Installation Guide Flatpack2 PS System Indoor v3

Installation Guide

DC Power Supply System, 16kW, 48VDC Indoor 2.0m Cabinet 3 3 0 . 5 7 4 1 5 3

1 Welcome

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek 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 of Eltek Energy . Copyright ©: Eltek Energy , Norway 2007

Power Distribution Centre for Communications Equipment 35KS

Certificate no: 900005E

Certificate no: 900005Q

NS-EN ISO 14001: 1996 Certificate No: 900005E

NS-EN ISO 9001: 1994 Certificate No: 900005Q

This product is CE marked and complies with all current requirements for relevant standards and directives. This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).

EMC

LVD

EN61000-6-2 Industrial Environment EN61000-6-3 Residential, Commercial and Light Industry ETS 300386 Telecommunication Equipment

LVD73/23/EEC Low Voltage Directive EN60950 Safety of Technology Equipment UL60950,UL1801

“FP2 PRSB 16KW/48Vdc ID 2m” has 2m” has part no. CF1042.010.

351475.033

Issue 3, 2007 June

Published 2007-06-19 Mfm

2

Installation Guide Flatpack2 PS System, 16kW, 48VDC, Indoor 2.0m Cabinet

351475.033, v3-2007-06

1 Welcome

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek 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 of Eltek Energy . Copyright ©: Eltek Energy , Norway 2007

Power Distribution Centre for Communications Equipment 35KS

Certificate no: 900005E

Certificate no: 900005Q

NS-EN ISO 14001: 1996 Certificate No: 900005E

NS-EN ISO 9001: 1994 Certificate No: 900005Q

This product is CE marked and complies with all current requirements for relevant standards and directives. This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).

EMC

LVD

EN61000-6-2 Industrial Environment EN61000-6-3 Residential, Commercial and Light Industry ETS 300386 Telecommunication Equipment

LVD73/23/EEC Low Voltage Directive EN60950 Safety of Technology Equipment UL60950,UL1801

“FP2 PRSB 16KW/48Vdc ID 2m” has 2m” has part no. CF1042.010.

351475.033

Issue 3, 2007 June

Published 2007-06-19 Mfm

2


351475.033, v3-2007-06

1 Welcome

Table of Contents

1.

Welcome

4

About this Guide ......................... .............................. ............................. ......................... 4

2.

System Description

4

Location of Components ~ General Arrangement.............................................. Arrangement.............................................. 5 External AC Fuses ~ Recommended Recommended Ratings ............................ .............................. ...... 6 Mains Reconfiguration Reconfiguration ~ AC Terminal Block .................................. .............................. .. 6 Terminals & Pin-out Location, GMT Fuses ........................... .............................. ............ 7 Alarm Relays Relays & Digital Inputs Inputs........................... ............................. .............................. .... 7 Terminals & Pin-out Location, Alarm Interface Card ................................................................8 ................................................................8 Terminals & Pin-out Location, System Interface Card .............................................................. ..............................................................9 9

LVD Latching Contactors ............................. .............................. ............................. ........ 9

Monitoring, Control and Signal Interface .......................... ............ ........................... .......................... ................... ...... 10 System Monitoring .............................. ............................... ............................... ............ 10

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

3.

Installation

12

Safety Precautions ............................. ............................. .............................. ................ 12

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

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

4.

Commissioning

19

Pre-Start Check ................................................................................................... 19 Commissioning Steps, Startup .......................... ............. ........................... ........................... .......................... ..................... ........ 20 Startup and No-Load Adjustments ......................................................................................... ...........................................................................................20 20 Load Adjustments Adjustments ....................................................................... ................................................................................................................... ............................................21

5.

