qstart-installation-operation-commissioning and maintenance.pdf

Quick Start Guide Installation, Operation, Commissioning and Maintenance

DC Power Supply System Integrated, Cabinetized and Outdoor Applications

Flatpack2, PS System

356804.103

Miscellaneous Communication o CAN Bus Termination ( 9) o Installing PowerSuite – PC software ( 9) AC Mains o 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 Monitoring o Battery Symmetry – Connections (16 ) o Terminals & Pin-out Location, Battery Interface Card ( 17) Alarms & Monitoring o 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)

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

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

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

Operation

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

Check Lists pullout forms o Installation Check List o Circuit Distribution List o Commissioning Procedure o Maintenance Procedure

Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 2

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 power system 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 part of the system.

Introduction

Flapack2 System, Integrated4U and 1U Distributions

Flapack2 System, Cabinetized Flapack2 SystemOutdoor Cabinet

Flatpack2 Cabinetized

Battery string #1

AC mains supply selector

SymmetryAlarm &

Temp. Sensor

LVLD

LVBD

Fuse Alarm

AC Fuses, external

(230VAC or 400VAC

Telecom equipment

AC Supply (Single- or

three-phase)

Alarm Outputs NC-C-NO Digital Inputs

BatteryFuses

Load Fuses & MCBs

Smartpack (Ctrl. Unit)

Flatpack2(rectifiers)

PowerSuiteApplication

CAN Bus

USB cable

DC distribution

DC Supply (24V, 48V or 60V*) *Available from 2006


Installing Smartpack and Rectifier Modules

Installation

Handle in unlocked position

Flatpack2 rectifier

Smartpack controller

Handle in locked position

Hole to release the handle’s spring mechanism

Removing Blind Panels 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

Mounting Blind Panels 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.

Screwdriver to release the locking tabs

Blind panel’s upper locking 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 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


Installation Steps

Installation

Check off in the Installation Check List, that you find in the pullout section of this folder. Also, refer to the system’s 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 top o 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 Access

Locations (RAL) 2 Prepare the installation tools

o Use insulated tools suitable for telecom installations 3 Prepare AC Supply: AC input cable(s) and fuses

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

EMCregard

200 mm

600 mm

For external AC fuses and AC input cable ratings, refer to your site’s AC supply specification. Read also our external AC fuse recommendationsin 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 located behind the upper dummy panels

o Battery shelves (if any) are placed behind the lower panels 6 Position and fasten the cabinet or subassembly

o Cabinets are floor-mounted on levelled surface. Adjust the legs if necessary. 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 upwards o Do not terminate the battery cables yet!

Electricshock

Devicehazard

Flatpack2 PSS, batteries, Doc. Chart, Spec. Drawings, CD-ROM


Installation

Electrical Installation Power is OFF!

Carry out the following: (Refer to the system’s specific drawings)

8 Make the system completely voltage free o Switch OFF or remove all load fuses (MCB1, MCBx), battery

fuses (Fb1, Fbx) and the AC supply fuses, in external fuse boards

9 AC Connections o Check AC configuration: the AC terminals are correct configured

to 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 Circuits

o 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 DC output rail, and the other directly to the MCB or load fuse

11 DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration, or

to the “Miscellaneous, Alarms & Monitoring” section (Factory Settings)

o Terminate Alarm Circuit cables to the relay output terminals o 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 shelf’s 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 via PowerSuite

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) Outer

Terminal +

0V Outer Terminal

Link 2(DC Earth)

Common DC Rail EG Battery

Fuse

Intercell Links

Battery Cable S

ymm

etry

1

2-1

Chassis

Card Art.200576

+ -

15 pins D-Sub (male)

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enso

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Block1

- ++ - + - + -

Block4 Block3

Electricshock


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 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 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

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 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 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

Commissioning

Device hazard

Device hazard

I

II


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 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

Refer to chapter “Installing PowerSuite ⎯ PC Application”, page 9, if required 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 (refer to page 8) 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.

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. 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 (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 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

Commissioning


Front Keys and display, menus, etc.

