Professional Documents
Culture Documents
1 Welcome
Information in this document is subject to change without notice and does not represent
a commitment on the part of Eltek Energy.
No part of this document may be reproduced or transmitted in any form or by any means
electronic or mechanical, including photocopying and recording for any purpose
without the explicit written permission of Eltek Energy.
Copyright : Eltek Energy, Norway 2007
Power Distribution
Centre for
Communications
Equipment
35KS
This product is CE marked and complies with all current requirements for relevant
standards and directives.
This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).
EMC
LVD
351476.033
Published 2007-06-19
Mfm
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
1 Welcome
Table of Contents
1.
Welcome
2.
System Description
3.
Installation
12
4.
Commissioning
23
5.
Maintenance
26
6.
28
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
1 Welcome
1. Welcome
The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m is a DC power supply for
telecom equipment suitable for outdoor fan cooled applications.
2. System Description
The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m is a DC power supply system
based on the Flatpack2 2000W 48V rectifier.
The system contains AC termination blocks, DC distribution, Flatpack2 Power Rack,
Flatpack2 2000W rectifier modules and the Flatpack2 Smartpack control unit. The system
is designed for cable entry from top and the cabinet size is 770x820x2030 mm
(30.3x32.3x80) (WxDxH).
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
Common
positive bus bar,
2
70 mm , AWG 2/0
Terminals for
GMT 10A
Load
2
Smartpack controller
Alarm Terminals
2
1.5mm , 16AWG
(Front access)
AC Earth
DC Earth
Smartpack
controller unit
DC Distribution
Flatpack2
rectifier modules
AC Mains
Terminals
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
L2
L3
Fish Plate
L1
L2
L3
AC Mains
Cable
AC Mains
wires
N
Wires
Links
AC Mains
wires
L2
L1
AC Mains
Cable
Fish Plate
L1
L2
L3
Fish Plate
L1
L2
L3
L1
L2
L3
AC Mains
wires
AC Mains
Terminal
Block
AC Mains
Terminal
Block
Mains, TN
Three-phase & N, 400VAC
Mains
One-phase, 230VAC/208VAC
AC Mains
Terminal
Block
(To internal connections)
Flatpack2 DC Power System
Mains, IT
Three-phase, 230VAC/208VAC
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
Pin 16
GMT fuses
Max. 10A each
F12
F5
F8
Figure 2
The table below shows the pin-out location for the GMT load fuse card:
Pin Assignment for GMT Fuse
Pin
1
2
3
4
5
6
7
8
Signal
+
Function
GMT fuse 1 (F5)
GMT fuse 2 (F6)
GMT fuse 3 (F7)
GMT fuse 4 (F8)
Pin
9
10
11
12
13
14
15
16
Signal
+
Function
GMT fuse 5 (F9)
GMT fuse 6 (F10)
GMT fuse 7 (F11)
GMT fuse 8 (F12)
(fan fuse)
Relay X
(Energized coil)
NO
Com
NC
NO
Com
Relay X
(De-energized coil)
NC
Flatpack2 PS System
Alarm Mode
Normal Mode
External Relay Y
(Energized coil)
Alarm Mode
External Relay Y
(De-energized coil)
Flatpack2 PS System
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
Out
Digital Input 1
Digital Input 2
*X1:
+
Relay 1 NO
OVP & Door Alarm COM
NC
CON2A
CON1A
CON1
Battery Connections
Card, Art. 200576
CON2
Smartpack
CON1A
CON2A
*X1
Battery Connections
Card, Art. 200576
Relay 2
High Battery Alarm
To Smartpack,
CON1
System Connections
Card, Art. 200625
*X2
10
20
To Smartpack,
CON2
NO
COM
NC
1
2
3
4
5
6
7
8
9
10
Input Circuit 1
Input Circuit 2
Alarm Circuit 1
Alarm Circuit 2
*X2:
1
2
3
Digital Input 4
4
5
Digital Input 5
6
7
Digital Input 6
8
Relay 3 NO 9
Low Battery Alarm COM 10
NC 11
Relay 4 NO 12
Fuse Alarm COM 13
Load & Battery NC 14
Relay 5 NO 15
Battery Alarm: -10C >Temp>50C COM 16
& Rectifier Alarm NC 17
Relay 6 NO 18
Mains Alarm & COM 19
Mains Low & High Alarms NC 20
(Customer Connections)
Digital Input 3
In
SIGNAL PIN-OUT
Input Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6
Alarm Circuit 3
Alarm Circuit 4
Alarm Circuit 5
FUNCTION
Card Art.105954
Alarm Circuit 6
2
1.5 mm , max.
wire section
The figure shows the position of the relay contacts when the relay coils are de-energized
(PS system in alarm mode. Factory Settings in bold).
