installation guide flatpack2 ps system indoor v3

35

1475

.033

Installation Guide

DC Power Supply System, 16kW, 48VDC Indoor 2.0m Cabinet

1 Welcome

2 Installation Guide Flatpack2 PS System, 16kW, 48VDC, Indoor 2.0m Cabinet 351475.033, v3-2007-06

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

Certificate no: 900005E

Certificate no: 900005Q

Power Distribution Centre for

Communications Equipment

35KS

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/48Vdc ID 2m” has part no. CF1042.010.

351475.033 Issue 3, 2007 June Published 2007-06-19 Mfm

1 Welcome

Installation Guide Flatpack2 PS System, 16kW, 48VDC, Indoor 2.0m Cabinet 351475.033, v3-2007-06 3

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 System Specification .......................................................................................... 11

3. Installation 12

Safety Precautions ........................................................................................................ 12 Installing the Modules ......................................................................................... 13

Mounting or Removing Smartpack and Flatpack2 Modules ................................................... 13 Mounting and Removing Blind Panels .................................................................................... 14 Correct Rectifier Position in Power Shelves ........................................................................... 14

System Installation .............................................................................................. 15 Site Preparation ............................................................................................................ 15 Mechanical Installation .................................................................................................. 15 Electrical Installation ..................................................................................................... 16

4. Commissioning 19

Pre-Start Check ................................................................................................... 19 Commissioning Steps, Startup .......................................................................... 20

Startup and No-Load Adjustments .......................................................................................... 20 Load Adjustments ................................................................................................................... 21

5. Forms, Schematics & Drawings 22

Installation Check List ............................................................................................. 22 Commissioning Procedure ....................................................................................... 22 Maintenance Procedure ........................................................................................... 22 General Arrangement Drawing ............................................................................... 22 System Schematic Drawing ..................................................................................... 22 Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m .......... 22 Load Distribution List ............................................................................................. 22

1 Welcome


1. Welcome The Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m is a DC power supply for telecom equipment suitable for indoor applications.

About this Guide This booklet provides users of the Flatpack2 PS System, 16kW, 48VDC, ICab 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. 351475.003

2. System Description The Flatpack2 PS System, 16kW, 48VDC, ICab 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 600x600x2000 mm (23.6”x23.6”x78.7”) (WxDxH).

2 System Description


Location of Components ~ General Arrangement

Figure 1 General Arrangement Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m

AC MainsTerminals

AC EarthMains Protective Earth (PE)

Connection(Cabinet main ground bar) DC Earth

Telecom Earth (TE) Connection

Battery DC (+) terminalsBus bar, 35mm2, AWG 2

Smartpack controllerand CON 4 (monitoring terminals on the controller’s rear panel)

DC (+) Load TerminalsCommon positive bus bar, 70 mm2, AWG 2/0

DC (-) Load Terminals(BTS MCBs) 25mm2, AWG 4, 70mm2, AWG 2/0 (on top of each load breaker)

Battery DC (-) terminalsBus bar, 35mm2, AWG 2

Alarm Terminals1.5mm2, 16AWG

(Front access)

Terminals forGMT 10A Load

Fuses, 1.5mm2, AWG 16

Smartpackcontroller unit

Flatpack2rectifier modules

Battery strings and fuses in the lower part of the

cabinet

DC DistributionMCB Load, Alarm and Signal Terminals located behind the front cover

AC Input Terminals Located behind the front cover



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.

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

3. Rewire internal cables N2 and N4 as shown, ONLY when reconfiguring to “∇ Mains, IT Three-phase, 230VAC”. Do not rewire the rest of the internal cables

N N L1 L2 L3

Υ Mains, TN Three-phase & N, 400VAC

AC Mains Cable

AC Mains wires

AC Mains Terminal Block

Flatpack2 DC Power System

Fish Plate

Factory configured AC Mains terminal block.

L1 L2 L3

(To internal connections)

N2 N4

N N L1 L2 L3

MainsOne-phase, 230VAC/208VAC

AC MainsCable

AC Mains wires



Fish PlateWires Links

L1 L2


N2 N4

N N L1 L2 L3

Δ Mains, ITThree-phase, 230VAC/208VAC

AC MainsCable

AC Mains wires



Fish Plate

L1 L2 L3


N4 N2 Rewire!Swap the position of internal cables N2 and N4.