Operation

Flatpack2 Rectifier Module — front panel Power LED is OFF (mains unavailable), Flashing (controller accessing information) or ON (powered). Warning LED is ON (derating or similar minor warning), Flashing (over-voltage mode) or OFF (OK) Alarm LED is ON (shutdown or similar major alarm) or OFF (OK, no alarm)

Flatpack2 rectifier

AlarmLED Lamp (red)

PowerLED Lamp (green)

WarningLED Lamp (yellow)

Software Menus

Service menu <ServiceOption> NomVolt ↓↑

BoostVolt ↓↑

LowBatt1 ↓↑ VoltAdjustment LowBatt2 ↓↑

HighBatt1 ↓↑

HighBatt2 ↓↑

LVD 1 ↓↑

LVD 2 ↓↑ VoltCalibration ------ VoltCal ↓↑ ChangePassword -- Password ↓↑ SetBoostTime-------- ↓↑ Start/StopBoost Auto Boost Conf. -- Enable/Disable & AutoBThrs ↓↑

Nxt Test DateTime

End 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 / TempComp Change Date/Time

Alarm Output 1 RelayTest Alarm Output 2

Batt Contactor Load Contactor Alarm Output nn

BattLifeTime Rst 1v0

Level 2 Level 3

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Smartpack Control Unit — front keys, display, etc Display: is in Status Mode (displays the system’s status) or in Menu 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 “enter” Menu Mode (Level 1), you access the User Options. You may also scroll down to password protected Service Options. Default password <0003> should be changed.

User menu <UserOption> AlarmReset

NomVolt

BoostVolt

LowBatt1

VoltageInfo LowBatt2

HighBatt1

HighBatt2

LVD 1

LVD 2

DisplayMessages Message ↓↑

SoftwareInfo

SerialNumber 1v01

NoOfRects. Nn

RectCurrent 1v0

Rectifier Info RectSerialNumber 1v0

Rect.PrimaryVolt 1v0

Rectifier Status 1v0

Rectifier Temp 1v0

NoOfPhases nn

Mains Info Mains Status

Mains Voltage

Temp Level Info - Level ↓↑ 1v0

Level 2 Level 3

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PowerLED Lamp (green)

Warning LED Lamp (yellow)

AlarmLED Lamp (red)

Graphical Display

16 char. x 2 lines LCD display

”Up” arrow key ”Down” arrow key

”Enter” key

USB0ype B port

Smartpack control unit


CAN Bus Termination Flatpack2 systems are shipped from factory with the CAN bus already terminated with 120Ω resistors.

To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120Ω resistors, one at each end of the line. The figure shows a Flatpack2 system communicating via the CAN bus.

The Smartpack dynamically 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 Smartpack’s ID numbers (1, 2…) are assigned by DIP switches on the controller’s side. Terminate the CAN bus with only two 120Ω resistors, one at each end of the line. The figure shows two Flatpack2 systems communicating via the CAN bus.

Installing PowerSuite ⎯ PC Application The PowerSuite software application enables you to configure and operate the Flatpack2 Power Supply System from a personal computer.

Communication Miscellaneous

120Ω

Flatpack2 DC Power System

End-of-Line Resistor

End-of-LineResistor

120Ω

CAN bus(twisted-pair internal CAT5 cable)

USB A-B cable(standard)

01 02 n

1

120Ω

Flatpack2DC Power System 2

120Ω

Flatpack2DC Power System 1

End-of-Line Resistor

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 twice New hardware

is ready to use 3

If PowerSuite 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).

PowerSuite’s newest version is always available on our FTP server. Call your Eltek’s contact person.

Flatpack2 system configuration from a PC running MS Windows XP

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

1. Install PowerSuite Insert the CD in your PC drive, start the PowerSuite installation and follow & accept the wizard default steps to install “.Net” software and PowerSuite

1

4. Start PowerSuite and establish connection Select “Start > All Programs > Eltek > PowerSuite”. On the toolbar, click “Connect” button. On the Connection dialogue box, click the “Connect” button

4


External AC Fuses ⎯ Recommended Rating 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.