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
Smartpack
JP1
3
2
1
JP2
JP1
Battery Connections
Card, Art. 200576
Pos. Distr.
Neg. Distr.
JP2
1
2
3
X*****
1
11
CON5A
7
13
15
6
12
9+, Neg.D.
11,Pos.D.
1+/
3+/
2+/
1
Power Input
2
3
Batt. Current 1
4
Batt. Fuse Fail 1
5
6
Load Fuse Fail 1
7
LVD1A
8 LVD Common
LVD1
9
LVD2A
10 LVD Common
LVD2
11
(To latching contactors
LVD1 & LVD2)
(Internal Connections)
Neg. Distr.
Pos. Distr.
10
JP2
CON5
System Connections
Battery Connections
Card, Art. 200576
System Connections
Card, Art. 200625
CON5A
Flatpack2 systems are shipped from factory with the CON5 signals already connected.
Some of the Smartpack controllers internal system signals are accessible on D-Sub
connector CON5, 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.
In
Out
X:*****
Terminals & Pin-out Location
ON
+ Pulse
PCB Art.
200625
LVD1A
X
X:*****
8
9
10
11
Bidirectional
diode
Latching
Contactor
LVD1
LVD Common
LVD2A
Y
X
X
Latching
Contactor
LVD2
Smartpack
Unit
- Pulse
Latching Contactor
LVD Common
LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
System Monitoring
The Smartpack Control Unit monitors and controls the entire rectifier system including
distribution and batteries, as well as other equipment on site. The unit also incorporates
a communication port for connecting computers via the USB interface.
The Flatpack2 system can be operated and configured locally via the keypad on the
Smartpack unit, by selecting commands from set-up menus in a hierarchical menu
system.
Remote system monitoring and configuration may also be performed using PowerSuite -a Windows-based program that runs on a connected PC.
Following configuration tasks require the use of a PC:
o Installation settings
o System calibration
o Battery configuration
o Alarm setup
o Alarm log retrieval
o Site information
o Site specific configuration
Please, refer to the Smartpack controllers Users Guide --Art. No. 350003.013 and to
the PowerSuite programs online help (press function key F1) for detailed information
about system monitoring and functionality.
10
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
2 System Description
System Specification
Technical Specification
DC OUTPUT
Voltage
Current
CONNECTIONS
Battery connections
Load MCB
connections
48VDC
Up to 16 KW 340A
VAC
Note
1
185 275
Full output power
1
275 300
Full power, reduced power factor
2
300 350
Shutdown
3
350 420
Shutdown* (see note below)
At no load, the rectifier will survive 350Vac. With load
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
11
3 Installation
3. Installation
This section describes how to install the Flatpack2 PS System, 16kW, 48VDC, OCab, FanC
2.0m.
Step-by-step procedures will guide you through the installation.
Read also the generic documentation included in the systems documentation set, Art.
No. 351476.003
Safety Precautions
To be installed only in restricted access areas or the like, in accordance with
articles 110-16, 110-17, and 110-18 of the National Electrical Code,
ANSI/NFPA 70
For supply connectors use wires suitable for at least 75C (167F)
Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.
Use copper conductors only
The equipment described in this manual must only be operated by
Eltek Energy personnel or by persons who have attended a suitable
Eltek Energy training course
CAUTION: Even though the product incorporates protection circuitry and
other safeguards, it can be damaged, perform poorly or have a reduced
lifecycle if it is exposed to incorrect treatment during transport, installation
or service.