Forms, Schematics & Drawings

22

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


351475.033, v3-2007-06

3

1 Welcome

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

About this Guide This booklet provides users of the Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m with the required information to perform system installation, commissioning and maintenance. The booklet also describes the system’s technical specifications, and includes check lists, arrangement and schematic drawings. Read also the generic documentation included in the system’s documentation set, Art. No. 351475.003

2. System Description The Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m is a DC power supply system based on the Flatpack2 2000W 48V rectifier. The system contains AC termination blocks, DC distribution, Flatpack2 Power Rack, Flatpack2 2000W rectifier modules and the Flatpack2 Smartpack control unit. The system is designed for cable entry from top and the cabinet size is 600x600x2000 mm (23.6”x23.6”x78.7”) (WxDxH).

4


351475.033, v3-2007-06

2 System Description

Location of Components ~ General Arrangement

AC Earth

Smartpack controller unit

Mains Protective Earth (PE) Connection (Cabinet main ground bar)

DC Earth Telecom Earth (TE) Connection

AC Mains

Flatpack2 rectifier modules

Terminals

AC Input Terminals Located behind the front cover

Battery strings and fuses in the lower part of the cabinet

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

Figure 1 General Arrangement Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m Battery DC (+) terminals Bus bar, 35mm2, AWG 2

DC (+) Load Terminals Common positive bus bar, 2 70 mm , AWG 2/0

Battery DC (-) terminals Bus bar, 35mm2, AWG 2

Terminals for GMT 10A Load 2

DC (-) Load Terminals (BTS2MCBs) 2

25mm , AWG 4, 70mm , AWG 2/0 (on top of each load breaker)

Fuses, 1.5mm , AWG 16

Smartpack controller

Alarm Terminals 2

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

1.5mm , 16AWG (Front access)


351475.033, v3-2007-06

5


External AC Fuses ~ Recommended Ratings The site’s AC supply quality is of great importance. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers. Use the type of external AC fuses recommended in the table below. External AC Fuses ~ Recommended Ratings AC Mains Type External Fuse Type 50A – C-char. 400VAC +N, 3 ph 100A – C-char. 230VAC, 1 ph 63A – C-char. 230VAC, 3 ph 70A. 208VAC, 1 ph Note: An external AC breaker is required on all sites, and it must be switched off under installation.

Mains Reconfiguration ~ AC Terminal Block The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase & N. To reconfigure the system’s AC mains feed, perform the following: 1. Switch OFF the AC supply fuses in external fuse boards 2. Connect the AC Mains wires to the AC terminal block, and mount the fish plate(s) shipped with the cabinet, according to the type of AC mains to be used, as shown in the actual example in this section 3. Rewire internal cables N2 and N4 as shown, ONLY when reconfiguring to “∇ Mains, IT Three-phase, 230VAC”. Do not rewire the rest of the internal cables

AC Mains Cable Fish Plate N

N

L1

L2

L3

L1

L2

L3

AC Mains wires Fish Plate

L1 N

N

L2 L1

L2

L3

AC Mains Cable

Fish Plate

AC Mains Cable AC Mains wires Wires Links

L1 N

L2 N

L1

L3 L2

L3

AC Mains Terminal Block N2

(To internal connections) Flatpack2 DC Power System Factory configured AC Mains terminal block.

Mains, TN Three-phase & N, 400VAC

6

AC Mains Terminal Block

AC Mains Terminal Block

N4

N2

N4

(To internal connections) Flatpack2 DC Power System

Mains One-phase, 230VAC/208VAC

AC Mains wires

N4

N2

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

(To internal connections) Flatpack2 DC Power System

Mains, IT Three-phase, 230VAC/208VAC


351475.033, v3-2007-06


Terminals & Pin-out Location, GMT Fuses Pin 1

Pin 16

GMT fuses Max. 10A each

F12

F5

F8

Figure 2

2

GMT fuse board (max. cable size 1.5mm , AWG 16)

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)

Alarm Relays & Digital Inputs The alarm outputs in Flatpack2 systems use the Fail-Safe Operation Mode (relay coils energized in the system’s normal operation mode). When the system is in alarm mode, the alarm relay coils are de-energized. The figure shows the position of the relay contacts when the relay coils are de-energized (PS system in alarm mode) Alarm Relays & Digital Inputs

Normal Mode Relay X (Energized coil)

NO Com NC

+ —

NO Com Relay X (De-energized coil) NC Flatpack2 PS System Alarm Mode

+

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

—

Correct Use of Alarm Outputs (example) Digital Input X (Normal mode) Digital Input X (Activated)

+

Normal Mode

—

External Relay Y (Energized coil)

+

Alarm Mode

—

External Relay Y (De-energized coil)

Flatpack2 PS System

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.