External AC Fuses ~ Recommended Ratings

AC Mains Type External Fuse Type 400VAC +N, 3 ph 50A – C-char. 230VAC, 1 ph 100A – C-char. 230VAC, 3 ph 63A – C-char. 208VAC, 1 ph 70A. Note: An external AC breaker is required on all sites, and it must be switched off under installation.



Terminals & Pin-out Location, GMT Fuses

Figure 2 GMT fuse board (max. cable size 1.5mm2, AWG 16)

The table below shows the pin-out location for the GMT load fuse card:

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)

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.

Pin Assignment for GMT Fuse Pin Signal Function Pin Signal Function 1 2

+ —

GMT fuse 1 (F5) 9 10

+ —

GMT fuse 5 (F9)

3 4

+ —

GMT fuse 2 (F6) 11 12

+ —

GMT fuse 6 (F10)

5 6

+ —

GMT fuse 3 (F7) 13 14

+ —

GMT fuse 7 (F11)

7 8

+ —

GMT fuse 4 (F8) 15 16

+ —

GMT fuse 8 (F12)

Alarm Relays & Digital Inputs

Correct Use of Digital Inputs (example)

Normal ModeExternal Relay Y(Energized coil)

+—

Digital Input X (Normal mode)

Alarm ModeExternal Relay Y

(De-energized coil) +

—Digital Input X (Activated)

Flatpack2 PS System

Correct Use of Alarm Outputs (example)Flatpack2 PS System

—

+

NC

NOCom

Normal ModeRelay X

(Energized coil)

+—

Alarm Mode

Relay X(De-energized coil) NC

NOCom

Alarm Relay Specification 30 VDC, 2A Nominal switching capacity 60W (resistive load) Maximum switching power 220 VDC Maximum switching voltage 2A DC Maximum switching current

GMT fuses Max. 10A each

Pin 16 Pin 1

F5

F12

F8



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.

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).

Terminals & Pin-out Location

Alarm Outputs & Digital Inputs Card, Art. 105954

CON2A CON1A

1 10 20 1

*X1 *X2


System Connections Card, Art. 200625

Smartpack

Battery Connections Card, Art. 200576


CON1A

CON2A

CON2

CO

N1

4 3 2 1

5

9 8 7 6

10

*X1:

(Customer Connections)

Input Circuit 1

Input Circuit 2

Alarm Circuit 1

Alarm Circuit 2

OutIn

(To

and

from

ex

tern

al e

quip

men

t) 1.5 mm2, max.

wire section

Relay 2High Battery Alarm

Relay 1OVP Alarm

+−

NOCOM

NC

NOCOM

NC

+−

Digital Input 1

Digital Input 2

Alarm Outputs & Digital InputsVoltage free relay outputs and Configurable monitoring digital inputs

FUNCTION SIGNAL PIN-OUT

Input Circuit 3

Alarm Circuit 3

Input Circuit 4

Input Circuit 5

Input Circuit 6

Alarm Circuit 4

Alarm Circuit 5

Alarm Circuit 6

4 3 2 1

5

9 8 7 6

10

14 13 12 11

15

*X2:

16 17 18 19 20

+−

+−

+−

+−

NOCOM

NC

NOCOM

NC

NOCOM

NC

NOCOM

NC

Digital Input 3

Digital Input 4

Digital Input 5

Digital Input 6

Relay 3Low Battery Alarm

(To

exte

rnal

equ

ipm

ent)

(Fro

m e

xter

nal e

quip

men

t)

Card Art.105954 1

To S

mar

tpac

k,C

ON

2To

Sm

artp

ack,

CO

N1

Relay 5Battery Alarm: -10°C >Temp>50°C

& Rectifier Alarm

Relay 4Fuse Alarm

Load & Battery

Relay 6Mains Alarm &

Mains Low & High Alarms



Terminals & Pin-out Location, System Interface Card 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.

LVD Latching Contactors Flatpack2 systems’ LVBD and LVLD1 functionality is implemented by the Smartpack controlling magnetically latching contactors.

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

Latching Contactors, LVD1 & LVD2

A latching contactor changes state only when a reversed pulse voltage is applied to its coil

+ Pulse

ON

- Pulse

OFF

Correct Use of Latching Contactors (example)

PCB Art. 200625

10

8 9

X:*****

+

—

LVD1A

LVD2A LVD Common

Smartpack Unit

Flatpack2 PS System (internal)

11

LVD Common

Latching Contactor LVD2

Y

X

Latching Contactor LVD1

Y

X

Latching Contactor

Y

X

Bidirectional diode

Warning! The bidirectionaldiode must always bemounted to avoid dam-aging the controller.

