Professional Documents
Culture Documents
Flatpack PS System
PRS, PRSB PRSV
(with external
batteries)
MPSU
(w/ without
internal batteries)
Introduction
o The Flatpack Product Range (2 )
o Brief System Description (2 )
Installation
o Installing Rectifier Modules and MCU Controller ( 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)
Miscellaneous
Communication
o Installing WinPower Silver PC software ( 9)
AC Mains
o External AC Fuses, Recommended Rating (10 )
Earthing
o About AC, DC Earthing Systems ( 11)
Battery Monitoring
o Battery Terminology (12)
o Battery Symmetry Connections (12 )
Alarms & Monitoring
o Fail-Safe Operation Alarm Relays & Digital Inputs (13 )
o Terminals & Pin-out Location, Alarm Card 100350 (13 )
o Terminals & Pin-out Location, Front Access Alarm Card 101825 (14 )
MPSU
Modular Power Supply Unit
PRSV
Power Rack System
Wall-mounted PRSB
Power Rack System
with or without Batteries
MPSU systems consist of the power system, which includes rectifiers and controller(s), and the
distribution unit (1U or 4U high). MPSU systems are sold primarily for mounting in existing
cabinets.
In PRS systems, the cabinet contains the power system and the distribution unit. In addition, the
cabinet may also enclose battery banks, additional distribution and other dedicated equipment.
Flatpack
(rectifiers)
LVLD
Telecom
equipment
AC mains
supply LVBD
AC Fuses, selector
external Load Fuses
(230VAC or & MCBs
400VAC Service
Symmetry Switch
Alarm & +/- DC
Temp. Sensor distribution
AC Supply DC Supply
(Single- or Battery string #1 Battery (24V, 48V
three-phase) Fuses or 60V)
Example of a typical Flatpack 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.
Installation Steps
Check off in the Installation Check List, that you find in the pullout section of
this folder. Also, refer to the systems specific drawings.
200 mm 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 (PRSB),100 kg (PRSV) EMC
regard
o Explosive atmospheres are to be avoided. Ensure suitable
ventilation
o 60V systems are only to be installed in Restricted Access
Locations (RAL)
600 mm 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
For external AC fuses and AC input cable ratings, refer to your sites AC
supply specification. Read also our external AC fuse recommendations
in section Miscellaneous. In general, a site with better AC supply
quality (stable nominal voltage) may use smaller breakers.
input terminals, and fix the temperature sensor (at the end
Symmetry cable
Battery
Cable
- + - + - + - +
(-48V) Outer
Terminal Block1 Block3 Block4
+
Intercell Links 0V Outer
Terminal
MCU Control Unit front keys, display, etc Flatpack rectifier module front panel, left side
Display: is in Status Mode (displays the systems Power LED is OFF (mains unavailable) or ON
status) or in Menu Mode (displays the menu structure). (powered). Alarm LED is ON (shutdown or similar
Operation: Press on the key to change from major alarm) or OFF (OK, no alarm)
Status Mode to Menu Mode. Press the or Output voltage is factory adjusted on delivery. In
keys to scroll up or down and navigate to find menu stand-alone operation (MCU ctrl. unit is not used),
options (function or parameter). Press then the you can use the potentiometer to adjust the output
key to select the function. voltage.
Menus: When you enter Menu Mode, you access
the User Options. You may also scroll down to
password protected Service Options. Default password
<0000> and <0003> should be changed. Level 2 Level 3
Service menu <ServiceOption> Password= 0000
NomVolt
Level 2 Level 3 BoostVolt
User menu <UserOption> LowBatt1
LowBatt2
System ON/OFF Turn system ON/OFF * VoltAdjustment HighBatt1
Alarm Reset Alarm Reset HighBatt2
NomVolt LVD 1
LVD 2
Firmware 402080.009 5v1
BoostVolt
LowBatt1 LVD 3
LowBatt2 Calibration VoltCal
VoltageInfo HighBatt1 SetDefaultCalib.
HighBatt2 ChangePassword Password
LVD 1 SetBoostTime BoostTime
LVD 2 Start/StopBoost StartBoost/StopBoost
LVD 3 Auto Boost Cfg. Enable/Disable
DisplayMessages Display messages Threshold
Software Menus
Sw Info SwInfo
* The ON/OFF function may be disabled in some IntervalTest Date Time
Test End Volt
Firmware 402080.009 5v1
Form XXX-gb-v1-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
CIRCUIT DISTRIBUTION LIST
System Data
Flatpack Power Supply System, type: Article No.:
Site, name:
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
Fb1
Fb2
Fb3
Fb4
BATT.
Fb5
Fb6
F1
F2
F3
F4
F5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
LOAD
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Continue
Form 165-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
CIRCUIT DISTRIBUTION LIST
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
LOAD
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
Form 165-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
MAINTENANCE PROCEDURE
System Data Flatpack PS System
Flatpack 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: Maintenance carried out by, name:
WARNING: Maintenance work on live equipment is only to be performed by authorized and
Electric qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.
shock
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 MCU & 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 & MCUs keys and display work OK; verify
Correct possible abnormalities before continuing.
7. Connect the PS system to a PC (install the WinPower Silver application if required)
The WinPower Silver program in the PC enables system configuration from the PC.
8. Rectifiers load current sharing; verify.
The number of LEDs illuminated on every rectifier's bar graph should be equal (1 LED).
9. Display the stored log of Alarm Messages.
Using the keypad on the MCU controller or from the PC.
System Adjustment Activate the Service Switch, if installed
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 MCUs 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 systems 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 MCUs 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.:
Form 166-gb-v2-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
PULLOUT
COMMISSIONING PROCEDURE
System Data Flatpack PS System
Suppliers Order No.: Flatpack 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: Commissioning carried out by, name:
I Pre-Start Check Power is OFF!