The equipment represents an energy hazard and failure to observe this
could cause terminal injury and invalidate our warranty
There are hazardous voltages inside the power system. As the modules
incorporate large charged capacitors, it is dangerous to work inside the
system even if the mains supply is disconnected
Products into which our components are incorporated have to comply with a
number of requirements. Installation is to be in accordance with the
recommendations herein
Please read the manual carefully before using the equipment
12
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
Electrical Safety
Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical
connection or conductor is not energized. Check the circuit with a volt meter with respect to the
grounded portion of the enclosure (both AC and DC) prior to any installation or removal procedure
An external electrical service disconnect must be used that is properly sized as required by the NEC
and/or local codes
The supply neutral conductor must be bonded to earth ground at the disconnect panel
Do not work alone under hazardous conditions
A licensed electrician is required to install permanently wired equipment
Ensure that utility power is disabled before beginning installation or removal
Ensure no liquids or wet clothes contact internal components
Hazardous electrically live parts inside the enclosure are energized by batteries even when the AC input
power is disconnected. Make sure the power is removed via the battery disconnect breaker before
servicing any of the equipment
The internal equipment may be powered by AC circuits. Make sure power is removed via the appropriate
breaker before servicing any of the equipment
Prior to installation, verify that the AC input voltage to the enclosure and its equipment with respect to
voltage and frequency
Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage
requirements of the connected equipment loads
Prior to installation, verify that the enclosures utility service panel is equipped with a properly rated
circuit breaker for use with the equipment inside. Refer to the manufacturers recommendations
Prior to installation, contact local utilities, local building maintenance departments, and cable/piping
locating services to ensure that installation does not interfere with existing utilities or building
cables/piping
Fuses/circuit breakers may not be provided with the equipment. Refer to the documentation for the
proper hardware. Use only the parts specified in the documentation. Installing fuses or circuit breakers
not specified for use in this equipment may result in injury to service personnel or equipment damage
Where required for installations in the United States or Canada, use listed/certified compression
connectors to terminate listed/certified field-installed conductors. If the proper connector for the country
of installation is not provided, obtain the appropriate connectors and follow all manufacturer and local
requirements for proper connections
Torque the electrical connections to the values specified on labels or in the product documentation
The DC distribution is considered a Safety Extra Low Voltage (SEL V) with the return side connected to
the chassis (earth ground) inside the enclosure
The supply neutral conductor must be grounded at the external service supply disconnect panel
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
13
3 Installation
Do not use other methods for cable entry than what is specified in the documentation for this product
Ensure proper cable support is used to support the weight of cables and cable conduits that enter/exit
the cabinet
Do not drill new holes or use other methods for cable entry than what is described in the product
documentation
Mechanical Safety
Keep hands, hardware and tools clear of the fans. Fans are thermostatically controlled and will turn on
automatically as a function of temperature
Rectifiers can reach extreme temperatures under load and normal operation
Use caution around sheet metal components and sharp edges
Do not climb on the enclosure to access the cable entrance. Always use the proper ladder and safety
precautions as dictated by the site conditions
Battery Safety
Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove
all metallic objects from hands, wrists, and neck
Batteries contain dangerous voltages and current, as well as corrosive material. Battery maintenance,
service, and replacement must be performed by authorized personnel only
Never use non-insulated tools or other conductive materials when installing, maintaining, servicing, or
replacing batteries
Use special caution when connecting or adjusting battery cables. An improperly connected battery cable
can result in arcing, fire, or possibly an explosion
A battery showing signs of cracks, swelling or leaking must be replaced immediately by authorized
personnel using a battery of identical type and make
Do not smoke or introduce sparks in the vicinity of a battery
Follow the battery manufacturers approved transportation and storage instructions
Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may
have developed in your body
Batteries contain or emit chemicals known to the State of California to cause cancer and birth defects or
other reproductive harm. Battery post terminals and related accessories contain lean and lead
compounds. Wash hands after handling
If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your
companys approved chemical exposure procedures
Neutralize any spilled battery emission with a special solution contained in an approved spill kit or with a
solution of 1 lb bicarbonate of soda to 1 gallon of water. Report a chemical spill using your companys
spill reporting procedures and seek medical attention, if necessary
Each individual battery should have at least 0.25 inches of space between it and surrounding surfaces,
or per the battery manufacturers specification to allow for convective cooling
Battery cables must be dressed to avoid damage to the conductors. Damage or stress can be caused by
routing around sharp edges or in areas where wires could get pinched
Follow battery manufacturers approved instructions to set all battery related parameters accordingly
14
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
CAUTION:
- The modules may be warm, but do not hand-carry them by their handles
- Open the handles before inserting them into the power shelves (hot-pluggable)
The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing
Smartpack
controller
Flatpack2
rectifier
Handle in
unlocked position
or
using both handles to pull the module loose. Support from underneath before
the unit is completely free. Unplug the cables, when removing the Smartpack
module
3. Lock the handles by
pushing the handles up into their housings (locked position). Then, the module
will be securely locked in the shelf, or ready for transport
Electric
shock
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
15
3 Installation
Insert & hot-plug the rectifiers in the indicated power shelf positions,
one module at a time, allowing a 2s delay between them and starting with ID
number 1, 2, 3, and so on. (indifferent after ID# 6)
Correct Rectifier Position in the Power Shelves
Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
and
Mains
Three-phase, 230VAC
Mains
Three-phase & N, 400VAC
Flatpack2
rectifier
Smartpack
controller
Position 1
Position 9
16
01
04
03
06
-----
-----
02
05
Position 4
---
---
Position 8
---
-----
---
Phase 1
Phase 2
Phase 3
ID number
(Assigned CAN
bus address)
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
System Installation
Check off in the Installation Check List, that you find in the last section of this folder.