Correct Use of Digital Inputs (example)


351475.033, v3-2007-06

7


Terminals & Pin-out Location, Alarm Interface Card The Smartpack controller’s alarm and digital input monitoring signals are accessible from the controller’s rear panel, on mini power connector CON1 (2 outputs & 2 inputs) and on D-Sub connector CON2 (4 outputs & 4 inputs). Using the Alarm Interface Card (Art. 105954) – located on top of the controller; see page 5 -- and two interface cables, you can make the signals on CON1 & 2 accessible at any suitable location inside your system. For detailed information about the card’s pin-out location and terminal block connections, refer to the figures in this section. Alarm Outputs & Digital Inputs Voltage free relay outputs and Configurable monitoring digital inputs FUNCTION

Card Art.105954

In

Terminals & Pin-out Location System Connections Card, Art. 200625

Alarm Outputs & Digital Inputs Card, Art. 105954

Battery Connections Card, Art. 200576

CON2 1 Battery Connections CON2A N OSmartpack Card, Art. 200576 C CON1A

CON1A

CON2A

*X1

1

, k 1 c N a O p C t r a m S

o T

*X2

10

1

20


, k 2 c N a O p C t r a m S

o T

SIGNAL PIN-OUT

*X1:

Out Digital Input 1

+

Digital Input 2

+

Relay 1 OVP Alarm

NO COM NC

− −

Relay 2 NO High Battery Alarm 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 Digital Input 3 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: -10°C >Temp>50°C COM 16 NC 17 & Rectifier Alarm Relay 6 NO 18 Mains Alarm & COM 19 Mains Low & High Alarms NC 20 (Customer Connections)

) t n e m m o p r i f d u q n e a l o a r T n ( e t x e

Input Circuit 3 Input Circuit 4 Input Circuit 5 Input Circuit 6

Alarm Circuit 3 Alarm Circuit 4 Alarm Circuit 5

) t n e m p i u q e l a n r e t x e m o r F (

) t n e m p i u q e l a n r e t x e o T (

Alarm Circuit 6 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).

8


351475.033, v3-2007-06


Terminals & Pin-out Location, System Interface Card Flatpack2 systems are shipped from factory with the CON5 signals already connected. Some of the Smartpack controller’s internal system signals are accessible on D-Sub connector CON5, on the controller’s rear panel. Using the System Interface Card (Art. 200625) and a standard 15 pins D-Sub cable, the signals on CON5 may be accessible at any suitable location inside your system. For detailed information about the card’s pin-out location and terminal block connections, refer to the figures in this section. In Out X:***** Terminals & Pin-out Location A 5 System Connections N O Card, Art. 200625 C

5

Battery Connections Card, Art. 200576

CON5


Smartpack

Battery Connections Card, Art. 200576 Pos. Distr.

JP1 3 2 1

JP2

JP1

Neg. Distr.

X***** 1

11

CON5A

m ( r T e T

JP2 1 2 3

10

s 2 ) 15 n 6 5 o 0 i 6 N 0 t 2 c . O 7 e t C n r , 12 n A , k c 13 o d C r a p9+, Neg.D. a t m o r a11−,Pos.D. e B t l m s a S1+/− y n S i o3+/−

2+/−

+ −

+ −

+ −

2 P J

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.

