Installation Guide Flatpack2 PS System Outdoor v4

Installation Guide

DC Power Supply System, 16kW, 48VDC Outdoor 2.0m Fan Cooled Cabinet 3 3 0 . 6 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 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

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/48V OD fan 2.0m” has part no. CF1032.006.

351476.033

Issue 4, 2007 June

Published 2007-06-19 Mfm

2

Installation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet

351476.033, v4-2007-06

1 Welcome

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek 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

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/48V OD fan 2.0m” has part no. CF1032.006.

351476.033

Issue 4, 2007 June

Published 2007-06-19 Mfm

2


351476.033, v4-2007-06

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

Fan and Heater Operation............. Operation.......................... ......................... ......................... .......................... .......................... ................... ...... 10 System Specification .......................................................................................... 11

3.

Installation

12

Safety Precautions ............................. ............................. .............................. ................ 12 General Safety Precautions ............................ .............................. ............................. ... 13 Electrical Safety .......................... ............................. .............................. ....................... 13 Mechanical Safety ............................ ............................ ............................. .................... 14 Battery Safety ............................................................................................................... 14

Installing the Modules .......................... ............. .......................... .......................... .......................... .......................... ........................ ........... 15 Mounting or Removing Smartpack and and Flatpack2 Modules ...................................................15 ...................................................15 Mounting and Removing Blind Panels ................................................................................ .................................................................................... ....16 16 Correct Rectifier Position in Power Shelves ...........................................................................16 ...........................................................................16

System Installation .......................... ............. .......................... .......................... .......................... ........................... ........................... ............... .. 17 Site Preparation .......................... ............................. .............................. ....................... 17 Mechanical Installation........................... ............................ ............................ ............... 17 Electrical Installation ........................... ............................ ............................. ................. 18

4.

Commissioning

23

Pre-Start Check ................................................................................................... 23 Commissioning Steps, Startup .......................... ............. ........................... ........................... .......................... ..................... ........ 24 Startup and No-Load Adjustments ......................................................................................... ...........................................................................................24 24 Load Adjustments Adjustments ....................................................................... ................................................................................................................... ............................................25

5.

Maintenance

26

Replacement Replacement of Door Filter .............................. ............................. .............................. .. 27 Replacement Replacement of Fan Filter ............................ ............................. .............................. ...... 27

6.

Forms, Schematics & Drawings

28

Installation Check List ....................................................................................................... .......................................................................................................28 Commissioning Procedure ................................................................................................. .................................................................................................28 Maintenance Procedure................................................................. Procedure...................................................................................................... .....................................28 General Arrangement Drawing ............................................................ .......................................................................................... ..............................28 Cabinet’s Neoprene Mat Table, Drilling Template, Plinth’s fastening fast ening holes .................... ....................28 Cabinet Clearance Drawing ............................................................................................... ...............................................................................................28 System Schematic Drawing ............................................................................................... ...............................................................................................28 Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m ........28 Load Distribution List ............................................................... ........................................................................................................ .........................................28


351476.033, v4-2007-06

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1 Welcome

1. Welcome The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m 2.0m is a DC power supply for telecom equipment suitable for outdoor fan cooled applications.

About this Guide This booklet provides users of the Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 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. 351476.003

2. System Description The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m is a DC power supply system based on the Flatpack2 2000W Flatpack2 2000W 48V rectifier. The system contains AC termination blocks, DC distribution, Flatpack2 Flatpack2 Power Rack, Flatpack2 2000W Flatpack2 2000W rectifier modules and the Flatpack2 Smartpack Flatpack2 Smartpack control unit. The system is designed for cable entry from top and the cabinet size is 770x820x2030 mm (30.3x32.3x80”) (WxDxH).

4


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2 System Description

Location of Components ~ General Arrangement Battery DC (+) terminals

DC (+) Load Terminals

Bus bar, 35mm2, AWG 2

Common positive bus bar, 2 70 mm , AWG 2/0

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

DC (-) Load Terminals (BTS2 MCBs) 2

25mm , AWG 4, 70mm , AWG 2/0 on to of each load breaker

Terminals for GMT 10A Load 2

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)

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

DC Earth Telecom Earth (TE) Connection

Smartpack controller unit

DC Distribution MCB Load, Alarm and Signal Terminals

Flatpack2 rectifier modules

AC Mains Terminals

AC Input & Earth Terminals AUX.AC MCB (heater, AC socket, air -conditioner)

