qstart-installation-operation-commissioning and maintenance

7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance

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Quick Start GuideInstallation, Operation, Commissioning and Maintenance

DC Power Supply SystemIntegrated, Cabinetized and Outdoor Applications

Flatpack2, PS System

356804.103

MiscellaneousCommunicationo CAN Bus Termination ( 9)o Installing PowerSuite PC software ( 9)AC Mainso External AC Fuses, Recommended Rating (10 )o Identifying Power Shelves, 4AC or 2AC ( 11)o Mains Reconfiguration, Integrated Systems, 1U DC Distribution ( 11)o Mains Reconfiguration, Cabinetized & Integrated, 4U DC Distr. (12-13)o About AC, DC Earthing Systems ( 13)o Mains Phases vs. Rectifier ID Phase Balancing & Monitoring (14-15)Battery Monitoringo Battery Symmetry Connections (16 )o Terminals & Pin-out Location, Battery Interface Card ( 17)Alarms & Monitoringo Standard Alarm Relays & Digital Inputs Connections (18 )o Terminals & Pin-out Location, Alarm Interface Card (18 )Internal Connections

o Terminals & Pin-out Location, System Interface Card ( 19)o LVD Latching Contactors Connections ( 19)

Introductiono The Flatpack2 Product Range (2 )o Brief System Description (2 )

Installationo Installing Smartpackand Rectifier Modules ( 3)o Installation steps; mechanical, electrical (4-5)

Commissioningo Pre-start check (6 )o Commissioning steps, Startup (6-7)

Operationo Front keys and display ( 8)o Software Menus ( 8)

Check Lists pullout formso Installation Check Listo Circuit Distribution Listo Commissioning Procedureo Maintenance Procedure


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Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-012

The Flatpack2 Product Range

Eltek Energy's Flatpack2 product range utilizes the Flatpack2 rectifier and the Smartpack

controller as building blocks for implementing effective DC power systems, suitable for a wide

range of applications and power ratings.

Cabinetized systems are suitable for indoor or outdoor applications. In addition to the powersystem and the distribution unit, the cabinet may also contain battery banks, additional

distribution and other dedicated equipment.

Integrated systems consist of the power system, which includes rectifiers and controller(s), and

the distribution unit (1U or 4U high). Integrated systems are sold primarily for mounting in

existing cabinets.

Brief System Description

The Flatpack2 PS system is a compact, powerful and cost-effective DC power supply system,

specifically developed for the telecom industry.

Example of a typical Flatpack2 PS system for DC power supply of telecom equipment. The

system is fed from an external AC mains supply, and consists of rectifiers in power shelves, a

control unit and DC distribution unit. Battery banks, LVD contactors, etc. are typically also a partof the system.

Introduction

Flapack2System, Integrated4U and 1U Distributions

Flapack2System, Cabinetized Flapack2SystemOutdoorCabinet

Flatpack2Cabinetized

Battery string #1

AC mains

supplyselector

SymmetryAlarm &

Temp. Sensor

LVLD

LVBD

Fuse Alarm

AC Fuses,external

(230VAC or400VAC

Telecomequipment

AC Supply(Single- or

three-phase)

Alarm Outputs NC-C-NODigital Inputs

BatteryFuses

Load Fuses& MCBs

Smartpack(Ctrl. Unit)

Flatpack2(rectifiers)

PowerSuiteApplication

CAN Bus

USB cable

DCdistribution

DC Supply(24V, 48Vor 60V*)

*Available from 2006


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Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 3

Installing Smartpackand Rectifier Modules

Installation

Handle inunlocked position

Flatpack2rectifier

Smartpackcontroller

Handle in locked position

Hole to release thehandles springmechanism

Removing Blind Panels

1. Release the panels upper left and right corners byinserting a small screwdriver into the panels 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 byusing you hand to pull the panel loose

Mounting Blind Panels

1. Insert the panels upper edge bypressing gently so that its upper locking tabs engage

2. Lock the panels lower edge bypressing with your hand so that the blind panels lower tabs lock

into position.

Screwdriver torelease the lockingtabs

Blind panels upperlocking tabs

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)

Electricshock

Mounting or Removing Smartpackand Flatpack2Modules

Note that cables are plugged to the Smartpacks rear panel. When

mounting the controller, you must plug the cables before step 2. When

removing it, unplug the cables duringstep 2.

1. Unlock the handles byinserting 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 makesproper contact (forSmartpack, 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 Smartpackmodule

3. Lock the handles bypushing 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


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Installation Steps

Installation

Check off in theInstallation Check List, that you find in the pullout section of

this folder. Also, refer to the systems specific drawings.

Preparing the Installation Site

Begin preparing the following:

1 Organize the installation site

o Min. clearances for cabinet access: 60 cm in front, 20 cm on topo Levelled surface able to support 600 kg (cabinetized systems)o Explosive atmospheres are to be avoided. Ensure suitable

ventilation

o 60V systems are only to be installed in Restricted AccessLocations (RAL)

2 Prepare the installation tools

o Use insulated tools suitable for telecom installations3 Prepare AC Supply: AC input cable(s) and fuses

o Correct type AC supply is availableo External AC fuses have correct ratingo AC input cable(s) are sized correctly

EMCregard

200 mm

600 mm

For external AC fuses and AC input cable ratings, refer to your sites AC

supply specification. Read also ourexternal AC fuse recommendations

in section Miscellaneous. In general, a site with better AC supply

quality (stable nominal voltage) may use smaller breakers.

Mechanical Installation Power is OFF!

Carry out the following:

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. To be installed under commissioning

5 Remove top cover and dummy front panels

o Cable entry from the top. Connection terminals are locatedbehind the upper dummy panels

o Battery shelves (if any) are placed behind the lower panels6 Position and fasten the cabinet or subassembly

o Cabinets are floor-mounted on levelled surface. Adjust the legs ifnecessary. If the cabinet must be fastened, unscrew the legs and

use suitable bolts to fasten it to the floor

o Subassemblies are fastened in existing 19 or in ETSI cabinets,using brackets. Mount the support & heat deflecting plate under

the lower power shelf

7 Mount the batteries on the shelves

o Start (if applicable) placing the batteries on the lower shelf first,

and continue upwardso Do not terminate the battery cables yet!

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Flatpack2PSS, batteries, Doc.Chart, Spec. Drawings, CD-ROM


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Installation

Electrical Installation Power is OFF!