205V

AC In

puts

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

1 21.6 25A-C 2 43.1 50A-C 3 43.1 50A-C

400VAC +N3 phase

4 64.7 80A-C 1 37.4 40A-C2 56.1 63A-C3 74.8 80A-C

230VAC 3 phase

4 112.2 125A-C1 43.0 50A-C 230VAC

1 phase 2 86.0 100A-C

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1 21.6 25A-C 400VAC +N3 phase 2 32.3 40A-C

1 29.5 32A-C230VAC 3 phase 2 56.1 63A-C

1 43.1 50A-C 230VAC 1 phase 2 86.2 100A-C

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1 23.9 25A-C 400VAC +N3 phase 2 35.8 40A-C

1 32.7 40A-C230VAC 3 phase 2 62.1 63A-C

1 47.8 50A-C 230VAC 1 phase 2 95.6 100A-C

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1 23.9 25A-C 2 47.8 50A-C 3 47.8 50A-C

400VAC +N3 phase

4 71.7 80A-C 1 41.4 50A-C2 62.1 63A-C3 82.9 100A-C

230VAC 3 phase

4 124.3 125A-C1 48.0 50A-C 230VAC

1 phase 2 96.0 100A-C

External AC Fuses Recommended Ratings

1AC Feed to 1 Flatpack2 rectifier

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

185VAC 25A-C 13A-B 205VAC 25A-C 10A-B FS=I (Fuse Selectivity: Internal) which means that the Flatpack2 rectifier’s internal fuse will trip be-fore the external AC fuse. FS=0 (Fuse Selectivity: none) these fuse types may be used when it is irrelevant whether the internal or the external fuse trips first. Note: Always replace a rectifier with blown internal AC fuse with a new module, and send the mal-functioning module for servicing.

Miscellaneous AC Mains

Use the recommendations in the 205VAC table, if you are sure the available AC mains voltage will not drop below 205VAC.

OR If you are unsure ⎯ or know that the voltage may drop below 205VAC ⎯ use the 185VAC table recommendations.

Only difference between the 205 and the 185VAC recommendation tables

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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 and dummy front panels o Check that cable entry from the top is possible

6. Position and fasten the cabinet or subassembly o Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor o Subassemblies in existing 19” or in ETSI cabinets, using brackets. Mount the support & heat deflecting plate

7. Mount the batteries on the shelves o Start (if applicable) on the lower shelf first, and continue upwards 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, or to the Factory Settings in the Quick Start Guide o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output terminals

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 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

Form 173-gb-v1-C

01_356804-103_qstart-inst-comm

-oper_flatpack2-pss.doc_mfm

_2006-01-06

Eltek Energy AS Tel. +47 32 20 32 00

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

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

Site, name:

CIRC. NO. FUSE

KNIFE TYPE

MCB LVLD

CONTROLLED DESCRIPTION FUSE

AMPERE CABLE

mm2

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

LOA

D

BA

TT.

Form 172-gb-v2-C



_2006-01-06



CIRCUIT DISTRIBUTION LIST

CIRC. NO. FUSE KNIFE

TYPE MCB

LVLD CONTROLLED

DESCRIPTION FUSE AMPERE

CABLE mm

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.

LOA

D



Form 172-gb-v2-C



_2006-01-06

Form 171-gb-v2-C



_2006-01-06



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.:

PU

LLOU

T

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

Form 170-gb-v4-C


-oper_flatpack2-pss.doc _mfm

_2006-01-06



PU

LLOU

T

Check Lists Pu

llout

Pull o

ut th

e pag

es with

the g

ray outer b

and,

and u

se them

as check lists


Identifying Power Shelves, 4AC or 2AC Flatpack2 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 1 rectifier)

• 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 shelf’s label, or by looking at the shape of the shelf’s AC mains terminals, at its rear. (Also viewable by removing the rectifier in the shelf’s 4th position)

Mains Reconfiguration, Integrated Systems 1U Distr. The AC mains terminals of Flatpack2 integrated systems with 1U DC distribution units are located on the power shelf’s 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.

4AC

Pow

er S

helv

es

Sin

gle

AC

feed

: 4 A

C in

puts

per

sh

elf,

each

feed

ing

1 re

ctifi

er L1 L2 PE

Υ MainsThree-phase & N, 400VAC

L3 N

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

PE(CON18) L1(CON17) L2(CON16) PE(CON21)L1(CON20)L2(CON19)

L (L1) N (L2) PE

Mains One-phase, 230VAC

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


L1 L2

∆ MainsThree-phase, 230VAC

L3



2AC

Pow

er S

helv

es

Dua

l AC

feed

: 2 A

C in

puts

per

sh

elf,

each

feed

ing

2 re

ctifi

ers

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

Flatpack2 System, 1U DC Distr.

AC Mains &PE terminals

Power Shelf (rear view)

AC Mains Miscellaneous


Mains Reconfiguration, Cabinetized & Integrated 4U To reconfigure the AC mains feed of Flatpack2 DC power systems ⎯ cabinetized or integrated with 4U DC distribution units ⎯ you have to rewire the internal cables of the system’s AC Mains connection box.