JP1 and JP2 are used to configure the system for Negative DC distribution (48 and 60V systems) or Positive DC distribution (24V systems)

System Connections Card, Art. 200625

! y l n O e s U l a n r e t n I r o F

LVD Latching Contactors Flatpack2 systems’ LVBD and LVLD1 functionality is implemented by the Smartpack controlling magnetically latching contactors. Latching Contactors, LVD1 & LVD2 A latching contactor changes state only when a reversed pulse voltage is applied to its coil

OFF

ON + Pulse

+

LVD1A X

X:***** 8 9 10 11

Bidirectional diode

Latching Contactor

LVD1 LVD Common LVD2A

Y X

X Latching Contactor

LVD2

—

Smartpack Unit

Y

- Pulse PCB Art. 200625

Warning! The bidirectional diode must always be mounted to avoid damaging the controller.

Y

Latching Contactor

LVD Common

Flatpack2 PS System (internal)

Correct Use of Latching Contactors (example)

The coil of latching contactors is not energized in any state. They change state from open to close, or vice versa, when a reversed pulse is applied to the coil.

1

LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect


351475.033, v3-2007-06

9


Monitoring, Control and Signal Interface The Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m is available with basic functionality for monitoring and control of the system, and is equipped with: Relay outputs, 6 pcs o Digital inputs, 6 pcs o

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: Installation settings o System calibration o Battery configuration o Alarm setup o Alarm log retrieval o Site information o Site specific configuration o

Please, refer to the Smartpack controller’s User’s Guide --Art. No. 350003.013 – and to the PowerSuite program’s online help (press function key F1) for detailed information about system monitoring and functionality.

10


351475.033, v3-2007-06


System Specification Technical Specification Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m Max. No. of rectifiers 8 AC INPUT Voltage 1 phase 230VAC (max 3 rectifiers, 6kW) 3 phase 208VAC ( Δ ) 3 phase 230VAC ( Δ ) 3 phase 400VAC+N ( Y ) Frequency 45 to 66Hz Maximum Current See Flatpack2 48VDC datasheet (241115.001.DS3) OVP Live – surge arrestor (Optional) Neutral – spark gap Class C, type II In(8/20) – 40kA MONITORING Monitoring Unit Smartpack Local operation Menu driven software via keypads and LCD or PC (PowerSuite) Remote operation PowerSuite via modem or Web NMS via SNMP-agent Alarm relays 6 relays are standard Visual indications Green LED – System ON Amber LED – Minor Alarm Red LED – Active alarm(s) LCD – system status Digital inputs 6 (for monitoring of external equipment) Current Battery current measurements Rectifier current Load current Alarms Load fuse alarm OVP Alarm* Battery fuse alarm Low Battery Voltage High Battery Voltage Temperature alarm Mains detect alarm

DC OUTPUT Voltage Current CONNECTIONS Battery connections Load MCB connections

48VDC Up to 16 KW – 340A Battery cable, M8 bolts

Negative distribution, Negative load cable, 70mm2 cable clamps Common positive bus bar, 70mm2 cable clamps Alarm Plug-in wire connectors front connections access DISTRIBUTION OPTIONS No. of DC Load Up to 4 x 3pole 150A breakers No. of Battery Up to 4 x 150A MCBs mount next breakers to each battery shelf No. of Aux. fuses 8 x 10A GMT type Programmable Standard: 1 LVBD (max. 300A) LVD OTHER SPECIFICATIONS Isolation 3.0 KVAC – input and output 1.5 KVAC – input earth 1.0 KVDC – output earth Operating temp -10 to +50°C (14 to +122°F) Storage temp -10 to +85°C (14 to +185°F) Dimensions 600x600x2000mm (WxDxH) (23.6”x23.6”x78.7”) Weight Approx. 80kg excl. rectifiers and batteries Max. 250kg load per battery shelf APPLICABLE STANDARDS Electrical safety EN 60950 UL 60950 EMC ETSI EN 300 386 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) Environment ETSI EN 300 019-2 ETSI EN 300 132-2 2002/95/EC RoHS Compliant Rectifier Input Voltages

Type VAC Note Type VAC Note Nominal 230 High voltage 1 185 – 275 Full output power Range 185 – 275 Full output power High voltage 1 275 –300 Full power, reduced power factor Low voltage 1 0 – 85 Shutdown High voltage 2 300 – 350 Shutdown Low voltage 2 85 – 185 Linear between 850W and 2000W High voltage 3 350 – 420 Shutdown* (see note below) * Note: If the input voltage is > 300Vac the rectifier will go into self protective mode. At no load, the rectifier will survive 350Vac. With load or battery connected, it will survive 420Vac.