+

4321

5

9876

1011

X:*****Power Input

−+−+−

10156

712

139+, Neg.D.

11−,Pos.D.1+/−3+/−

2+/−

Batt. Fuse Fail 1 Load Fuse Fail 1

Batt. Current 1

LVD1A LVD Common LVD1

OutIn

Term

inal

Boa

rd, A

rt. 2

0062

5 (T

o S

mar

tpac

k, C

ON

5)

(Internal Connections)Sy

stem

Con

nect

ions

JP2

LVD2ALVD Common LVD2(To latching contactors LVD1 & LVD2)

JP1 and JP2 are used to configure thesystem for Negative DC distribution (48 and60V systems) or Positive DC distribution(24V systems)

System Connections Card, Art. 200625 111 CON5A

JP1 JP2

X*****

Terminals & Pin-out Location

JP1

2 3

1 JP2

21

3

Neg. Distr.Pos. Distr.

Neg. Distr.Pos. Distr.


System Connections Card, Art. 200625

Smartpack



CO

N5A

CON5

For I

nter

nal U

se O

nly!



Monitoring, Control and Signal Interface The Flatpack2 PS System, 16kW, 48VDC, ICab 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.



System Specification

Technical Specification

Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m Max. No. of rectifiers 8 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 Current See Flatpack2 48VDC

datasheet (241115.001.DS3)

OVP (Optional)

Live – surge arrestor Neutral – spark gap Class C, type II In(8/20) – 40kA

MONITORING Monitoring Unit Smartpack Local operation Menu driven software via

keypads and LCD 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 measurements

Battery current Rectifier current Load current

Alarms Load fuse alarm OVP Alarm* Battery fuse alarm Low Battery Voltage High Battery Voltage Temperature alarm Mains detect alarm

DC OUTPUT Voltage 48VDC Current Up to 16 KW – 340A CONNECTIONS Battery connections

Battery cable, M8 bolts

Load MCB connections

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 breakers

Up to 4 x 3pole 150A

No. of Battery breakers

Up to 4 x 150A MCBs mount next to 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 -10 to +50°C (14 to +122°F) Storage temp -10 to +85°C (14 to +185°F) Dimensions 600x600x2000mm (WxDxH)

(23.6”x23.6”x78.7”) Weight Approx. 80kg excl. rectifiers and

batteries Max. 250kg load 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

Rectifier Input Voltages Type VAC Note Nominal 230 Range 185 – 275 Full output power Low voltage 1 0 – 85 Shutdown Low voltage 2 85 – 185 Linear between 850W and 2000W

Type VAC Note High voltage 1 185 – 275 Full output power High voltage 1 275 –300 Full power, reduced power factor High voltage 2 300 – 350 Shutdown High voltage 3 350 – 420 Shutdown* (see note below)

* Note: If the input voltage is > 300Vac the rectifier will go into self protective mode. At no load, the rectifier will survive 350Vac. With load or battery connected, it will survive 420Vac.

Specifications are subject to change without notice

3 Installation


3. Installation This section describes how to install the Flatpack2 PS System, 16kW, 48VDC, ICab 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. 351475.003

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

3 Installation


Installing the Modules

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.

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

4. Mount blind panels in unused module locations

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

Handle in unlocked position

Flatpack2rectifier

Smartpack controller

Handle in locked position

Hole to release the handle’s spring mechanism

Electric shock

3 Installation


Mounting and Removing Blind Panels

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)

Screwdriver to release the locking tabs

Blind panel’s upper locking tabs

Correct Rectifier Position in the Power Shelves Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers

Δ Mains Three-phase, 230VAC

Υ MainsThree-phase & N, 400VAC

and

01 04

03 06

--- ---

02 05

--- ---

--- ---------------

Position 1

Position 4

Flatpack2rectifier

Position 8

Position 9

Smartpackcontroller

ID number (Assigned CAN bus address)

Phase 1

Phase 2

Phase 3

3 Installation


System Installation

Site Preparation Refer also to chapter “Location of Components ~ General Arrangement” on page 5. Step Action OK