Figure 1 General Arrangement Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m

Door Filter Outlet

Fan Filter Inlet

Battery strings and fuses in the lower part of the cabinet


351476.033, v4-2007-06

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

AC Mains Cable L1

L2

L3

N

Fish Plate L1

L2

L3

N

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

N

N

L1

L2

L3

N

N

AC Mains wires

AC Mains Terminal Block AC Mains Terminal Block

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

Mains, TN Three-phase & N, 400VAC

6

(To internal connections) Flatpack2 DC Power System

Mains One-phase, 230VAC/208VAC

AC Mains Terminal Block (To internal connections) Flatpack2 DC Power System

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


351476.033, v4-2007-06


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) (fan fuse)

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)


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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

CON2 1 CON2A N OSmartpack C CON1A

CON1A

Battery Connections Card, Art. 200576

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

Out

SIGNAL PIN-OUT

*X1:

Digital Input 1

+

Digital Input 2

+

Relay 1 OVP & Door 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


351476.033, v4-2007-06


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


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

+

Y

- 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

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


351476.033, v4-2007-06

9


Monitoring, Control and Signal Interface The Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 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.

Fan and Heater Operation The fan runs as soon as the temperature in the cabinet passes 25oC (77°F). Hysteresis is 1°C (1.8°F). The heater is controlled through a thermostat and it starts up at cabinet temperature of 5°C (41°F).

10


351476.033, v4-2007-06


System Specification Technical Specification Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m Max. number of 8 rectifiers 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 See Flatpack2 48VDC datasheet Current (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, USB 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 Battery fuse alarm Low Battery Voltage High Battery Voltage Temperature alarm Door switch alarm Mains detect alarm OVP 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, 70mm 2 cable clamps Alarm connections Plug-in wire connectors front 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 to breakers each battery shelf No. of Aux. fuses 8 x 10A GMT type Programmable LVD Standard: 1 LVBD (max. 300A) OTHER SPECIFICATIONS Isolation 3.0 KVAC – input and output 1.5 KVAC – input earth 1.0 KVDC – output earth Operating temp -40 to +50°C (-40 to +122°F) *** Storage temp -40 to +85°C (-40 to +185°F) Dimensions 770 x 820 x 2030 mm (WxDxH) (30.3 x 32.3 x 79.9”) Weight Cabinet: 150 kg excl. optional plinth, rectifiers and batteries Flatpack2 rectifiers: 1.9 kg per rectifier Batteries: Max. 250 kg 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 *** Note that the cabinet’s operating temperature range does not apply to batteries. Refer to the manual for used batteries.

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


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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 system’s 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 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


351476.033, v4-2007-06

3 Installation

General Safety Precautions Please read and follow all safety instructions or warnings before installing or maintaining the power system. Review any supporting documentation regarding the power system and its components prior to installation. 

The enclosure must be installed, serviced, maintained, and operated by a qualified technician who is familiar with electrical wiring, electrical equipment, and enclosure deployment techniques and best practices for safety



The enclosure must remain locked at all times, except when authorized service personnel are present



Remove all conductive jewelry or personal equ ipment prior to servicing equipment, parts, connectors, wiring, or batteries



Read and follow all installation, equipment grounding, usage, and service instructions included in this manual



Use proper lifting techniques whenever handling the enclosure, equipment, parts, or batteries



Do not roll the cabinets on their sides



Do not store anything on top of the cabinet

Electrical Safety 

Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical connection or conductor is not energized. Ch eck 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 permanent ly 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 enclosure’s utility service panel is equipped with a properly rated circuit breaker for use with the equipment inside. Refer to the manufacturer’s recommendations



Prior to installation, contact local utilities, local building maintenance depa rtments, and cable/piping locating services to ensure that installation does n ot 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 fu ses 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 manufa cturer 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


351476.033, v4-2007-06

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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 n eck



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, f ire, or possibly an explosion



A battery showing signs of cracks, swelling or leaking must be replaced immediately by a uthorized personnel using a battery of identical type and make



Do not smoke or introduce sparks in the vicinity of a battery



Follow the battery manufacturer’s 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 company’s 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 company’s 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 manu facturer’s 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 manufacturer’s approved instructions to set all battery related parameters accordingly

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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


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15

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

16

Phase 1

02

05

Position 4

---

---

Position 8

---

-----

---

Phase 2

Phase 3 ID number (Assigned CAN bus address


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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 o

Power is OFF! Check min. clearances for cabinet access: front access, 100 cm, top access, 60 cm, rear clearance 100 cm * See page 36

OK

* Note, The minimum rear clearance is only needed if Flexi kit 2 will be installed o

2.