Carry out the following: (Refer to the systems specific drawings)

8 Make the system completely voltage free

o Switch OFF or remove all load fuses (MCB1, MCBx), batteryfuses (Fb1, Fbx) and the AC supply fuses, in external fuse

boards

9 AC Connections

o Check AC configuration: the AC terminals are correct configuredto the external AC supply, otherwise reconfigure the terminals

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 Circuitso Terminate DC Earth (TE), and check that the common DC

Output Rail is connected to Telecom Earth (TE) at only one

place (at the cabinet or at a central distribution point). Se

chapter about AC, DC earthing systems

o For each DC load, connect one of the cables to the common DCoutput rail, and the other directly to the MCB or load fuse

11 DC Connections Alarm & Signal Circuits

o Refer to your systems connection drawings and configuration, orto the Miscellaneous, Alarms & Monitoring section (Factory

Settings)

o Terminate Alarm Circuit cables to the relay output terminalso Terminate Signal Circuit cables to the digital input/output

terminals

12 DC Connections Battery Cables

Careful! Use correct polarity.

For each battery shelf: (refer to the figure in this page)

(In cabinetized systems, steps b, d and f are usually performed in factory)

a Mount 3 intercell links to connect in series 4 battery blocks

b-c Connect battery cables to fuses and common DC rail, and to

the shelfs outer terminals; black (+); blue (-)

d-e Connect battery symmetry cables, if applicable, to the input

terminals, and to the center terminal of the battery string(+) and to the -48V outer terminal. Deviation from factory

settings requires Symmetry reconfiguration viaPowerSuite

f-g Connect the temperature sensor cable, if applicable, to the

D-Sub plug or input terminal, and fix the temperature

sensor (at the end of the cable) to a suitable place in the

middle of the installed battery bank

(-48V) OuterTerminal

+0V OuterTerminal

Link 2(DC Earth)

CommonDC RailEGBattery

Fuse

Intercell Links

BatteryCable S

ym

metry1

2-1

Chassis

Card Art.200576

+-

15 pins D-Sub(male)

Temp.sensorT

emp.Sensorcable1

Block1

- ++-+-+-

Block4Block3

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The commissioning ofFlatpack2 PS System consists of following stages:

I. Perform a pre-start check before the PS system is switched ONII. Switch ON the system with disconnected load; adjust output voltage

III. Adjust the nominal output voltage with connected batteries and load

Pre-Start Check Power is OFF!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 theFlatpack2 PSsystem, verify the following:

1. System installation is completedo Ensure a correctly performed system installation, with correct polarity on all

connections, has been carried out (Installation Check Listfilled in)

o All cabling and copper bars are securely terminated and supportedo All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled

2. Battery and load fuses are disconnectedo Verify that all battery and load MCBs/ fuses are switched OFF or removed

3. AC input cable(s) and AC Earth wire (PE) are terminatedo Make sure that the AC input cable(s) are connected to correctly configured AC terminalso Verify that the AC input cable(s) and external AC fuses are sized and rated as specifiedo Check that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)

4. Site specific parameters and settings are knowno Read the system specific drawings and documentation

5. AC supply and all MCBs, fuses are switched OFFo Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF

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 thenmeasure the output voltage, and adjust it if required. Carry out the following:

Startup and No-Load Adjustments Power is ON!

1. Disconnect all rectifier modules, without removing them (keep original location)o Read how to install modules, on page 3 in this guide. Also, read about the correct

rectifier position on page 15, and then,

o IfFlatpack2 rectifier modules are installed, unlock the handles and pull themodules partially out (fan housing visible), but do NOT physically remove them

from the power shelves

o IfFlatpack2 rectifier modules are not yet mounted, release their handles and insertthem partially into the correct position in the shelves

2. Switch ON the systemo Switch ON the AC input supply (external AC fuses) to the PS cabinet

3. Measure and verify that theAC input voltage is correcto Measure the AC input voltage at the cabinets mains connection boxo Verify the AC voltage is within range

Commissioning

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I

II


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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 15

o Mount blanking panels over unused positions

5. Ensure that theSmartpackand all rectifier modules are working: LEDs are ONo Verify correct operation, by monitoring the modules LED lamps and display:

No alarms are present on rectifiers; The Smartpackdisplays 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 Smartpackcontrollero StartPowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite

Refer to chapter InstallingPowerSuitePC Application, page 9, if required

o On the toolbar, click the Connect button to establish connection

7. Measure and adjustDC output voltageo Read the DC output voltage on the controllers displayo 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 MCBso If required, adjust the voltage using the controllers front keys or viaPowerSuite

8. Verify the alarm relays are working correctly (alarm relay test)o Run the alarm relay test using the controllers front keys (refer to page 8) or via

PowerSuite (select the menu Go > Output Test)

9. Make sure theSystem Setup is in accordance with configurationo Verify system settings using the controllers front keys or viaPowerSuiteo Use the opportunity to enter site related information, number of used AC phases,

type of batteries, etc.

Load Adjustments Power is ON!

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.AdjustDC output voltage to equal measured battery voltageo Measure the battery voltage is within range (check connections have correct polarity)o Adjust DC output voltage using the controllers front keys (refer to page 8) 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 partiallyout (fan housing visible). Do NOT physically remove them from the power shelveso Switch ON all battery fuses or MCBs

12.Adjust DC output voltage again to equal the nominal battery voltageo Adjust DC output voltage using the controllers front keys or viaPowerSuite 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 IIo Wait for about 2 min., and check using thePowerSuite 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 displayedo Switch ON all load MCBs/ fuseso Verify correct operation: rectifiers and controller display no alarms

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III

Commissioning


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Front Keys and display, menus, etc.