1. Find out first whether your system is implemented with 4AC or 2AC powers

shelves (read the Identifying Power Shelves section, page11).

2. Rewire then the internal cables of your system’s 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 Shelves Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

L3

X:******

Flapack2 DC Power System

(To internal connections)

AC Mains Cable

Chassis

L1L2 PE

Υ Mains Three-phase & N, 400VAC

N

PS1:C

ON

20P

S1:C

ON

19PS

1:CO

N17

PS

1:CO

N16

PS1:C

ON

14P

S1:C

ON

13PS

1:CO

N11

PS

1:CO

N10

PS

2:CO

N19

PS

2:CO

N16

PS

2:CO

N13

PS

2:CO

N10

PS2:C

ON

20PS

2:CO

N17

PS2:C

ON

14PS

2:CO

N11

AC

Mai

ns

conn

ectio

n bo

x

Rewire the box

as shown

X:******



AC MainsCable

Chassis

L1L2 PE L3


PS1:C

ON

20P

S1:C

ON

19PS

1:CO

N17

PS

1:CO

N16

PS1:C

ON

14P

S1:C

ON

13PS

1:CO

N11

PS

1:CO

N10

PS

2:CO

N19

PS

2:CO

N16

PS

2:CO

N13

PS

2:CO

N10

PS2:C

ON

20PS

2:CO

N17

PS2:C

ON

14PS

2:CO

N11

AC

Mai

ns

conn

ectio

n bo

x

Rewire the box

as shown

AC

Mai

ns

conn

ectio

n bo

x

X:******



AC MainsCable

Chassis

PE L (L1)N (L2)

MainsOne-phase, 230VAC

PS1:C

ON

20P

S1:C

ON

19PS

1:CO

N17

PS

1:CO

N16

PS1:C

ON

14P

S1:C

ON

13PS

1:CO

N11

PS

1:CO

N10

PS

2:CO

N19

PS

2:CO

N16

PS

2:CO

N13

PS

2:CO

N10

PS2:C

ON

20PS

2:CO

N17

PS2:C

ON

14PS

2:CO

N11

Rewire the box

as shown

AC Mains Connection Box

PS1:C

ON

20P

S1:C

ON

19PS

1:CO

N17

PS

1:CO

N16

PS1:C

ON

14P

S1:C

ON

13PS

1:CO

N11

PS

1:CO

N10

PS

2:CO

N19

PS

2:CO

N16

PS

2:CO

N13

PS

2:CO

N10

PS2:C

ON

20PS

2:CO

N17

PS2:C

ON

14PS

2:CO

N11

Rewire the internal cables

For externalAC Mains

cable

For external AC Mains cable

Internal connection point (power shelf # and connector #) for each cable


About AC, DC Earthing Systems To prevent the risk of electric shock, all cabinet’s 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:C

ON

11P

S1:C

ON

12P

S1:C

ON

9P

S1:C

ON

10PS

2:CO

N11

PS

2:CO

N12

PS

2:CO

N9

PS

2:CO

N10

PS3:C

ON

11P

S3:C

ON

12P

S3:C

ON

9P

S3:C

ON

10PS

4:CO

N11

PS

4:CO

N12

PS

4:CO

N9

PS

4:CO

N10

X:******



AC Mains Cable

Chassis

L1 L2 PE


L3 N

AC

Mai

ns

conn

ectio

n bo

x

Rewire the box

as shown

X:******



AC MainsCable

Chassis

L1L2 PE L3


L1

N

L3

L2

AC

Mai

ns

conn

ectio

n bo

x

Rewire the box

as shown

X:******



AC MainsCable

Chassis

PE L (L1)N (L2)

MainsOne-phase, 230VAC

PS

1:CO

N11

PS

1:CO

N12

PS

1:CO

N9

PS

1:CO

N10

PS

2:CO

N11

PS

2:CO

N12

PS

2:CO

N9

PS

2:CO

N10

PS

3:CO

N11

PS

3:CO

N12

PS

3:CO

N9

PS

3:CO

N10

PS

4:CO

N11

PS

4:CO

N12

PS

4:CO

N9

PS

4:CO

N10

AC

Mai

ns

conn

ectio

n bo

x

Rewire the box

as shown

CabinetPE

AC Mains Common DC Rail EG

.