Site Preparation
Refer also to chapter Location of Components ~ General Arrangement on page 5.
Step - Site Preparation
1. Organize the
installation site
Action
Power is OFF!
o Check min. clearances for cabinet access:
front access, 100 cm, top access, 60 cm,
rear clearance 100 cm *
See page 36
OK
2.
Prepare the
installation tools
3.
Prepare AC Supply: AC
input cable(s) and
fuses
Mechanical Installation
Step - Mechanical Installation
4. Remove packaging
and check equipment
5.
Action
Power is OFF!
CAUTION: Do not step nor walk on the cabinets
roof.
o Check you have received all the parts,
correct cabinet, documentation, batteries (if
applicable), etc
o Inspect the equipment for physical damage
(report any damages)
o Leave rectifier modules in their packaging or
in the selves, if factory installed.
(commissioning task)
Note: Only to be used when the cabinet is placed
directly on concrete floor and a cabinet plinth is
not mounted.
o Use the attached neoprene mat between the
cabinet and the concrete floor. See Table 1,
page 35 for specifications
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
OK
17
3 Installation
Step - Mechanical Installation
6. Position and fasten
the cabinet
Action
Power is OFF!
Note: If Flexi kit 2 will be installed, ensure a
minimum clearance of 1m between the cabinet rear
wall and any obstacle. See also Figure 7, page 36
OK
7.
Electrical Installation
Refer also to chapter Location of Components ~ General Arrangement on page 5.
Step - Electrical Installation
8. Make the system
completely voltage free
9.
Action
Power is OFF!OK
Switch OFF or remove ALL load fuses (F1, Fx),
battery fuses (Fb1, Fbx) and external AC supply
fuses
The cabinet roof is locked with 2 screws in the
front, from inside the door opening.
o Open these screws and lift up the roof
o Secure the roof during installation with the
rod on the right side under the roof
..
18
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
Step - Electrical Installation
10. Insert the cables
Marcon 25 multigate
Action
Power is OFF!OK
Cable (all phases in one cable) max 6mm2 each
Single phase cable (one cable per phase) max
35mm2
CAUTION: Do not use the metal blind plates as
cable entry plates.
o Use a screw driver to puncture the
appropriate grommet(s) of the Marcon 25
multigate. Do not use a knife!
The cut must be smaller than the cable
diameter. The pictures show how to cut the
.
grommets.
11. AC Connections
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
19
3 Installation
Step - Electrical Installation
12. AC Socket Connection
Action
Power is OFF!OK
The system is prepared for an AC socket, located
to the right side of the cabinet. This AC outlet is
intended for optional equipment. Due to the many
different socket types all over the world, no socket
is delivered with the system.
o
o
o
20
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
3 Installation
Step - Electrical Installation
13. DC Connections
Load Circuits
14. DC Connections
Alarm & Signal Circuits
Action
Power is OFF!OK
o Terminate DC Earth (TE)
- Terminals DC Earth (TE) is mechanically
connected to cabinet chassis. Refer to page
5.
- The Common Positive Bus bar is internally
cabled to DC Earth (TE); thus the positive
output of the rectifiers is connected to
ground (TE), and the negative output
represents the 48VDC supply voltage.
Refer to Figure 1 General Arrangement
Flatpack2 PS System, 16kW, 48VDC, OCab,
FanC 2.0m, on page 5.
The Common DC Output Rail is to be
connected to TE at only one place.