Operation

Flatpack2Rectifier Module front panel

Power LED is OFF (mains unavailable), Flashing

(controller accessing information) orON (powered).Warning LED is ON (derating or similar minor

warning), Flashing (over-voltage mode) orOFF (OK)

Alarm LED is ON (shutdown or similar major alarm)

orOFF (OK, no alarm)

Flatpack2rectifier

AlarmLED Lamp (red)

PowerLED Lamp (green)

WarningLED Lamp (yellow)

Software Menus

Service menu

NomVolt BoostVolt LowBatt1

oltAdjustment LowBatt2 HighBatt1 HighBatt2 LVD 1 LVD 2

oltCalibration ------ VoltCal

ChangePassword -- Password SetBoostTime--------

Start/StopBoost

Auto Boost Conf. -- Enable/Disable & AutoBThrs

Nxt Test DateTimeEnd Volt

Batt Test Setup MaxTestDur Test int Guard time

Start/Stop Test

Charge Curr Lim. --- Enable/Disable & Max C.Curr

Battery Setup -------- NumOfString Output Control------- VoltageCtrl / TempCompChange Date/Time

Alarm Output 1RelayTest Alarm Output 2

Batt Contactor

Load ContactorAlarm Output nnBattLifeTime Rst 1v0

Level 2 Level 3

TheX

vXreferences,

ifany,ontherighthandoftheoption,arenotshowninthedisplay.

Theyo

nlyindicateinwhichsoftwarevesjon(x)theoptionwas

firstimplemented.

SmartpackControl Unit front keys, display, etc

Display: is in Status Mode (displays the systems

status) or inMenu Mode (displays the menu structure).

Operation: Press on the key to change from

Status Mode to Menu Mode. Press the or

keys to scroll up or down and navigate to find menu

options (function or parameter). Press then the

key to select the function.

Menus: When you enterMenu Mode (Level 1), you

access the User Options. You may also scroll down to

password protected Service Options. Default password

should be changed.

User menu

AlarmResetNomVoltBoostVoltLowBatt1

VoltageInfo LowBatt2HighBatt1HighBatt2LVD 1

LVD 2DisplayMessages Message SoftwareInfoSerialNumber 1v01

NoOfRects. NnRectCurrent 1v0

Rectifier Info RectSerialNumber 1v0

Rect.PrimaryVolt 1v0

Rectifier Status 1v0

Rectifier Temp 1v0

NoOfPhases nnMains Info Mains Status

Mains VoltageTemp Level Info - Level 1v0

Level 2 Level 3

TheXvXreferences,

ifany,ontherighthandoftheoption,arenotshowninthedisplay.

Theyonlyindicateinwhichsoftwarevesjon(x)the

optionwasfirstimplemented.

PowerLED Lamp (green)

WarningLED Lamp (yellow)

Alarm

LED Lamp (red)

Graphical

Display16 char. x 2 linesLCD display

Up arrow keyDown arrow key

Enter keyUSB0ype B port

Smartpackcontrol unit


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CAN Bus TerminationFlatpack2 systems are shipped from factory with the CAN bus already terminated with 120resistors.

To ensure a correct bus communication and avoid data reflection, you must always terminate

the CAN bus with two 120 resistors, one at each end of the line. The figure shows aFlatpack2system communicating via the CAN bus.

The Smartpackdynamically software-assigns ID numbers to rectifiers. The controller registers

the rectifiers ID numbers, or CAN bus address (01, 02), together with their Serial Numbers.

The Smartpacks ID numbers (1, 2) are assigned by DIP switches on the controllers side.

Terminate the CAN bus with only two 120 resistors, one at each end of the line. The figureshows twoFlatpack2 systems communicating via the CAN bus.

Installing PowerSuitePC ApplicationThePowerSuite software application enables you to configure and operate theFlatpack2 Power

Supply System from a personal computer.

Communication Miscellaneous

120

Flatpack2DC Power System

End-of-LineResistor

End-of-LineResistor

120

CAN bus(twisted-pair internal CAT5 cable)

USB A-B cable(standard)

01 02 n

1

120

Flatpack2DC Power System 2

120

Flatpack2DC Power System 1

End-of-LineResistor

End-of-LineResistor

01 02 n n+1 n+2 m

1 2

3. Wait for Windows to install USB driversFollow & accept the wizard default steps to automatically install the USB drivers; the wizard runs twiceNew hardware

is ready to use

3

IfPowerSuite fails communicating via the standard COM port, find the COMx assigned to Smartpack (My Computer/ Properties / Hardware/Device Manager) and configure PowerSuite to communicate via this COMx (read the instructions in the installation CD).

PowerSuites newest version is always available on our FTP server. Call your Elteks contact person.

Flatpack2system configuration from a PC running MS Windows XP

2. Switch SmartpackON and plug USB cable (Part 202073)to Smartpackand to any available USB port in the PC 2

1. Install PowerSuiteInsert the CD in your PC drive, start the PowerSuite installation and follow & accept the wizard default steps toinstall .Net software and PowerSuite

1

4. Start PowerSuite and establish connectionSelect Start > All Programs > Eltek > PowerSuite. On the toolbar, click Connect button. On the Connectiondialogue box, click the Connect button

4


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External AC Fuses Recommended RatingThe sites AC supply quality is of great importance. In general, a site with better AC supply

quality (stable nominal voltage) may use smaller breakers.

205V

ACInputs

AC Mains No of Power Current Ext. FuseType Shelves Max. (A) Type

1 21.6 25A-C2 43.1 50A-C3 43.1 50A-C

400VAC +N3 phase

4 64.7 80A-C

1 37.4 40A-C

2 56.1 63A-C

3 74.8 80A-C

230VAC3 phase

4 112.2 125A-C

1 43.0 50A-C230VAC1 phase 2 86.0 100A-C

2ACPowerShelves

2ACinputspershelf,each

feeding2rectifiers


1 21.6 25A-C400VAC +N3 phase 2 32.3 40A-C

1 29.5 32A-C230VAC3 phase 2 56.1 63A-C

1 43.1 50A-C230VAC1 phase 2 86.2 100A-C

4ACPowerShelves


feeding1rectifier

185VA

CInputs

4ACPowerShelves


feeding1rectifier


1 23.9 25A-C400VAC +N3 phase 2 35.8 40A-C

1 32.7 40A-C230VAC3 phase 2 62.1 63A-C

1 47.8 50A-C230VAC1 phase 2 95.6 100A-C

2ACPowerShelves


feeding2rectifiers


1 23.9 25A-C2 47.8 50A-C3 47.8 50A-C

400VAC +N3 phase

4 71.7 80A-C

1 41.4 50A-C

2 62.1 63A-C

3 82.9 100A-C

230VAC3 phase

4 124.3 125A-C

1 48.0 50A-C230VAC1 phase 2 96.0 100A-C

External AC FusesRecommended Ratings

1AC Feed to 1 Flatpack2rectifier

AC Mains Ext. Fuse TypeType FS=I FS=0

185VAC 25A-C 13A-B

205VAC 25A-C 10A-B

FS=I (Fuse Selectivity: Internal)which means that the Flatpack2rectifiers internal fuse will trip be-fore the external AC fuse.