Prepare the installation tools

3.

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

The floor construction must be capable of supporting the equipment, refer to System Specification, page 11

Check that insulated tools suitable for te lecom installations are used 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 - Mechanical Installation 4. Remove packaging and check equipment

5.

Use the Neoprene Mat

Action Power is OFF! CAUTION: Do not step nor walk on the cabinet’s roof. Check you have received all the parts, o correct cabinet, documentation, batteries (if applicable), etc Inspect the equipment for physical damage o (report any damages) Leave rectifier modules in their packaging or o 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. Use the attached neoprene mat between the o cabinet and the concrete floor. See Table 1, page 35 for specifications


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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

Drill holes on the floor or support beams, See Figure 5, page 35 and Perform Alt. A OR Alt. B Alt. A: Cabinet Plinth Option NOT Used Bolt the cabinet to the ground or support o beams Alt. B: Cabinet Plinth Option Used Fasten the plinth to the ground or support o beams using M10 bolts. See Figure 6, page 35 o Bolt the cabinet to the plinth, using the “2m Cabinet-to-Plinth Fastening Holes”. See Figure 6, page 35 o Start (if applicable) mounting them on the lower shelf first, and continue upwards. Use the battery kits, if supplied Do not terminate the battery cables yet! o

7.

Mount the batteries on the shelves

Do not remove Condensation Stopper yet! The condensation stopper (yellow plastic) prevents humidity from entering the cabinet and must therefore not be removed until the system is powered up during commissioning. Humidity before powering up the system may cause serious damage to the system. The condensation stopper is attached to the filter on the inside of the door.

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.

Open the cabinet’s roof

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. Open these screws and lift up the roof o Secure the roof during installation with the o rod on the right side under the roof

..

18


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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. Use a screw driver to puncture the o 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. o

Note! Other optional cable entry solutions are available for larger size cables and/or cable conduit. Please contact you local representative for details if the cable entry solution provided is not sufficient for your needs.

o

o

Push cable(s) through the grommet(s):

Then pull the cable(s) back out of the grommet, approx. 10mm. This will lock the cable in the grommet and ensure full IP protection Ensure that the fixing screws of all Marcon 25 multigate cable entry plates and metal blind plates are properly tightened

Note! Ensure that any blind plates that are refitted to the cabinet are mounted with the gasket joint (spline) facing downwards.

Gasket joint/spline must face downwards when plate is mounted back to cabinet

11. 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) - 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.


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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

Turn OFF the AC breaker. Connect the cables L, N and PE (not part of the cabinet) to the preferred socket type and mount the socket to the bracket. Mount the cables from AC socket to the AC breaker. Turn ON the AC Breaker


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3 Installation

Step - Electrical Installation 13. DC Connections Load Circuits

Action o

3-pole link for CBI MCB

2-pole link for CBI MCB

o

o

14. DC Connections Alarm & Signal Circuits

2

o

Power is OFF!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, 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. Terminate DC Load Circuits The kit includes two copper links. 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 link. Then the 3rd hole in the breaker cannot be used. If the load current is larger than 100 A, use the three pin copper link. Insert the chosen copper link on to the top of the MCB. - Connect the orange alarm wire to the copper links with a screw, if the links are used. - Connect the positive cable(s), max 70 mm sq (AWG 2/0), to the common positive bus 2 bar on the 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 links. 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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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 cabinet’s wall. o o

o

22

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. 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 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

1. System installation is completed Ensure a correctly performed system installation, with correct polarity on o all connections, has been carried out (Installation Check List filled in) All cabling and copper bars are securely terminated and supported o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled o 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 Make sure that the AC input cable(s) are connected to correctly configured o AC terminals Verify that the AC input cable(s) and external AC fuses are sized and rated o as specified Check that AC Earth (PE) is terminated, and electrically connected to o chassis (Link 1) 4. Site specific parameters and settings are known Read the system specific drawings and d ocumentation o 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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23