Specifications are subject to change without notice


351475.033, v3-2007-06

11

3 Installation

3.

Installation

This section describes how to install the Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m. Step-by-step procedures will guide you through the installation. Read also the generic documentation included in the system’s documentation set, Art. No. 351475.003

Safety Precautions 

To be installed only in restricted access areas or the like, in accordance with articles 110-16, 110-17, and 110-18 of the National Electrical Code, ANSI/NFPA 70 For supply connectors use wires suitable for at least 75 C (167 F) Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar. Use copper conductors only ˚

˚



The equipment described in this manual must only be operated by Eltek Energy personnel or by persons who have attended a suitable Eltek Energy training course



CAUTION: Even though the product incorporates protection circuitry and other safeguards, it can be damaged, perform poorly or have a reduced lifecycle if it is exposed to incorrect treatment during transport, installation or service.



The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty



There are hazardous voltages inside the power system. As the modules incorporate large charged capacitors, it is dangerous to work inside the system even if the mains supply is disconnected



Products into which our components are incorporated have to comply with a number of requirements. Installation is to be in accordance with the recommendations herein



Please read the manual carefully before using the equipment

12


351475.033, v3-2007-06

3 Installation

Installing the Modules Device hazard

CAUTION: - The modules may be warm, but do not hand-carry them by their handles - Open the handles before inserting them into the power shelves (hot-pluggable) The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing

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.


Hole to release the handle’s spring mechanism

Flatpack2 rectifier

Handle in locked position

Handle in unlocked position

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 Electric shock

4. Mount blind panels in unused module locations


351475.033, v3-2007-06

13

3 Installation

Mounting and Removing Blind Panels Screwdriver to release the locking tabs

Blind panel’s upper locking tabs

To remove blind panels, carry out the following: 1. Release the panel’s upper left and right corners by inserting a small screwdriver into the panel’s upper left gap and carefully press down and out to release the locking tabs. Repeat on the upper right gap. 2. Remove the blind panel by using you hand to pull the panel loose To mount blind panels, carry out the following: 1. Insert the panel’s upper edge by pressing gently so that its upper locking tabs engage 2. Lock the panel’s lower edge by pressing with your hand so that the blind panel’s lower tabs lock into position.

Correct Rectifier Position in Power Shelves Flatpack2 DC power systems are normally shipped from factory with empty power shelves. The rectifier modules are shipped in separate packaging, and you have to install the modules in the correct position in the power shelves, with respect to their ID number (or CAN bus address). Do not relocate already pre-installed rectifiers. Follow the scheme below to install the Flatpack2 rectifier modules: o

Insert & hot-plug the rectifiers in the indicated power shelf positions, one module at a time, allowing a 2s delay between them and starting with ID number 1, 2, 3, and so on. (indifferent after ID# 6) Correct Rectifier Position in the Power Shelves Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifi ers

Mains Three-phase, 230VAC

and

Mains Three-phase & N, 400VAC Flatpack2 rectifier


01

04

03

06

-----

-----

Position 1

Position 9

14

Phase 1

02

05

Position 4

---

---

Position 8

---

-----

---

Phase 2

Phase 3 ID number (Assigned CAN bus address


351475.033, v3-2007-06

3 Installation

System Installation

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

Step

Action o

1.

Organize the installation site

o

o

OK

Check min. clearances for cabinet access: front access, 60cm, top access, 20cm. If Flexi Kit(s) are going to be installed, ensure sufficient space behind the cabinet to allow access to rear panel Check that the levelled surface is able to support 600 kg (cabinetized systems). Refer to System Specification, page 11. Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas

2.