FS=0 (Fuse Selectivity: none) thesefuse types may be used when it isirrelevant whether the internal orthe external fuse trips first.

Note: Always replace a rectifier

with blown internal AC fuse with anew module, and send the mal-functioning module for servicing.

Miscellaneous AC Mains

Use the recommendations in the205VAC table, if you are sure theavailable AC mains voltage will notdrop below 205VAC.

OR

If you are unsure or know thatthe voltage may drop below

205VAC

use the 185VAC tablerecommendations.

Only difference between the 205 and the185VAC recommendation tables


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PULLOUT

CheckL

istsPullout

Pulloutthepagesw

iththegrayouterba

nd,

andusethe

maschecklists


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INSTALLATIONCHECKLIST

SystemDataFlatpack2PSSystemFlatpack2PowerSupplySystem,type:ArticleNo.:

Site,name:

SerialNo.:Software,versionNo.:Rectifiers,type&numberof:

ACInputVoltage,measured:BatteryType:BatteryCapacity:Installationcarriedoutby,name:

SitePreparations

CARRYOUTFOLLOWING:OK1.Organizetheinstallationsite

oCheckmin.clearancesforcabinetaccess:frontaccess,60cm,topaccess,20cmoCheckthatthelevelledsurfaceisabletosupport600kg(cabinetizedsystems)oEnsuretheinstallationsiteissuitablyventilatedandinanon-explosiveatmosphere.60VsystemsinRALareas

2.PreparetheinstallationtoolsoCheckthatinsulatedtoolssuitablefortelecominstallationsareused

3.PrepareACSupply:ACinputcable(s)andfusesoChecktheACsupplyisthecorrecttype,andthattheexternalACfusesandACinputcable(s)aresuitablyrated

MechanicalInstallationPowerisOFF!

CARRYOUTFOLLOWING:OK4.Removepackagingandcheckequipment

oCheckyouhavereceivedalltheparts,correctcabinet,documentation,batteries(ifapplicable),etcoInspecttheequipmentforphysicaldamage(reportanydamages)oLeaverectifiermodulesintheirpackagingorintheselves,iffactoryinstalled.(commissioningtask)

5.Removetopcoveranddummyfrontpanels

oCheckthatcableentryfromthetopispossible

6.PositionandfastenthecabinetorsubassemblyoCabinetsonlevelledsurface,adjustthelegs.Ifnecessary,unscrewthelegsandfastenthecabinettoflooroSubassembliesinexisting19orinETSIcabinets,usingbrackets.Mountthesupport&heatdeflectingplate

7.MountthebatteriesontheshelvesoStart(ifapplicable)onthelowershelffirst,andcontinueupwardsoDonotterminatethebatterycablesyet!

ElectricalInstallationPowerisOFF!

CARRYOUTFOLLOWING:OK8.Makethesystemcompletelyvoltagefree

oSwitchOFForremoveallloadfuses(MCB1,MCBx),batteryfuses(Fb1,Fbx)andexternalACsupplyfuses9.ACConnections

oCheckACconfiguration:TheACterminalsarecorrectconfiguredtotheexternalACsupplyoConnecttheACEarthwire(PE)totheterminalsACEarth(PE)oConnecttheACinputcable(s)totheterminals.Cableandterminalblocklabelingaretocorrespond

10.DCConnectionsLoadCircuitsoTerminateDCEarth(TE):CommonDCOutputRailisconnectedtoTEatonlyoneplaceoForeachDCload,connectoneofthecablestothecommonDCoutputrail,andtheotherdirectlytotheMCB

11.DCConnectionsAlarm&SignalCircuitsoRefertoyoursystemsconnectiondrawingsandconfiguration,ortotheFactorySettingsintheQuickStartGuideoTerminateAlarmCircuitcablestotherelayoutputterminalsoTerminateSignalCircuitcablestothedigitalinput/outputterminals

12.DCConnectionsBatteryCablesCareful!Usecorrectpolarity.Foreachbatteryshelf,

oMount3intercelllinkstoconnectinseries4batteryblocksoConnectbatterycablestofusesandcommonDCrail,andtotheshelfsouterterminals;black(+);blue(-)

oConnectbatterysymmetrycables,ifapplicable,totheinputterminalsoConnectthetemperaturesensorcable,ifapplicable,totheD-Subplugorinputterminal,andfixthesensor(atthe

endofthecable)toasuitableplaceinthemiddleoftheinstalledbatterybank

ApprovalResponsibleofinstallation,sign.:Date:Approvedbycustomer,sign.:

EMCregard

Electricshock

Devicehazard

Electricshock

Form17

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EltekEnergyASTel.+4732203200

Internet:www.eltekenergy.comE-Mail:[email protected]


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CIRCUITDISTRIBUTIONLIST

SystemDataFlatpack2PSS,type:ArticleNo.:

Site,name:

CIRC.NO.FUSEKNIFE

TYPEMCB

LVLDCONTROLLED

DESCRIPTIONFUSEAMPERE

CABLEmm

2

Fb1

Fb2

Fb3

Fb4

Fb5

Fb6

F1

F2

F3

F4

F5

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14. 15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25. 26.

27.

28.

29.

30.Continue

LOAD

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CIRCUITDISTRIBUTIONLIST

CIRC.

NO.

FUSEKNIFE

TYPEMCB

LVLDCONTROLLED

DESCRIPTIONFUSEAMPERE

CABLEmm

2

31.

32.

33.

34.

35.

36.

37.

38.

39.40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.62.

63.

64.

65.

66.

LOAD



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Form171-g

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WARNING:Maintenanceworkonliveequipmentisonlytobeperformedbyauthorizedandqualifiedpersonsusinginsulatedtools.Hazardousvoltagesinsidemaycauseterminalinjury. Electric

shock

MAINTENANCEPROCEDURE

SystemDataFlatpack2PSSystemFlatpack2PowerSupplySystem,type:ArticleNo.:

Site,name:


ACInputVoltage,measured:BatteryType:BatteryCapacity:Maintenancecarriedoutby,name:

SystemInspectionPowerisON!CARRYOUTFOLLOWING:OK

1.Sitespecificparametersandsettingsareknown.Usermanualsandsitespecificconnection&arrangementdrawingsareavailable.