CHECK FOLLOWING: OK
1. Flatpack system installation is completed; The Flatpack Installation Check List is filled in.
All cabling is securely terminated with correct polarity
Device
hazard 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!
II CARRY OUT FOLLOWING: OK
1. Disconnect all rectifier modules, without removing them
Device 2. Switch ON the system (external AC fuses ON)
hazard
3. AC input voltage is correct; Measure and verify
4. Insert all Flatpack rectifiers in their locations in the power shelves
5. The MCU and all rectifier modules are working, LEDs are ON; Verify
6. Connect a PC to the PS system Install the WinPower Silver program, 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 WinPower Silver
III 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
Device
hazard 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.:
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
Form 164-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
PULLOUT
Communication Miscellaneous
1 1
RxD 2 2 RxD PC
9 pins (female)
COM1, D-Sub
COMx, D-Sub
9 pins (female)
9 pins (male)
9 pins (male)
TxD 3 3 TxD
MCU WinPower
4 4 DTR Silver
Control Unit GND 5 5 GND
6 6
7 7
CTS
D-Sub 8 8
9 9
D-Sub D-Sub
Technical Room Control Room
205VAC Inputs
1-phase
3 48.6 50A-C
For Flatpack 1500 sys- 1* 8.1 25A-C
tems use the recom- 230/400VAC
3-phase, TN network 2 or 3 16.2 25A-C
mendations in the
205VAC table, if you (5 wire system) 4,5 or 6 32.4 40A-C
are sure the available 1* 14.0 25A-C
Flatpack 1500
1-phase
3 58.5 63A-C
For Flatpack 1800 sys- 1* 9.8 25A-D
tems use the recom- 230/400VAC
3-phase, TN network 2 or 3 19.5 25A-D
mendations in the
205VAC table, if you (5 wire system) 4,5 or 6 39.0 40A-C
are sure the available 1* 16.9 25A-D
Flatpack 1800
* The calculation for single sub-rack configuration requires separate AC feed to each module position
Note: The above recommendations apply for use of Thermal magnetic circuit breaker, type Siemens 5SX or 5SY series, MG C60H
series or similar. For more information regarding External AC fuses and other types of fuses, please read the article 2014385 for
Flatpack 1500 systems or the article 2014386 for Flatpack 1800 systems on the CD, 356802.CD3.
Link 1 . DC Load
PE (AC Earth) Circuit
Cabinet
Chassis
AC Earth (PE) and DC Earth (TE) are usually connected to chassis via Link 1 and Link 2.
Remove the links (floating earth) for compliance with other local earthing systems. Refer to
your systems specific drawings to identify how these links are implemented in your DC power
system.
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.
Common DC Rail + Common DC Rail
DC Load
DC Load
+ wires
wires
+
+
+
Negative DC Positive DC
Distribution Distribution
Battery Terminology
Refer to your systems specific drawings for the exact connection points.
Battery Terminology
11
13
11
100986
Front access CON4 CON4
circuit card Symmetry Symmetry
100986 cable 3 cable 1
Symmetry
cable 1
+ + + +
(-48V) Outer (-48V) Outer
Terminal Terminal
+ +
Intercell Links 0V Outer Intercell Links 0V Outer
Terminal Terminal
+ 1 1 10 1 18
AGND 2
+ 3 FUNCTION SIGNAL PIN-OUT
Monitoring Input Signals
Digital Input 2
4
**
+ 5 CON5
Digital Input 3 AGND 6 Relay 6 NC 1
+ 7 Common Alarm NO 2 Alarm Circuit 6
Voltage free (circuit card 100350)
+ 9 Relay 5 NC 4
1.5 mm , max. wire section
Symmetry Alarm 2
(digital input) AGND 10 (From external Symmetry Module Alarm NO 5 Alarm Circuit 5
Alarm circuit card, art. 26851) Com 6
+ 11
Analogue
12
batteries)
Fuse Alarm, NO 8
internal
(From
Symmetry Alarm 3 + 13
14 Load & Battery Com 9
Alarm Circuit 4
(Not used) 17
+ 18 Relay 2 NC 13
internal batteries)
Temperature Sense
(From area with
* CON2 & CON3 are used for internal connections (connected from factory)
** For correct use of digital inputs, see the Fail-Safe Operation chapter
Quick Start Guide Flatpack PS System 356803.103, v4-2006-10
13
Miscellaneous Alarms & Monitoring
Terminals & Pin-out Location The figure shows the position of the
Alarm & Signal Front Access Kit, Art. 101825 relay contacts when the PS system
Circuit Card 100985 is in its alarm mode of operation.
The relay coils are then de-
Internal System
1
Connections,
11
(Front access circuit card 100986)
2 Alarm Circuit 4
Monitoring Input Signals
AGND
Alarm Relay Outputs
AGND 4
Relay 5NO
Digital Input 3 AGND 5
+ Module Alarm
14 Alarm Circuit 5
**
6 NC 15
Com 16
Digital Input 4 AGND + 7 Relay 6
NO 17
8 Common Alarm Alarm Circuit 6
NC 18
Digital Input 5 AGND + 9
2
10 Com 19
Relay 7 20
Symmetry Alarm 1 + 11 NO
Analogue
NC 21
batteries)
Symmetry Alarm 2 + 12
external
(From
Head Office
Eltek Energy AS Copyright Eltek Energy AS, Norway 2006
PO Box 2340 Strms; N-3003 Drammen; Norway This document may be changed without notice
Tel:+47 32 20 32 00 Fax:+47 32 20 32 10 Doc. No. 356803.103, Issue 4, 2006 Oct
E-mail: eltek@eltekenergy.com Internet: www.eltekenergy.com Published 2006-10-11