Prepare the installation tools

Check that insulated tools suitable for te lecom installations are used

3.

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

Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated. Refer to page 6

Mechanical Installation Step

Action o

4.

Remove packaging and check equipment

o

o

o

5.

Remove top cover, dummy front panels and Tool Kit

o

o

OK

Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc Inspect the equipment for physical damage (report any damages) Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task) This is required for accessing the connection terminals Check that cable entry from the top is possible Please refer to “Assembly Guide for IFC” , doc. no. 351478.033, chapter 2 “Description of the Toolbox” for detailed information on how to remove the tool kit.


351475.033, v3-2007-06

15

3 Installation

Step

Action

6.

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

7.

Position and fasten the cabinet

OK

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

Electrical Installation Refer also to chapter “Location of Components ~ General Arrangement” on page 5.

Step 8.

Action

Make the system completely voltage free

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

o

9.

AC Connections o

o

16

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) - Terminal AC Earth (PE) is mechanically connected to cabinet chassis. Refer to page 5 Connect the AC input cable(s) to the terminals. Cable and terminal block labelling are to correspond. Read pages 5 and 6. Fasten the cables to the horizontal metal bar (I) as strain relief.


351475.033, v3-2007-06

3 Installation

Step

Action o

10. DC Connections Load Circuits

o

3-pole link for CBI MCB

2-pole link for CBI MCB

o

o

11. DC Connections Alarm & Signal Circuits

2

OK

Terminate DC Earth (TE) - Terminals DC Earth (TE) is mechanically connected to cabinet chassis. Refer to page 5. - The Common Positive Bus bar is internally cabled to DC Earth (TE); thus the positive output of the rectifiers is connected to ground (TE), and the negative output represents the –48VDC supply voltage. Refer to Figure 1 General Arrangement Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m, on page 5. The Common DC Output Rail is to be connected to TE at only one place. - If required, you can remove the internal cable that connects the positive bus bar to local TE. Terminate DC Load Circuits The kit includes two copper bridges. One for 100 A (two pins) and one for 150 A (three pins). If the load current is larger than 50 A use the two pin copper bridge. Then the 3rd hole in the breaker cannot be used. If the load current is larger than 100 A, use the three pin copper bridge. Insert the chosen copper bridge on to the top of the MCB. - Connect the orange alarm wire to the copper bridges with a screw if the bridges are used. - Connect the positive cable(s), max 70 mm sq (AWG 2/0), to the common positive bus bar on the 2 top of the power core. - Connect the negative (-48V) cables, max 25 mm sq each (AWG 3), to the top of the MCBs or the copper bridges. Terminate GMT Fuse Load Circuits Connect the adequate cables, 1.5 mm sq (AWG 16), to the GMT fuse card according to the table on page 7 Terminate Alarm Circuit cables to the relay output terminals. Refer to chapter “Terminals & Pin-out Location, Alarm Interface Card” on page 8.

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


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17

3 Installation

Step

Action

OK

The positive and negative (-48V) battery cables are connected from factory to the common positive bus bar and to the battery MCBs (additional battery string kits are not). The battery temperature sense cable is also pre wired to CON4, and temporally fixed to the cabinet’s wall. 12. DC Connections Battery Cables

o o

o o

18

Connect all battery inter-cell links Connect the loose end of the battery cables to the battery terminals; blue cable to the negative terminal and black cable to the positive terminal. Fix battery cables. Use attached cable ties Place the temperature sensor, located at the end of the battery temperature sense cable, on top of the topmost battery string


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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 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:

Device hazard

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 Verify that all battery and load MCBs/ fuses are switched OFF or removed o 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


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19

4 Commissioning

Commissioning Steps, Startup Check off in the Commissioning Procedure, that you find in the pullout section of this folder. After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you will switch ON the Flatpack2 PSS — while the batteries and load are disconnected ⎯ then measure the output voltage, and adjust it if required. Carry out the following:

II Power is ON!