2.Thebatterybankhasbeenfullychargedinadvance.Atleastfor12hourssincestart-upormainsfailure.Enablescorrectmeasurements&calibration

3.Theequipmentisfreefromdamage,dustordirt;verify.Carefullyvacuumcleanorremoveanyaccumulationofdust,corrosionordirt.

4.Allcablingandcopperbarsaresecurelyterminatedandsupported.Correctanylooseconnections,excessivecabletemperature,defectiveinsulation,etc.

5.TheSmartpack&allrectifiermodulesareON,noalarmpresent;verify.Otherwise,correctandputthePSsysteminnormalmodeofoperation.

6.Allrectifiersfunctionality&SmartpackskeysanddisplayworkOK;verifyCorrectpossibleabnormalitiesbeforecontinuing.

7.ConnectthePSsystemtoaPC(installthePowerSuiteapplicationifrequired)ThePowerSuiteprograminthePCenablessystemconfigurationfromthePC.

8.Rectifiersloadcurrentsharing;verify.UsethePowerSuitePCapplicationtocheckallrectifiersoutputthesameamountofcurrent(1A)

9.DisplaythestoredlogofAlarmMessages.UsingthekeypadontheSmartpackcontrollerorfromthePC.

SystemAdjustmentCARRYOUTFOLLOWING:OK

1.DCOutputVoltageCalibration;ensurecorrectdisplayreadings.IfmeasuredDCoutputvoltageattheloadterminalsdeviatesmorethan1%fromthedisplayreading,calibratetheoutputvoltagefromtheSmartpackskeypadorthePC.

2.Load&BatteryCurrentCalibration;verifycorrectdisplayreadings.Measurewithaclip-onammeterthebatterycurrent&everyloadcircuitcurrent.Calculatethetotalload&battery

current.Ifthecalculatedtotalvaluesdeviatemorethan1%fromthedisplayreadings,calibratethecurrentfromthePC(calibrationvalue>50%ofsystemsmax.capacity)

3.DCOutputVoltageAdjustment;measureandadjust.Measureand,ifrequired,adjusttheoutputvoltagetothenominalvoltagerecommendedbythebatterymanufacturer.(VoltagemeasurementstobedoneattheDCrail,withlittleloadcurrent)

4.AlarmRelayTest;verifyallalarmrelaysareworkingcorrectly.FromtheSmartpackskeypadorPCusetheRelayTestfunction;verifyactivationofexternalequipment

5.Batterybankcontrol;measureandverifybatteryspecifications.Followtherecommendationsoftheactualbatterymanufacturer.

ApprovalResponsibleofmaintenancecontrol,sign.:Date:Approvedbycustomer,sign.:


16/28

PULLOUT


17/28

COMMISSIONINGPROCEDURE

SystemDataFlatpack2PSSystemSuppliersOrderNo.:Flatpack2PowerSupplySystem,type:ArticleNo.:

Site,name:


ACInputVoltage,measured:BatteryType:BatteryCapacity:Commissioningcarriedoutby,name:

Pre-StartCheckPowerisOFF!

CHECKFOLLOWING:OK1.Flatpack2systeminstallationiscompleted;TheFlatpack2InstallationCheckListisfilledin.

Allcablingissecurelyterminatedwithcorrectpolarity

2.AllbatteryandloadMCBs/fusesaredisconnected

3.ACinputcable(s)andACearthwire(PE)areterminated

4.Sitespecificparametersandsettingsareknown

5.ACsupplyandallMCBs/fusesareswitchedOFF

Start-up,No-Load&LoadAdjustmentsPowerisON!

CARRYOUTFOLLOWING:OK1.Disconnectallrectifiermodules,withoutremovingthem(keeporiginallocation)

2.SwitchONthesystem(externalACfusesON)

3.ACinputvoltageiscorrect;Measureandverify

4.InsertallFlatpack2rectifiersintheiroriginallocationsinthepowershelves

5.TheSmartpackandallrectifiermodulesareworking,LEDsareON;Verify

6.ConnectaPCtothePSsystemInstallthePowerSuitesoftware,ifrequired

7.DCoutputvoltage;Measureandadjust

8.Alarmrelaytest;Verifyallalarmrelaysareworkingcorrectly

9.SystemSetupisinaccordancewithconfigurationEntersitespec.infoinPowerSuite

10.AdjustDCoutputvoltagetoequalmeasuredbatteryvoltageCheckcorrectpolarity!

11.Unplugallrectifiersbutone,andconnectallbatteryfuses/MCBs

12.AdjustDCoutputvoltagetoequalnominalbatteryorloadvoltage

13.Pluginagainallrectifiers,andverifytherectifierscurrentsharing

14.ConnectallloadMCBs/fuses,andverifynoalarmsaredisplayed

ApprovalResponsibleofcommissioning,sign.:Date:Approvedbycustomer,sign.:

Devicehazard

I

II

Devicehazard

III

Devicehazard

Form17

0-g

b-v4-C

01

_356804-1

03_q

start-in

st-comm-o

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ss.d

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18/28

PULLOUT

CheckLi

stsPullout

P

ulloutthepageswiththegrayouterband,

andusethem

aschecklists


19/28


Identifying Power Shelves, 4AC or 2ACFlatpack2 rectifiers are accommodated in one or several power shelves. Two types of power

shelves are available:

4AC Power Shelves, or single AC feed

(4 AC inputs per shelf, each feeding 1rectifier)

2AC Power Shelves, or dual AC feed(2 AC inputs per shelf, each feeding 2

rectifiers)

You can identify the type of power shelves used by your

system by reading the shelfs label, or by looking at the

shape of the shelfs AC mains terminals, at its rear. (Also

viewable by removing the rectifier in the shelfs 4th

position)

Mains Reconfiguration, Integrated Systems 1U Distr.The AC mains terminals ofFlatpack2 integrated systems with 1U DC distribution units arelocated on the power shelfs rear.

Find out whether your system is implemented with 4AC or 2AC powers shelves (read the

Identifying Power Shelves section, page11) and terminate the AC mains cable according to the

type of AC mains to be used, as shown in the actual example below.