AC

Mai

ns In

put

(L1,

L2,L

3,N

)

DC Load Circuit

Link 2(DC Earth)

Link 1 (AC Earth)

TE

Chassis

Chassis

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

Common DC Rail —

DC

Loa

d w

ires

+

+

+ +

Positive DC Distribution

—

—

——

Negative DCDistribution

Common DC Rail +

DC

Loa

d w

ires


Mains Phases versus Rectifier ID Phase Balancing & Monitoring When 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 shelf’s 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 Smartpack controller assigns the next available ID number to the rectifier, starting with “01”. The controller registers the rectifier’s Serial Number and ID number.

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


∆ Mains Three-phase, 230VAC

L1

L2 L3 230VAC

AC Mains

02

05

08

n

Phase 2

03 06 09 n Pha

se 3

01 04 07 n Pha

se 1

Flatpack2 rectifier


ID number (Assigned CAN bus address)

230V

AC

L1

L2

L3

Mains400VAC, 3ph+N

N 01 04 07 n Pha

se 1

030609nPha

se 3

Pha

se 2

02 05 08 n

Load Balancing of Mains Phases Even distribution of Flatpack2 rectifiers on the Mains phases


01 02 03 n N(L2)

230VAC

AC Mains

L(L1)


Correct Rectifier Positions 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.

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

1. Find out your system’s power shelf type, by reading the Identifying Power Shelves section, page11

2. Find out if your system’s AC mains feed is <230VAC, 3 phase> or <400VAC, 3 phase and N>

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:

Smartpack Located in Distribution Shelf

Correct Rectifier Position in 4AC Power Shelves Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier



and

01 02

05 06

09 ---

03 04

07 08

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

Position 1

Position 4

ID number (Assigned CAN bus address)

Flatpack2rectifier

Position 8

Position 9


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



and

01 04

03 06

08 ---

02 05

07 ---

09 --------- --- --- ID number

(Assigned CAN bus address)

Position 1

Position 4

Flatpack2rectifier

Position 8

Position 9

Smartpackcontroller


Smartpack Located in Power Shelf

Correct Rectifier Position in 4AC Power Shelves Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier



and

02

05 06

09 07

03 01

04 08

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

Position 1 Position 8


Position 9 ID number (Assigned CAN bus address)

Flatpack2rectifier

Position 4

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



and

01

03 06

08 ---

02 05

04 07

09 --------- --- --- ID number

(Assigned CAN bus address)

Position 1

Position 4

Flatpack2rectifier

Position 8

Position 9

Smartpackcontroller

Phase 1 Phase 2 Phase 3


Battery Symmetry Connections Connections Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors CON4 and CON3), enabling symmetry measurement of:

• 8 battery strings using the Mid-Point Measurement Method

• 4 battery strings using the more accurate Double Mid-Point Measurement Method

• 2 battery strings using the even more accurate Block Measurement Method

You can implement any of these methods using one or two Battery Connection Kits (refer to the illustration next page) and the appropriate number of Battery 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

Battery String #1 (48V)Batt.

Battery Block (12V)

Battery String #2 (48V)

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

Miscellaneous Battery Monitoring

Battery Symmetry Block Measurement

Four measurements per string (Serial measurement)

—(-48V) Outer

Terminal+

0V Outer Terminal

Intercell Links

X:****

Block1

- + + - +-+-

Block4 Block3

Card, Art. 200576Serial Switches

Set all 4 switches ON (down)

7

Sym

met

ry 4

+

2-1

Sym

met

ry 1

+-

5

Sym

met

ry 3

+

3

Sym

met

ry 2

+

Battery Symmetry Double-point Measurement

Two measurements per string, from the middle to the outer terminals

—(-48V) Outer

Terminal+

0V Outer Terminal

Intercell Links

X:****Card, Art. 200576 Serial Switches

Set all 4 switches ON

(down)

3

Sym

met

ry 2

+

2-1

Sym

met

ry 1

+ -

Block1

- + + - + -+-

Block4 Block3

Bat

t. S

ymm

etry

Kit,

Art.