Device hazard

Startup and No-Load Adjustments 1. Disconnect all rectifier modules, without removing them (keep original location) Read how to install modules, on page 13. Also, read about the correct rectifier position o on page 14, and then, If Flatpack2 rectifier modules are installed , unlock the handles and pull the modules o partially out (fan housing visible), but do NOT physically remove them from the power shelves If Flatpack2 rectifier modules are not yet mounted , release their handles and insert o them partially into the correct position in the shelves 2. Switch ON the system o Switch ON the AC input supply (external AC fuses) to the PS cabinet 3.

Measure and verify that the AC input voltage is correct o Measure the AC input voltage at the cabinet’s mains connection box o Verify the AC voltage is within range

4.

Mount all Flatpack2 rectifier modules in the power shelves (keep original location) o Push all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯ to plug them in the same shelf location. Lock their handles. Refer also to page 13 Mount blanking panels over unused positions o

5. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON Verify correct operation, by monitoring the modules’ LED lamps and display: o 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 Start PowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite o o On the toolbar, click the “Connect” button to establish connection 7. Measure and adjust DC output voltage 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. o between the common DC rail and the lower connection of one of the priority load MCBs o If required, adjust the voltage using the controller’s front keys or via PowerSuite 8. Verify the alarm relays are working correctly (alarm relay test) o Run the alarm relay test using the controller’s front keys or via PowerSuite (select the menu Go > Output Test ) 9. Make sure the System Setup is in accordance with configuration o Verify system settings using the controller’s front keys or via PowerSuite o Use the opportunity to enter site related information, number of used AC phases, type of batteries, etc.

20


351475.033, v3-2007-06

4 Commissioning

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: 10. Adjust DC output voltage to equal measured battery voltage o Measure the battery voltage is within range ( check connections have correct polarity) o Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to equal the measured battery voltage. (Important adjustment to avoid arcing when connecting the batteries) 11. Unplug all rectifiers but one, and connect the battery fuses /MCBs (CAUTION: Have only one rectifier connected, when switching ON the battery fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.) o Disconnect all rectifiers but one, by unlocking the handles and pulling them partially out (fan housing visible). Do NOT physically remove them from the power shelves o Switch ON all battery fuses or MCBs

Power is ON!

Device hazard

Device hazard

12. Adjust DC output voltage again to equal the nominal battery voltage Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to o 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 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 o 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


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5 Forms, Schematics & Drawings

5.

Forms, Schematics & Drawings

This section includes following forms and schematic drawings:

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

22


351475.033, v3-2007-06

INSTALLATION CHECK LIST System Data

Flatpack2 PS System

Flatpack2 Power Supply System , type:

Article No.:

Site, name: Serial No.:

Software, version No.:

AC Input Voltage, measured:

Battery Type:

Rectifiers, type & number of: Battery Capacity:

Installation carried out by, name:

Site Preparations CARRY OUT FOLLOWING:

OK

1. Organize the installation site o o

EMC regard

o



Check min. clearances for cabinet access: front access, 60cm, top access, 20cm Check that the levelled surface is able to support 600 kg (cabinetized systems) 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 CARRY OUT FOLLOWING:

Power is OFF! OK

4. Remove packaging and check equipment o

Device hazard

o o



Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc Inspect the equipment for physical damage (report any damages) Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)

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



Check that cable entry from the top is possible; Read how to remove the Tool Kit on Doc. No. 351478.033

6. Position and fasten the cabinet o



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

7. Mount the batteries on the shelves o

Electric shock

o



Start (if applicable) on the lower shelf first, and continue upwards. Use kits, if supplied; refer to Doc. 351485.033 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 o o



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 c orrespond



10. DC Connections ⎯ Load Circuits o o

Electric shock

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



11. DC Connections ⎯ Alarm & Signal Circuits o o o

Refer to your system’s connection drawings and configuration Terminate Alarm Circuit cables to the relay output terminals Terminate Signal Circuit cables to the digital input/output terminals, if applicable

12. DC Connections ⎯ Battery Cables

Careful! Use correct polarity.