4ACPowerShelve

s

SingleACfeed:4ACinputsper

shelf,eachfeeding1rectifier

L1 L2 PE

MainsThree-phase & N, 400VAC

L3 N

PE(CON12)L1(CON11)L2(CON10)PE(CON15)L1(CON14)L2(CON13)


L L1 N L2 PE

MainsOne-phase, 230VAC



L1 L2

MainsThree-phase, 230VAC

L3



2ACPowerShelves

DualACfeed:2ACinputsper

shelf,eachfeeding2rectifiers

L (L1) N (L2) PE


CON13(PE)

CON9(L1 1/2)

CON11(L1 3/4)

CON10(L2 1/2)

CON12(L2 3/4)

Power Shelf

L1 L2 PE


L3 N

CON13(PE)

CON9(L1 1/2)

CON11(L1 3/4)

CON10(L2 1/2)

CON12(L2 3/4)

Power Shelf Power Shelf

CON13(PE)

CON9(L1 1/2)

CON11(L1 3/4)

CON10(L2 1/2)

CON12(L2 3/4)

L1 L2 PE


L3

2AC Power Shelves

4AC Power Shelves

Flatpack2System, 1U DC Distr.

AC Mains &PE terminals

Power Shelf(rear view)

C Mains Miscellaneous


20/28


Mains Reconfiguration, Cabinetized & Integrated 4UTo reconfigure the AC mains feed ofFlatpack2 DC power systems cabinetized or integrated

with 4U DC distribution units you have to rewire the internal cables of the systems AC Mainsconnection box.

1. Find out first whether your system is implemented with 4AC or 2AC powersshelves (read the Identifying Power Shelves section, page11).

2. Rewire then the internal cables of your systems AC Mains connection box,according to the type of AC mains to be used , as shown in the actual example in

this section.


4AC Power ShelvesSingle AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

L3

X:******

Flapack2DC Power System

(To internal connections)

AC MainsCable

Chassis

L1L2 PE


N

PS1:CON20

PS1:CON19

PS1:CON17

PS1:CON16

PS1:CON14

PS1:CON13

PS1:CON11

PS1:CON10

PS2:CON19

PS2:CON16

PS2:CON13

PS2:CON10

PS2:CON20

PS2:CON17

PS2:CON14

PS2:CON11

ACMains

connectionbox

Rewirethe box

as shown

X:******



AC MainsCable

Chassis

L1L2 PE L3


PS1:CON20

PS1:CON19

PS1:CON17

PS1:CON16

PS1:CON14

PS1:CON13

PS1:CON11

PS1:CON10

PS2:CON19

PS2:CON16

PS2:CON13

PS2:CON10

PS2:CON20

PS2:CON17

PS2:CON14

PS2:CON11

ACMains

connectionbox

Rewirethe box

as shown

ACMains

connectionbox

X:******



AC MainsCable

Chassis

PE L (L1)N (L2)


PS1:CON20

PS1:CON19

PS1:CON17

PS1:CON16

PS1:CON14

PS1:CON13

PS1:CON11

PS1:CON10

PS2:CON19

PS2:CON16

PS2:CON13

PS2:CON10

PS2:CON20

PS2:CON17

PS2:CON14

PS2:CON11

Rewirethe box

as shown

AC MainsConnection Box

PS1:CON20

P

S1:CON19

PS1:CON17

P

S1:CON16

PS1:CON14

P

S1:CON13

PS1:CON11

P

S1:CON10

P

S2:CON19

P

S2:CON16

P

S2:CON13

P

S2:CON10

PS2:CON20

PS2:CON17

PS2:CON14

PS2:CON11

Rewire theinternalcables

For externalAC Mains

cable

For externalAC Mainscable

Internalconnection point(power shelf # andconnector #) foreach cable


21/28


About AC, DC Earthing SystemsTo prevent the risk of electric shock, all cabinets chassis are to be electrically

connected to AC Earth (PE). Also, it is a common practice for telecom equipment

to have its common DC output rail (+ or -) connected to a separate Telecom

Earth (TE) or DC Earth.

AC Earth (PE) and DC Earth (TE) are

connected to chassis via Link 1 and

Link 2. Remove the links (floating

earth) for compliance with other local

earthing systems.

Common Positive DC Output Rail is usual in 48 and 60V DC supply systems: Negative DC

Distribution. Common Negative DC Output Rail is usual in 24V systems: Positive DC

Distribution.


2AC Power Shelves

Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers

PS1:CON

11

PS1:CON12

PS1:CON

9

PS1:CON10

PS2:CON

11

PS2:CON12

PS2:CON

9

PS2:CON10

PS3:CON

11

PS3:CON12

PS3:CON

9

PS3:CON10

PS4:CON

11

PS4:CON12

PS4:CON

9

PS4:CON10

X:******



AC MainsCable

Chassis

L1L2 PE


L3N

ACMains

connectionbox

Rewirethe box

as shown

X:******



AC MainsCable

Chassis

L1L2 PE L3


L1

N

L3

L2

ACMains

connectionbox

Rewirethe box

as shown

X:******



AC MainsCable

Chassis

PE L (L1)N (L2)


PS1:CON

11

PS1:CON12

PS1:CON9

PS1:CON10

PS2:CON

11

PS2:CON12

PS2:CON9

PS2:CON10

PS3:CON

11

PS3:CON12

PS3:CON9

PS3:CON10

PS4:CON

11

PS4:CON12

PS4:CON9

PS4:CON10

ACMains

connectionbox

Rewirethe box

as shown

CabinetPE

AC MainsCommonDC RailEG

.

ACMainsInput

(L1,L2,L3,N)

DC LoadCircuit

Link 2(DC Earth)

Link 1(AC Earth)

TE

Chassis

Chassis

PE (Protective Earth)TE (Telecom Earth)EG (Exchange Ground)

Common DC Rail

DCLoad

wires

+

+

++

Positive DCDistribution

Negative DCDistribution

Common DC Rail +

DCLoad

wires


22/28


Mains Phases versus Rectifier ID Phase Balancing & MonitoringWhen Flatpack2 systems are fed with a 3-phase AC Mains input circuit, each rectifier is

internally connected to the 230VAC phases, in such a pattern that loads the 3 phases evenly.

The distribution of rectifiers among the phases is implemented both via internal wiring to the

power shelves, and how the shelfs back-wiring card routes the phases to each rectifier position.

There are two types of shelves: 4AC and 2AC power shelves. Read also the Identifying Power

Shelves section, page11.