- If required, you can remove the internal
cable that connects the positive bus bar to
local TE.
o
The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
21
3 Installation
Step - Electrical Installation
15. DC Connections
Battery Cables
Action
Power is OFF!OK
The positive and negative (-48V) battery cables
are connected from factory to the common positive
bus bar and to the battery MCBs (does not apply
for additional battery string kits).
The battery temperature sense cable is also pre
wired to CON4, and temporally fixed to the
cabinets wall.
22
o
o
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
4 Commissioning
4. Commissioning
The commissioning of Flatpack2 PS System consists of following stages:
I. Perform a pre-start check before the PS system is switched ON
II. Switch ON the system with disconnected load; adjust output voltage
III. Adjust the nominal output voltage with connected batteries and load
I
Power is
OFF!
Pre-Start Check
Check off in the Commissioning Procedure, that you find in the last section of this
folder. If you have just finished the system installation successfully and filled in the
Installation Check List, jump over the Pre-Start Check and continue with stage II.
Before you switch ON the Flatpack2 PS system, verify the following:
Device
hazard
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
23
4 Commissioning
II
Power is
ON!
Device
hazard
24
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
4 Commissioning
9. Verify the alarm relays are working correctly (alarm relay test)
o Run the alarm relay test using the controllers front keys or via PowerSuite
(select the menu Go > Output Test)
10.Make sure the System Setup is in accordance with configuration
o Verify system settings using the controllers front keys or via PowerSuite
o Use the opportunity to enter site related information, number of used AC
phases, type of batteries, etc.
III
Load Adjustments
Now, you can begin with stage III, where you will adjust again the output voltage
to the battery voltage, and connect the batteries and the load.
Carry out the following:
Power is
ON!
Device
hazard
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
25
5 Maintenance
5. Maintenance
You can carry out the DC power system maintenance, by following the steps in the
Maintenance Procedure that you find in the last section of this manual.
This chapter describes how to perform filter maintenance.
WARNING: You are operating in a live system. Precaution must be taken when changing
filter in front of the fan.
Lower Door Filter (Fan Filter) Locations:
Car park/road side: City roof top: Non central:
Pollution degrees:
Low
1 year
2 years
3-4 years
Medium
1 year
2 years
3-4 years
High
6 months
1 year
2 years
* Note! The filter replacement intervals listed in the above table are only guidelines.
Shorter intervals may be required, depending on the level of air pollution on site.
Eltek recommend bi-monthly site checks during the first year of operation, to establish
actual filter replacement intervals for each individual site
Upper Door Filter
Locations:
Pollution degrees: Car park/road side: City roof top: Non central:
Low
4 year
8 years
12 years
Medium
4 year
8 years
12 years
High
2 years
4 year
8 years
* Note! The filter replacement intervals listed in the above table are only guidelines.
Shorter intervals may be required, depending on the level of air pollution on site.
Eltek recommend bi-monthly site checks during the first year of operation, to establish
actual filter replacement intervals for each individual site
Filter frames
fastening screws
Filter frames
fastening screws
Figure 3
26
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
5 Maintenance
Action
1.
Remove
filter
OK
o Remove the Air baffle plate(s) that cover the filter grid on the
inside of the cabinet door (plates not shown in Figure 3).
o Remove the filter grid
by loosening the screws around it. Pull the grid towards you
when loose
2.
Exchange
filter
3.
Mount the
frame
o Mount the grid to the door again, fastening the screws around
it
o Mount the Air baffle plate(s) back on again and tighten the
screws
Disconnect
the fan
2.
Comments
OK
3.
Remove the
filter grid
4.
Exchange the
filter
o Exchange the old filter with a new. Make sure that the
smooth side of the filter faces the inside of the cabinet
5.
Mount the
grid
Close the Fan
Filter door
Connect the
fan
6.
7.
o Close the fan filter door, and turn the knobs closed
o Replace the fan fuse, and verify that the system is
operating normally
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
27
28
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
Flatpack2 PS System
Article No.:
Site, name:
Serial No.:
Battery Type:
Site Preparations
Power is OFF!
OK
Mechanical Installation
CARRY OUT FOLLOWING:
Power is OFF!
OK
Electrical Installation
Power is OFF!