For each battery shelf, Mount 3 intercell links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks) o o Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-) 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 o end of the cable) to a suitable place in the middle of the i nstalled battery bank



Approval Responsible of installation, sign.:

Date:

Approved by customer, sign.:


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351475.033, v3-2007-06

COMMISSIONING PROCEDURE System Data Supplier’s Order No.:

Flatpack2 PS System Flatpack2 Power Supply System , type:

Article No.:

Site, name:

I

Serial No.:



Battery Type:

II Device hazard

Battery Capacity:

Commissioning carried out by, name:

Pre-Start Check

Power is OFF!

CHECK FOLLOWING: 1.

Device hazard

Rectifiers, type & number of:

OK

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 CARRY OUT FOLLOWING:

Power is ON!

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; 6. Connect a PC to the PS system

8. Alarm relay test;

 

Install the PowerSuite software, if required



Measure and adjust



Verify all alarm relays are working correctly



Enter site spec. info in PowerSuite



Check correct polarity!



9. System Setup is in accordance with configuration

Device hazard



Verify

7. DC output voltage;

III



10. Adjust DC output voltage to equal measured battery voltage 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:



351475.033, v3-2007-06

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351475.033, v3-2007-06

MAINTENANCE PROCEDURE System Data

Flatpack2 PS System

Flatpack2 Power Supply System , type:

Article No.:

Site, name:

Electric shock

Serial No.:



Battery Type:

Rectifiers, type & number of: Battery Capacity:

Maintenance carried out by, name:

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.

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 output voltage from the Smartpack ’s keypad or the PC.

±1%



from the display reading, calibrate the

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; v erify 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:



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351475.033, v3-2007-06

AC Mains Connection, located behind the panel, on the right side

42U

*OVP behind panel Battery DC (+) terminals

40U Flatpack2 rectifiers

38U 36U 34U 32U 30U

Battery MCB FB4*

28U 26U 24U

Battery MCB22U FB3*

20U 18U 16U Battery MCB14U FB2*

12U 10U 8U 6U Battery MCB FB1*

Max. Battery Height: 7U

4U 2U

* Optional

HxDxW: 2000x600x600mm Figure 3

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


351475.033, v3-2007-06

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System Schematic Flatpack2 PS System, 16kW, 48VDC, ICab 2.0m

Doc, 2020388, 2v0


351475.033, v3-2007-06

Note! The values in this table are default factory settings. The settings of a Smartpack controller in an installed system may be different from the above settings, depending on the system’s final configuration of optional kits, number/type of batteries, alarm setup and/or any other changes done to the system and/or the Smartpack controller after the system was shipped from the factory. Installation Guide Flatpack2 PS System, 16kW, 48VDC, Indoor 2.0m Cabinet

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351475.033, v3-2007-06

LOAD DISTRIBUTION LIST System Data Flatpack2 PSS, type:

Article No.:

Site, name:

FUSE ID F1 F2 F3* F4* F5 F6 F7 F8 F9 F10 F11 F12 F13* F14* F15* F16* F17* F18* F19* F20* 9 1 6 0 7 0 0 2 _ m f m / s t _ c o d . 0 m 2 c n a f b a c o c d v 8 4 w k 6 1 s s p 2 p f _ e d g t s n i _ 3 3 0 6 7 4 1 5 3 _ 1 0 C 1 v b g x x x m r o F

FUSE TYPE BTS MCB

GMT FUSE

LTE MCB

LOAD DESCRIPTION

RATING

CABLE

CABLE

AMPERE

SIZE 2 mm

SIZE AWG

X X

X

10

X

10

X

10

X

10

X

10

X

10

X

10

X

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

BTS MCB`s For details, see chapter “Location of Components General arrangement”

GMT FUSES For details, see chapter “Terminals and pin-out location GMT fuse”

Eltek Energy AS Tel. +47 32 20 32 00

Internet: www.eltekenergy.com

E-Mail: [email protected]

Installation Guide Flatpack2 PS System Indoor v3

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