Plug-and-Play Rectifiers versus Phase Monitoring

When a rectifier is hot plugged in a power shelf for the first time , the Smartpackcontroller

assigns the next available ID number to the rectifier, starting with 01. The controller registers

the rectifiers Serial Number and ID number.

When a previously installed (hot plugged)Flatpack2 rectifier is inserted in a power shelf, the

Smartpackcontroller recognizes the module, and assigns the same ID to the rectifier. In other

words, the controller and the rectifier remember the assigned ID number, even after removing

and reinserting the rectifier in the shelf.

To achieve a more controlled ID assignment, you should always insert & hot-plug new Flatpack2

rectifiers in the power shelves, one module at a time, starting with shelf position 1, 2, 3, and so

on. The sequence is indifferent after positions 9. You find more information on page 15.

This position-versus-ID number relationship is very important for the correct monitoring of the

mains three phases, as the Smartpack controller always uses rectifier ID01, 02 and 03 to

monitor the Mains phase 1, 2 and 3 respectively. If these rectifiers malfunction, rectifier ID 04,

05 and 06 will automatically take over.

For example: accidentally inserting a rectifier with ID02 in a power shelf position internally

connected to mains phase 1, will cause the controller to monitor phase 1 thinking it monitors

phase 2.



L1

L2L3230VAC

ACMains

02

05

08

n

Phase 2

030609nPhase3

01 04 07 n Phase1

Flatpack2rectifier


ID number(AssignedCAN busaddress)

230V

AC

L1

L2

L3

Mains

400VAC, 3ph+N

N 01 04 07 n Phase1

030609nPhase3

Phas

e2

02 05 08 n

Load Balancing of Mains Phases

Even distribution ofFlatpack2rectifiers on the Mains phases


01 02 03 nN(L2)

230VAC

ACMains

L(L1)


23/28


Correct Rectifier Positions in Power Shelves

Flatpack2 DC power systems are normally shipped from factory with empty power shelves. Therectifier 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.

For first time installations of rectifiers in Flatpack2 systems, follow the scheme below:

1. Find out your systems power shelf type, byreading the Identifying Power Shelves section, page11

2. Find out if your systems AC mains feed is or

3. Insert & hot-plug the rectifiers in the power shelves,one module at a time, allowing a 2s delay between them and

starting with shelf position 1, 2, 3, and so on.

Follow one of the four figures below:

SmartpackLocated in Distribution Shelf

Correct Rectifier Position in 4AC Power Shelves

Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

Mains

Three-phase, 230VACMains

Three-phase & N, 400VACand

01 02

05 06

09---

03 04

0708

------

------

------

Position 1

Position 4

ID number

(Assigned CANbus address

Flatpack2rectifier

Position 8

Position 9

Smartpackcontroller


Dual AC feed: 2 AC inputs per shelf, each feeding 2 recti fiers

Mains



0104

03 06

08---

02 05

07 ---

09---

------

------ ID number

(Assigned CANbus address

Position 1

Position 4

Flatpack2rectifier

Position 8

Position 9

Smartpackcontroller


SmartpackLocated in Power Shelf


Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

Mains



02

0506

0907

03 01

04 08

------

---------

---

Position 1 Position 8

Smartpackcontroller

Position 9 ID number(Assigned CANbus address

Flatpack2rectifier

Position 4


Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers

Mains



01

0306

08---

02 05

04 07

09---

---------

--- ID number(Assigned CANbus address

Position 1

Position 4

Flatpack2rectifier

Position 8

Position 9

Smartpackcontroller

Phase 1 Phase 2 Phase 3


24/28


Battery Symmetry Connections ConnectionsEach Smartpack controller is equipped with 8 battery symmetry inputs (on connectors

CON4 and CON3), enabling symmetry measurement of:

8 battery strings

using theMid-Point Measurement Method 4 battery strings

using the more accurateDouble Mid-Point Measurement Method

2 battery stringsusing the even more accurateBlock Measurement Method

You can implement any of these methods using one or twoBattery Connection Kits (refer

to the illustration next page) andthe appropriate number ofBattery Symmetry Kits, which

contain a single cable strand with suitable cable eyes, etc.

Battery Terminology

Battery Block, Battery String and Battery Bank

48V Battery Bank

BatteryString #1(48V)Batt.

BatteryBlock (12V)

BatteryString #2(48V)

Notice that, if you open the serial switches in card, Art.200576 setting all to OFF (up) you have to connectthe + and wires of every symmetry input.

Miscellaneous Battery Monitoring

Battery SymmetryBlock Measurement

Four measurements per string(Serial measurement)

(-48V) Outer

Terminal

+0V OuterTerminal

Intercell Links

X:****

Block1

- ++-+-+-

Block4Block3

Card, Art. 200576Serial Switches

Set all 4 switchesON (down)

7

Symmetry4

+

2-1

Symmetry1

+-

5

Symmetry3

+

3

Symmetry2

+

Battery SymmetryDouble-point Measurement

Two measurements per string, from themiddle to the outer terminals

(-48V) Outer

Terminal

+0V OuterTerminal

Intercell Links

X:****

Card, Art. 200576

Serial Switches

Set all 4switches ON

(down)

3

Symmetry2

+

2-1

Symmetry1

+-

Block1

- ++-+-+-

Block4Block3

Batt.

SymmetryKit,

Art.2

00830

CableEyes

SingleCableStra

nd

ExamplesofBatterySymmetryConnec

tions

48VDCSupplySystems

Battery SymmetryMid-point Measurement

One measurement per string

(-48V) Outer

Terminal

+0V OuterTerminal

Intercell Links

2-1

X:****

Symmetry1

+-

Card, Art. 200576Serial Switches

Set all 4switchesOFF (up)

Block1

- ++-+-+-

Block4Block3


25/28


Terminals & Pin-out Location, Battery Interface CardThe Smartpack controllers battery monitoring signals are accessible on D-Sub connectors

CON4 and CON3, on the controllers rear panel.

Using the Battery Connection Kitwhich consists of a BatteryInterface Card(Art. 200576) and a standard 15 pins D-Sub cable

you can make the signals on CON4 accessible at any suitablelocation inside your system, e.g. near the battery blocks.

When extra battery monitoring signals are required, you can use an

extraBattery Connection Kitconnected to the controllers CON3.

For detailed information about the cards pin-out location and

terminal block connections, refer to the figures in this section.

For temperature monitoring of the battery

compartment, we recommend the use of the

Temperature Sense Kit, instead of

connecting the sensor cable directly to the

terminals, pin 9-10.