OK
Check AC configuration: The AC terminals are correct configured to the external AC supply
Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
o
o
Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place
For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB
Terminate the GMT load circuits
Approval
Responsible of installation, sign.:
Date:
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
29
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Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
COMMISSIONING PROCEDURE
System Data
Suppliers Order No.:
Flatpack2 PS System
Flatpack2 Power Supply System, type:
Article No.:
Site, name:
Serial No.:
Battery Type:
Battery Capacity:
Pre-Start Check
Power is OFF!
CHECK FOLLOWING:
1.
Device
hazard
OK
II
Device
hazard
Power is ON!
OK
1. Disconnect all rectifier modules, without removing them (keep original location)
2. Remove the Condensation Stopper
3. Switch ON the system (external AC fuses ON)
4. AC input voltage is correct;
5. Insert all Flatpack2 rectifiers in their original locations in the power shelves
6. The Smartpack and all rectifier modules are working, LEDs are ON;
7. Connect a PC to the PS system
Verify
8. DC output voltage;
III
Device
hazard
12. Unplug all rectifiers but one, and connect all battery fuses/ MCBs
13. Adjust DC output voltage to equal nominal battery or load voltage
14. Plug in again all rectifiers, and verify the rectifiers current sharing
15. Connect all load MCBs/ fuses, and verify no alarms are displayed
Approval
Responsible of commissioning, sign.:
Date:
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
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Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
MAINTENANCE PROCEDURE
System Data
Flatpack2 PS System
Article No.:
Site, name:
Electric
shock
Serial No.:
Battery Type:
System Inspection
Power is ON!
OK
3. The equipment and door filters are free from damage, dust or dirt; verify.
Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt. Perform filter maintenance.
4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.
5. The Smartpack & all rectifier modules are ON, no alarm present; verify.
Otherwise, correct and put the PS system in normal mode of operation.
6. All rectifiers functionality & Smartpacks keys and display work OK; verify
Correct possible abnormalities before continuing.
System Adjustment
CARRY OUT FOLLOWING:
OK
If measured DC output voltage at the load terminals deviates more than 1% from the display reading, calibrate the
output voltage from the Smartpacks keypad or the PC.
4. Alarm Relay Test; verify all alarm relays are working correctly.
From the Smartpacks keypad or PC use the Relay Test function; verify activation of external equipment
Approval
Responsible of maintenance control, sign.:
Date:
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
33
770.0000
Door Switch
41U
DC Distribution
Cabinet main ground bar
AC Earth (PE) and DC
Earth (TE) connection
Smartpack
controller
35U
AC Mains Terminals
AUX.AC MCB
(heater, AC socket,
air-conditioner)
29U
1944.4200
Battery MCB
FB4*
21U
Battery MCB
FB3*
14U
Battery MCB
FB2*
7U
Battery MCB
FB1
* Optional
Figure 4
34
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
Feature
Shore hardness A
Tensile strength
Elongation at rupture
Density
Mass per unit area
Compression stress at 30% deformation
Operational temperature
Flammability
Table 1
655
0,45 N/mm
45%
730 kg/m
730g/m/mm
0,75 N/mm
-40 to +155C
Class B 2din 4102
DIN 53 505
DIN 53 571
DIN 53 571
DIN 53 577
FRONT
620 mm
620 mm
Front
Note: The mat is only to be used when the cabinet is placed directly on concrete floor and a cabinet
plinth is not mounted.
75 mm
75 mm
75 mm
75 mm
120 mm
575 mm
125 mm
120 mm
575 mm
125 mm
2m
Cabinet-to-Plinth
Fastening Holes
Figure 6
Cabinets plinth, top and 3D view. Cabinets and plinths fastening holes
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
35
Figure 7
36
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
*OPTION
PS 1
PS 2
Relay
62950-734
11
14 11
A2 A1
PE
Battery Heater*
A1 A2
Door Switch
JP2
3
Battery Current
Power Input
+
+
+
-
1
2
3
4
5
6
7
8
9
10
11
*X1
Con 2A*
Ext. Alarm I/O Connections
Con 1A*
Alarm I/O Connections
3
4
5
6
7
8
9
10
Relay 6
Relay 5
Relay 4
Relay 3
Digital Input 6
Digital Input 5
Digital Input 4
Digital Input 3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
LTE EQUIPMENT*
NO
COM
NC
+
+
+
+
NO
COM
NC
NO
COM
NC
NO
COM
NC
*X2
Ext. Alarm I/O Connections
Relay 2
Relay 1
Digital Input 2
+
NO
COM
NC
NO
COM
NC
JP1
POS. DIST.
