e-mail:
Location
Norway
Americas
Asia/Pacific
China
Europe
Middle East
+47 32203200
+47 32203210
http://www.eltekenergy.com
eltek@eltekenergy.com
Company
Eltek Energy AS
Eltek Energy, LLC
Eltek Energy Pte Ltd.
Eltek Energy Ltd.
Eltek Energy UK Ltd.
Eltek Middle East
Telephone
+47 32 20 32 00
+1 815 459 9100
+65 6 7732326
+769 22651108
+44 1442 219355
+971 4 887 1176
Fax
+47 32 20 32 10
+1 815 459 9118
+65 6 7753602
+44 1442 245894
+971 4 887 1175
www.eltekenergy.com