4 Commissioning

Commissioning Steps, Startup Check off in the Commissioning Procedure, that you find in the last 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 15. Also, read about the correct o rectifier position on page 16, and then, If Flatpack2 rectifier modules are installed , unlock the handles and pull the o modules 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 o and insert them partially into the correct position in the shelves 2. Remove the Condensation Stopper Remove the Condensation Stopper placed in front of both filters, inside the o door and in front of the fan. Read more about the Condensation Stopper on page 18 3. Switch ON the system Switch ON the AC input supply (external AC fuses) to the PS cabinet o 4. Measure and verify that the AC input voltage is correct Measure the AC input voltage at the cabinet’s mains connection box o Verify the AC voltage is within range o 5. Mount all Flatpack2 rectifier modules in the power shelves (keep original location) o Push all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯ to plug them in the same shelf location. Lock their handles. Refer also to page 15 Mount blanking panels over unused positions o 6. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON o Verify correct operation, by monitoring the modules’ LED lamps and display: No alarms are present on rectifiers; The Smartpack displays fuse alarms 7. Connect a PC to the PS system (to facilitate operation) Plug a standard USB A-B cable between the PC and the Smartpack o controller Start PowerSuite on the PC by selecting: o Start > All Programs > Eltek > PowerSuite On the toolbar, click the “Connect” button to establish connection o 8. 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 o point, e.g. between the common DC rail and the lower connection of one of the priority load MCBs If required, adjust the voltage using the controller’s front keys or via o PowerSuite

24


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 controller’s front keys or via PowerSuite (select the menu Go > Output Test ) 10.Make sure the System Setup is in accordance with configuration Verify system settings using the controller’s front keys or via PowerSuite o 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: 11.Adjust DC output voltage to equal measured battery voltage Measure the battery voltage is within range (check connections have o correct polarity ) Adjust DC output voltage — using the controller’s front keys or via o PowerSuite— to equal the measured battery voltage. (Important adjustment to avoid arcing when connecting the batteries) 12.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.) Disconnect all rectifiers but one, by unlocking the handles and pulling them o partially out (fan housing visible). Do NOT physically remove them from the power shelves Switch ON all battery fuses or MCBs o

Power is ON!

Device hazard

Device hazard

13.Adjust DC output voltage again to equal the nominal battery voltage Adjust DC output voltage — using the controller’s front keys or via o PowerSuite — to equal the nominal battery voltage (or the nominal load voltage, when not using batteries) 14.Plug in again all rectifiers, and verify the rectifiers’ current sharing o Connect all rectifiers again by pushing them firmly inwards ⎯ Repeat step 4, in stage II Wait for about 2 min., and check — using the PowerSuite application —that o each of the rectifiers delivers the same output current. A deviation of 1A is acceptable. 15.Connect the load breakers and verify that no alarms are displayed Switch ON all load MCBs/ fuses o Verify correct operation: rectifiers and controller display no alarms o


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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: Pollution degrees: Car park/road side: City roof top: Non central: 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 frame’s fastening screws

Door Filter, Outlet (The filter’s rough side facing inwards)

Open fan filter door

Filter frame’s fastening screws

Fan Filter Door Fastening knobs for fan filter door

Fan Filter, Inlet (The filter’s smooth side facing inwards)

Figure 3

26

Location of the cabinet’s door filter and fan filter


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5 Maintenance

Replacement of Door Filter Step

Action

1.

Refer to “Figure 3 Location of the cabinet’s door filter and fan filter”, on page 26.

Remove filter

o

o

2.

Exchange filter

3.

Mount the frame

o

o

o

OK

Remove the Air baffle plate(s) that cover the filter grid on the inside of the cabinet door (plates not shown in Figure 3). Remove the filter grid by loosening the screws around it. Pull the grid towards you when loose Exchange the old filter with a new. Make sure that the rough side of the filter faces the inside of the cabinet Mount the grid to the door again, fastening the screws around it Mount the Air baffle plate(s) back on again and tighten the screws

Replacement of Fan Filter Step 1.

Disconnect the fan

2.

Open the Fan Filter Door

Comments o

Remove the filter grid

4.

Exchange the filter

5.

Mount the grid Close the Fan Filter door Connect the fan

6. 7.

Remove the fan fuse, located at the GMT fuse card (fuse 8). Refer to “Terminals & Pin-out Location, GMT Fuses” on page 7

Refer to “Figure 3 Location of the cabinet’s door filter and fan filter”, on page 26. o

3.

OK

o

o

Open the fan filter door by turning the two knobs on the door (upper and lower right side) Remove the filter grid by loosening the screws around it. Pull the grid towards you when loose Exchange the old filter with a new. Make sure that the smooth side of the filter faces the inside of the cabinet

o

Mount the grid again, fastening the screws around it

o

Close the fan filter door, and turn the knobs closed

o

Replace the fan fuse, and verify that the system is operating normally


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27

6 Forms, Schematics & Drawings

6.