200

830

Cable Eyes

Sin

gle

Cab

le S

trand

Exam

ples

of B

atte

ry S

ymm

etry

Con

nect

ions

48

V D

C S

uppl

y S

yste

ms

Battery Symmetry Mid-point Measurement

One measurement per string

—(-48V) Outer

Terminal+

0V Outer Terminal

Intercell Links

2-1X:****

Sym

met

ry 1

+ -

Card, Art. 200576 Serial Switches

Set all 4 switches OFF (up)

Block1

- + + - + -+-

Block4Block3

cvkd34

Highlight

cvkd34

Highlight


Terminals & Pin-out Location, Battery Interface Card The Smartpack controller’s battery monitoring signals are accessible on D-Sub connectors CON4 and CON3, on the controller’s rear panel.

Using the Battery Connection Kit ⎯ which consists of a Battery Interface Card (Art. 200576) and a standard 15 pins D-Sub cable ⎯ you can make the signals on CON4 accessible at any suitable location inside your system, e.g. near the battery blocks.

When extra battery monitoring signals are required, you can use an extra Battery Connection Kit connected to the controller’s CON3.

For detailed information about the card’s 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 to the Battery Interface Card (Art. 200576), or directly to the controller’s CON3 or CON4, if unused.

Terminals & Pin-out Location

Battery Interface Card, Art. 200576 14

1

Serial Switch

For Temp. Sense Kit

CON3A or CON4A

X***/X**** X**/X*

1

Alarm Outputs & Digital Inputs Card, Art. 105954

System Connections Card, Art. 200625

Smartpack

Battery ConnectionsCard, Art. 200576

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 mm2, max. wire section

Battery Connections (Internal) Configurable monitoring digital inputs

FUNCTION SIGNAL PIN-OUT

(Internal Connections)

4 3 2 1

5

9 8 7 6

10

14 13 12 11

X:**** Batt. Symmetry 1 +

−+−+−+−

Batt. Symmetry 2

Batt. Symmetry 3

Batt. Symmetry 4

(Fro

m in

tern

al

batte

ries)

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperature sensor

+−Temperature Sense 1

(NA)

(NA)

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperature sensor

15-pins D-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

To S

mar

tpac

k,C

ON

4

CON3A or CON4A 15-pins D-Sub female

1 11

5 15

In

1.5 mm2, max.wire section

Battery Connections (Internal) Configurable monitoring digital inputs



4 3 2 1

5

9 8 7 6

10

14 13 12 11

X:*** +−+−+−+−

(Fro

m in

tern

al

batte

ries)

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperature sensor

+−

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperature sensor

15-pins D-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

To S

mar

tpac

k,C

ON

3

CON3A or CON4A 15-pins D-Sub female

1 11

5 15

The Temperature Sense Kits may also be connected directly to the Smartpack controller’s 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


Standard Alarm Relays & Digital Inputs Connections

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.

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) and two interface cables, you can make the signals on CON1 & 2 accessible at any suitable location inside your system.


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 Mode External 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

Miscellaneous Alarms & Monitoring


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

CON2A CON1A

110 20 1

X* X**



Smartpack

Battery Connections Card, Art. 200576


4 3 2 1

5

9 8 7 6

10

X:*

(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 2 Mains Alarm

Relay 1Common Alarm

+−

NO COM

NC

NO COM

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

4 3 2 1

5

9 8 7 6

10

14 13 12 11

15

X:**

16 17 18 19 20

+−

+−

+−

+−

NO COM

NC

NO COM

NC

NO COM

NC

NO COM

NC

Digital Input 3

Digital Input 4

Digital Input 5

Digital Input 6

Relay 3 Fuse Alarm

Load & Battery

Relay 5Low Battery Alarm

Relay 6 Rectifier 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

25

To S

mar

tpac

k,C

ON

19

Relay 4High Battery Alarm


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.


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. 20062511 1 CON5A

JP1 JP2

X*****




Smartpack



Latching Contactor

Y

X

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

+

4 3 2 1

5

9 8 7 6

10 11

X:***** Power Input

−+−+−

10156

712

139+, Neg.D.

11−,Pos.D.1+/−3+/−

2+/−

Batt. Fuse Fail 1Load 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)


Syst

em C

onne

ctio

ns

JP2

LVD2ALVD Common LVD2(To latching contactors LVD1 & LVD2)

Head Office Eltek Energy AS PO Box 2340 Strømsø; N-3003 Drammen; Norway

Tel:+47 32 20 32 00 — Fax:+47 32 20 32 10 E-mail: [email protected] Internet: www.eltekenergy.com

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

Art. No. 356804.103, Issue 3, 2006 JanPublished 2006-01-06

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

qstart-installation-operation-commissioning and maintenance.pdf

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