The Temperature Sense Kit is connected totheBattery Interface Card (Art. 200576), or

directly to the controllers CON3 or CON4,

if unused.

Terminals & Pin-out Location

Battery Interface Card, Art. 200576

141

Serial Switch

For Temp.Sense Kit

CON3A or CON4A

X***/X****

X**/X*

1

Alarm Outputs & DigitalInputs Card, Art. 105954

System ConnectionsCard, Art. 200625

Smartpack

Battery ConnectionsCard, Art. 200576


Battery Monitoring Miscellaneous

15 pins D-Sub cable

Card Art.200576

Battery Connection Kit

Temp. sensor

Temp. Sensor cable

Temperature Sense Kit

In

1.5 mm , max.wire section

Battery Connections (Internal)Configurable monitoring digital inputs

FUNCTION SIGNAL PIN-OUT

(Internal Connections)

4321

5

9876

10

14131211

X:****Batt. Symmetry 1 +

+

+

+

Batt. Symmetry 2

Batt. Symmetry 3

Batt. Symmetry 4(Fromi

nternal

batteries)

(Froma

reawith

internalbatteries)

Temperaturesensor

+

Temperature Sense 1

(NA)

(NA)

(Froma

reawith

internalbatteries)

Temperaturesensor

15-pinsD-Sub female

(Alternative use of Temp. Sense Kit,instead of connecting to X:****, 9-10)

Temperature Sense 1

X**/X*15-pins D-Sub male

1 5

11 15

Card Art.200576

ToSmartpack,

CON4

CON3A orCON4A15-pinsD-Sub female

1 11

5 15

In


Battery Connections (Internal)Configurable monitoring digital inputs



4

321

5

9876

10

14131211

X:***+

+

+

+

(Fromi

nte

rnal

batterie

s)

(Froma

reawith

internalbatteries)

Temperaturesensor

+

(Froma

reawith

internalbatteries)

Temperaturesensor

15-pinsD-Sub female

(Alternative use of Temp. Sense Kit,instead of connecting to X:***, 9-10)

Temperature Sense 2

X**/X*15-pins D-Sub male

1 5

11 15

Card Art.200576

ToSmartpack,

CON3

CON3A orCON4A15-pinsD-Sub female

1 11

5 15

The Temperature Sense Kits may also be connected directly to theSmartpackcontrollers CON3 or CON4, if these connectors are unused.

Batt. Symmetry 5

Batt. Symmetry 6

Batt. Symmetry 7

Batt. Symmetry 8

Temperature Sense 2

Batt Current 2

Batt Fuse Fail 2


26/28


Standard Alarm Relays & Digital Inputs Connections

The alarm outputs in Flatpack2 systems use the Fail-SafeOperation Mode (relay coils energized in the systems

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 systems normal mode of operation.

Terminals & Pin-out Location, Alarm Interface CardThe Smartpack controllers alarm and digital input monitoring signals are accessible from the

controllers 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) and two interface cables, you canmake the signals on CON1 & 2 accessible

at any suitable location inside your system.

For detailed information about the cards

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)

Standard 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 ModeRelay X

(De-energized coil) NC

NOCom

Miscellaneous Alarms & Monitoring


Alarm Outputs & Digital Inputs Card, Art. 105954(or Art. 200916 when X** and CON2A are not mounted)

CON2ACON1A

110 201

X* X**

Alarm Outputs & DigitalInputs Card, Art. 105954


Smartpack



4321

5

9876

10

X:*

(Customer Connections)

Input Circuit 1

Input Circuit 2

Alarm Circuit 1

Alarm Circuit 2

OutIn

(Toandfrom

externalequipment)


Relay 2Mains Alarm

Relay 1Common Alarm

+

NOCOM

NC

NOCOM

NC

+

Digital Input 1

Digital Input 2

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


Input Circuit 3

Alarm Circuit 3

Input Circuit 4

Input Circuit 5

Input Circuit 6

Alarm Circuit 4

Alarm Circuit 5

Alarm Circuit 6

43

21

5

9876

10

14131211

15

X:**

16171819

20

+

+

+

+

NOCOM

NC

NOCOM

NC

NOCOM

NC

NOCOM

NC

Digital Input 3

Digital Input 4

Digital Input 5

Digital Input 6

Relay 3Fuse Alarm

Load & Battery

Relay 5Low Battery Alarm

Relay 6Rectifier Alarm

(Toexternalequipment)

(Frome

xternaleq

uipment)

Card Art.105954

ToSmartpack,

CON2

ToSmartpack,

CON1

Relay 4High Battery Alarm


27/28


Terminals & Pin-out Location, System Interface CardFlatpack2 systems are shipped from factory with the CON5 signals already connected.

Some of the Smartpackcontrollers internal system signals are accessible on D-Sub connectorCON5, on the controllers 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 cards pin-out location and terminal block connections, refer

to the figures in this section.

LVD Latching Contactors Connections

Flatpack2 systems LVBD and LVLD functionality (Low Voltage Battery Disconnect; LV

Load Disconnect) 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.

Internal Connections Miscellaneous

System Connections Card, Art. 200625

111 CON5A

JP1 JP2

X*****


Alarm Outputs & Digital

Inputs Card, Art. 105954


Smartpack



Latching Contactor

Y

X

Latching Contactors, LVD1 & LVD2

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

+ Pulse

ON

- Pulse

OFF

Correct Use of Latching Contactors (example)

PCB Art.200625

10

89

X:*****

+

LVD1A

LVD2A

LVD Common

SmartpackUnit

Flatpack2 PS System (internal)

11

LVD Common

LatchingContactor

LVD2Y

X

LatchingContactor

LVD1Y

X

+

4321

5

9876

1011

X:*****

Power Input+

+

10

156

712

13

9+, Neg.D.

11,Pos.D.

1+/3+/

2+/

Batt. Fuse Fail 1

Load Fuse Fail 1

Batt. Current 1

LVD1ALVD Common LVD1

OutIn

TerminalBoard,Art.2

00625

(ToSmartpack,

CO

N5)


SystemC

onnec

tions

JP2

LVD2ALVD Common LVD2

(To latching contactorsLVD1 & LVD2)


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Copyright Eltek Energy AS, Norway 2005This document may be changed without notice

This product is CE marked andcomplies with all current requirementsfor relevant standards and directives.

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