1. Organize the installation site

o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm. If Flexi Kit(s) are going to be installed, ensure sufficient space behind the cabinet to allow access to rear panel

o Check that the levelled surface is able to support 600 kg (cabinetized systems). Refer to System Specification, page 11.

o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas

2. Prepare the installation tools

Check that insulated tools suitable for telecom installations are used

3. Prepare AC Supply: AC input cable(s) and fuses

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 Action OK

4. Remove packaging and check equipment

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)

5. Remove top cover, dummy front panels and Tool Kit

o This is required for accessing the connection terminals

o Check that cable entry from the top is possible

o Please refer to “Assembly Guide for IFC”, doc. no. 351478.033, chapter 2 “Description of the Toolbox” for detailed information on how to remove the tool kit.

3 Installation


Step Action OK 6. Position and fasten

the cabinet

Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor

7. Mount the batteries on the shelves

Start (if applicable) on the lower shelf first, and continue upwards. Use kits, if supplied; refer to the “Installation Guide for Battery string + Indoor Shelf”, Dc. No 351485.033, for details. Do not terminate the battery cables yet!

Electrical Installation Refer also to chapter “Location of Components ~ General Arrangement” on page 5. Step Action OK 8. Make the system

completely voltage free

Switch OFF or remove ALL load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses

9. 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.

o Fasten the cables to the horizontal metal bar (I) as strain relief.

3 Installation


Step Action OK

10. DC Connections Load Circuits

3-pole link for CBI MCB

2-pole link for CBI MCB

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, ICab 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 bridges. 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 bridge. Then the 3rd hole in the breaker cannot be used. If the load current is larger than 100 A, use the three pin copper bridge. Insert the chosen copper bridge on to the top of the MCB. - Connect the orange alarm wire to the copper bridges with a screw if the bridges 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 bridges.

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

11. DC Connections Alarm & Signal Circuits

o Terminate Alarm Circuit cables to the relay output terminals. Refer to chapter “Terminals & Pin-out Location, Alarm Interface Card” on page 8.

2 The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.

3 Installation


Step Action OK

12. DC Connections Battery Cables

The positive and negative (-48V) battery cables are connected from factory to the common positive bus bar and to the battery MCBs (additional battery string kits are not). The battery temperature sense cable is also pre wired to CON4, and temporally fixed to the cabinet’s wall.

o Connect all battery inter-cell links o 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 Fix battery cables. Use attached cable ties o Place the temperature sensor, located at the end of

the battery temperature sense cable, on top of the topmost battery string

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

Pre-Start Check Check off in the Commissioning Procedure, that you find in the pullout 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:

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

Device hazard

I Power is

OFF!

4 Commissioning


Commissioning Steps, Startup Check off in the Commissioning Procedure, that you find in the pullout 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:

Startup and No-Load Adjustments 1. Disconnect all rectifier modules, without removing them (keep original location)

o Read how to install modules, on page 13. Also, read about the correct rectifier position on page 14, 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. Switch ON the system o Switch ON the AC input supply (external AC fuses) to the PS cabinet

3. 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

4. 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 13

o Mount blanking panels over unused positions

5. 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

6. 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

7. 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

8. 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)

9. 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.

Device hazard

II Power is

ON!

4 Commissioning


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:

10. 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 PowerSuite— to

equal the measured battery voltage. (Important adjustment to avoid arcing when connecting the batteries)

11. 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

12. 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)

13. 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.

14. 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

Devicehazard

Devicehazard

III Power is

ON!

5 Forms, Schematics & Drawings


5. Forms, Schematics & Drawings This section includes following forms and schematic drawings:

Installation Check List

Commissioning Procedure

Maintenance Procedure

General Arrangement Drawing

System Schematic Drawing

Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m

Load Distribution List


INSTALLATION CHECK LIST System Data Flatpack2 PS System Flatpack2 Power Supply System, type: Article No.:

Site, name:

Serial No.: Software, version No.: Rectifiers, type & number of:

AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:

Site Preparations CARRY OUT FOLLOWING: OK

1. Organize the installation site o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm o Check that the levelled surface is able to support 600 kg (cabinetized systems) o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas

2. Prepare the installation tools o Check that insulated tools suitable for telecom installations are used

3. Prepare AC Supply: AC input cable(s) and fuses o Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated

Mechanical Installation Power is OFF! CARRY OUT FOLLOWING: OK

4. Remove packaging and check equipment 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)

5. Remove top cover, dummy front panels and Tool Kit o Check that cable entry from the top is possible; Read how to remove the Tool Kit on Doc. No. 351478.033

6. Position and fasten the cabinet o Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor

7. Mount the batteries on the shelves o Start (if applicable) on the lower shelf first, and continue upwards. Use kits, if supplied; refer to Doc. 351485.033 o Do not terminate the battery cables yet!