26
10
NEG. DIST.
1
NEG. DIST.
*X5
System Connection
J1
Red
351476.033, v4-2007-06
TERM 1
TERM 2
TERM 3
J1
Yellow
Brown
White
Temp
sensor
62950-421
AC socket*
Con 5A*
System Connections
SH1
TERM 1
TERM 2
TERM 3
Yellow
Blue
Red
FAN
62950-420
Brown
PE
Backwiring FP2
Low Current 2AC
4 rectifier positions
105581
Smartpack Power
- /CAN bus
interconnections
PE CON13
L1 CON9
L1 CON11
L2 CON10
L2 CON12
Backwiring FP2
Low Current 2AC
4 rectifier positions
105581
Smartpack Power
- /CAN bus
interconnections
PE CON13
L1 CON9
L1 CON11
L2 CON10
L2 CON12
15
-F13
-F5 GMT
POS. DIST.
-F14
OVP kit
-F15
Star (400Vac)
3-phase
L1 L2 L3 N
-F16
AC terminal
connections
-F17
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
-F18
Y
X
LVBD
10
8/26
9/15
15
15
DC Earth (TE)
2:
Customer
connections
- F4*
- F3*
- F2
- F1
- FB4*
- FB3*
- FB2*
- FB1
0V
Customer connections
1:
CAN port
CAN port
CON1
Alarm I/O Connections
CON2
Ext. Alarm I/O Connections
2: Optional: Web/SNMP (ENET)
1: Optional: RS232
USB
Front connections
Smartpack
monitoring and
control unit
CON3
Ext. Battery connections
1: Optional: RS 232
CON4
Battery connections
CON5
System Connections
Rear connections
16
F12 15
14
F11 13
12
F10 11
F9 10
9
F8 8
7
F7 6
5
4
F6 3
2
F5 1
CU-bar common +
Load
Alarm
-F19
203929
-F20
Figure 8
Load
Alarm
Diode
Matrix
101526
1
2
Diode
Matrix
101526
1
2
White
37
Customer connections
Note! The values in this table are default factory settings. The settings of a Smartpack controller in
an installed system may be different from the above settings, depending on the systems final
configuration of optional kits, number/type of batteries, alarm setup and/or any other changes done
to the system and/or the Smartpack controller after the system was shipped from the factory.
38
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet
351476.033, v4-2007-06
Article No.:
Site, name:
FUSE
ID
Form xxx-gb-v1-C01_351476-033_instgde_fp2-pss-16kw-48vdc-ocab-fanc-2m0.doc_ts/mfm_2007-06-19
F1
F2
F3*
F4*
F5
F6
F7
F8
F9
F10
F11
F12
F13*
F14*
F15*
F16*
F17*
F18*
F19*
F20*
FUSE TYPE
BTS
MCB
GMT
FUSE
LTE
MCB
RATING
LOAD DESCRIPTION
AMPERE
CABLE
SIZE
mm2
CABLE
SIZE
AWG
X
X
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
*Optional fuses/breakers.
F3 & F4 are only fitted if optional BTS breaker kit(s) are installed in the cabinet.
F13-F20 are only fitted if optional LTE kit is installed in the cabinet
Breakers F1, F2 and GMT fuses F5-F12 are always part of cabinet
LTE MCB`s
(Optional)
BTS MCB`s
GMT FUSES
Eltek Energy AS
Tel. +47 32 20 32 00
Internet: www.eltekenergy.com
E-Mail: eltek@eltekenergy.com
ELTEK Energy
P-O- BOX 2340 Stms
N-3003 DRAMMEN
NORWAY
Phone:
Telefax:
Internet:
e-mail:
Location
Norway
Americas
Asia/Pacific
China
Europe
Middle East
+47 32203200
+47 32203210
http://www.eltekenergy.com
eltek@eltekenergy.com
Company
Eltek Energy AS
Eltek Energy, LLC
Eltek Energy Pte Ltd.
Eltek Energy Ltd.
Eltek Energy UK Ltd.
Eltek Middle East
Telephone
+47 32 20 32 00
+1 815 459 9100
+65 6 7732326
+769 22651108
+44 1442 219355
+971 4 887 1176
Fax
+47 32 20 32 10
+1 815 459 9118
+65 6 7753602
+44 1442 245894
+971 4 887 1175
www.eltekenergy.com