Forms, Schematics & Drawings

This section includes following forms and schematic drawings:

Installation Check List Commissioning Procedure Maintenance Procedure

General Arrangement Drawing Cabinet’s Neoprene Mat Table, Drilling Template, Plinth’s f astening holes Cabinet Clearance Drawing

System Schematic Drawing Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m

Load Distribution List

28


351476.033, v4-2007-06

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

Power is OFF!

CARRY OUT FOLLOWING:

EMC regard

OK

1. Organize the installation site



2. Prepare the installation tools



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



Mechanical Installation CARRY OUT FOLLOWING:

Device hazard

Power is OFF! OK

4. Remove packaging and check equipment



5. Use the Neoprene Mat



6. Position and fasten the cabinet



7. Mount the batteries on the shelves



o o

Do not terminate the battery cables yet! Do not remove the Condensation Stopper!

Electrical Installation

Power is OFF!

CARRY OUT FOLLOWING: Electric shock

8. Make the system completely voltage free



9. Open the cabinet’s roof



10. Insert the cables



11. AC Connections



o o o

Electric shock

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 c orrespond

12. AC Socket Connection



13. DC Connections ⎯ Load Circuits



o 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



14. DC Connections ⎯ Alarm & Signal Circuits 15. DC Connections ⎯ Battery Cables

Careful! Use correct polarity.

For each battery shelf, o Mount 3 intercell links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks) Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-) 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.:


351476.033, v4-2007-06

29

30


351476.033, v4-2007-06

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. Remove the Condensation Stopper



3. Switch ON the system (external AC fuses ON)



4. AC input voltage is correct;

Measure and verify

5. Insert all Flatpack2 rectifiers in their original locations in the power shelves

7. Connect a PC to the PS system

Verify



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!



8. DC output voltage; 9. Alarm relay test;

Device hazard

 

6. The Smartpack and all rectifier modules are working, LEDs are ON;

III



10. System Setup is in accordance with configuration 11. Adjust DC output voltage to equal measured battery voltage 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:



351476.033, v4-2007-06

31

32


351476.033, v4-2007-06

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 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 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:



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


On cabinet’s side wall Flatpack2 rectifiers

35U

AC Mains Terminals AUX.AC MCB (heater, AC socket, air -conditioner) 29U

Battery MCB FB4*

0 0 2 4 . 4 4 9 1

21U

Battery MCB FB3*

14U

Battery MCB FB2*

7U

Battery MCB FB1

* Optional

Figure 4

General Arrangement Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m Doc, 24nnnn.yy, XvX

34


351476.033, v4-2007-06

Feature

Cabinet’s Neoprene Mat Specifications Value Test Standard

Shore hardness A Tensile strength Elongation at rupture Density Mass per unit area Compression stress at 30% deformation Operational temperature Flammability Table 1

65±5 0,45 N/mm² 45% 730 kg/m³ 730g/m²/mm 0,75 N/mm² -40 to +155°C Class B 2din 4102

DIN 53 505 DIN 53 571 DIN 53 571

DIN 53 577

Neoprene Mat Specifications

Note: The mat is only to be used when the cabinet is placed directly on concrete floor and a cabinet plinth is not mounted.

Figure 5 Drilling Template, top view of the cabinet’s bottom plate. For cabinet fastening directly to the floor or to a plinth

m t m n r 0 o 2 F 6 6 2 0 m m

F R O N T

7 5 m m

7 5 m m

75 mm

75 mm

1 2 5 m m

m m 5 2 1

5 7 5 m m

m m 5 7 5

1 2 0 m m

m m 0 2 1

2m Cabinet-to-Plinth Fastening Hole (4x) One hole in each corner 1.3m Cabinet-to-Plinth Fastening Hole (4x) One hole in each corner

2m Cabinet-to-Plinth Fastening Holes

Figure 6

Plinth-to-Floor Fastening Hole (4x) One hole in each corner

Cabinet’s plinth, top and 3D view. Cabinet’s and plinth’s fastening holes


351476.033, v4-2007-06

35

Figure 7

Cabinet Clearance, side and top view Doc No. 14990 - 109, 23.02.07

36


351476.033, v4-2007-06

Installation Guide Flatpack2 PS System Outdoor v4

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