Electrical Installation Power is OFF! CARRY OUT FOLLOWING: OK

8. Make the system completely voltage free o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses

9. 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) o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond

10. DC Connections ⎯ Load Circuits o Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place o For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB

11. DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output terminals, if applicable

12. 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 battery symmetry cables, if applicable, to the input terminals 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.:

EMC regard

Electric shock

Device hazard

Electric shock


COMMISSIONING PROCEDURE System Data Flatpack2 PS System Supplier’s Order No.: Flatpack2 Power Supply System, type: Article No.:

Site, name:


AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:

Pre-Start Check Power is OFF! CHECK FOLLOWING: OK 1. 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

Start-up, No-Load & Load Adjustments Power is ON! CARRY OUT FOLLOWING: OK 1. Disconnect all rectifier modules, without removing them (keep original location) 2. Switch ON the system (external AC fuses ON) 3. AC input voltage is correct; Measure and verify

4. Insert all Flatpack2 rectifiers in their original locations in the power shelves 5. The Smartpack and all rectifier modules are working, LEDs are ON; Verify

6. Connect a PC to the PS system Install the PowerSuite software, if required

7. DC output voltage; Measure and adjust

8. Alarm relay test; Verify all alarm relays are working correctly 9. System Setup is in accordance with configuration Enter site spec. info in PowerSuite 10. Adjust DC output voltage to equal measured battery voltage Check correct polarity! 11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs 12. Adjust DC output voltage to equal nominal battery or load voltage 13. Plug in again all rectifiers, and verify the rectifiers’ current sharing 14. Connect all load MCBs/ fuses, and verify no alarms are displayed

Approval Responsible of commissioning, sign.: Date: Approved by customer, sign.:

Device hazard

I

II

Device hazard

III

Device hazard


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.

Electric shock

MAINTENANCE PROCEDURE System Data Flatpack2 PS System Flatpack2 Power Supply System, type: Article No.:

Site, name:


AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:

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 is free from damage, dust or dirt; verify. Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.

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.:


Figure 3 General Arrangement Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m Doc, 24nnnn.yy, XvX

HxDxW: 2000x600x600mm

2U

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34U

36U

38U

40U

42UAC Mains Connection, located behind the panel, on the right side *OVP behind panel Battery DC (+) terminals

Flatpack2rectifiers

Battery MCBFB4*

Battery MCBFB3*

Battery MCBFB2*

Battery MCBFB1*

Max. Battery Height: 7U

* Optional


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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.

LOAD DISTRIBUTION LIST System Data Flatpack2 PSS, type: Article No.:

Site, name:

FUSE ID

FUSE TYPE LOAD DESCRIPTION

RATING

AMPERE

CABLE SIZE mm2

CABLE SIZE AWG BTS

MCB GMT FUSE

LTE MCB

F1 X

F2 X

F3*

F4*

F5 X 10

F6 X 10

F7 X 10

F8 X 10

F9 X 10

F10 X 10

F11 X 10

F12 X 10

F13* 10

F14* 10

F15* 10

F16* 10

F17* 10

F18* 10

F19* 10

F20* 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

BTS MCB`s For details, see chapter

“Location of Components General arrangement”

GMT FUSES For details, see chapter

“Terminals and pin-out location GMT fuse”

LTE MCB`s(Optional)

For details, see installation manual for LTE kit (351480.033)

Eltek Energy AS Tel. +47 32 20 32 00

Internet: www.eltekenergy.com E-Mail: [email protected]

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www.eltekenergy.com

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

Location Company Telephone Fax Norway Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10 Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118 Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602 China Eltek Energy Ltd. +769 22651108 Europe Eltek Energy UK Ltd. +44 1442 219355 +44 1442 245894 Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175

installation guide flatpack2 ps system indoor v3

Documents

system monitoring

system description

system interface card

system specification

e certificate

terminals pin

vdc indoor

location of components