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Quick Start Guide Installation, Operation, Commissioning and Maintenance
DC Power Supply System Integrated, Cabinetized and Outdoor Applications
Flatpack2, PS System
356804.103
Miscellaneous Communication o CAN Bus Termination ( 9) o Installing PowerSuite – PC software ( 9) AC Mains o External AC Fuses, Recommended Rating (10 ) o Identifying Power Shelves, 4AC or 2AC ( 11) o Mains Reconfiguration, Integrated Systems, 1U DC Distribution ( 11) o Mains Reconfiguration, Cabinetized & Integrated, 4U DC Distr. (12-13) o About AC, DC Earthing Systems ( 13) o Mains Phases vs. Rectifier ID – Phase Balancing & Monitoring (14-15) Battery Monitoring o Battery Symmetry – Connections (16 ) o Terminals & Pin-out Location, Battery Interface Card ( 17) Alarms & Monitoring o Standard Alarm Relays & Digital Inputs – Connections (18 ) o Terminals & Pin-out Location, Alarm Interface Card (18 ) Internal Connections o Terminals & Pin-out Location, System Interface Card ( 19) o LVD Latching Contactors – Connections ( 19)
Introduction o The Flatpack2 Product Range (2 ) o Brief System Description (2 )
Installation o Installing Smartpack and Rectifier Modules ( 3) o Installation steps; mechanical, electrical (4-5)
Commissioning o Pre-start check (6 ) o Commissioning steps, Startup (6-7)
Operation
o Front keys and display ( 8) o Software Menus ( 8)
Check Lists pullout forms o Installation Check List o Circuit Distribution List o Commissioning Procedure o Maintenance Procedure
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 2
The Flatpack2 Product Range Eltek Energy's Flatpack2 product range utilizes the Flatpack2 rectifier and the Smartpack controller as building blocks for implementing effective DC power systems, suitable for a wide range of applications and power ratings.
Cabinetized systems are suitable for indoor or outdoor applications. In addition to the power system and the distribution unit, the cabinet may also contain battery banks, additional distribution and other dedicated equipment.
Integrated systems consist of the power system, which includes rectifiers and controller(s), and the distribution unit (1U or 4U high). Integrated systems are sold primarily for mounting in existing cabinets.
Brief System Description The Flatpack2 PS system is a compact, powerful and cost-effective DC power supply system, specifically developed for the telecom industry.
Example of a typical Flatpack2 PS system for DC power supply of telecom equipment. The system is fed from an external AC mains supply, and consists of rectifiers in power shelves, a control unit and DC distribution unit. Battery banks, LVD contactors, etc. are typically also a part of the system.
Introduction
Flapack2 System, Integrated4U and 1U Distributions
Flapack2 System, Cabinetized Flapack2 SystemOutdoor Cabinet
Flatpack2 Cabinetized
Battery string #1
AC mains supply selector
SymmetryAlarm &
Temp. Sensor
LVLD
LVBD
Fuse Alarm
AC Fuses, external
(230VAC or 400VAC
Telecom equipment
AC Supply (Single- or
three-phase)
Alarm Outputs NC-C-NO Digital Inputs
BatteryFuses
Load Fuses & MCBs
Smartpack (Ctrl. Unit)
Flatpack2(rectifiers)
PowerSuiteApplication
CAN Bus
USB cable
DC distribution
DC Supply (24V, 48V or 60V*) *Available from 2006
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 3
Installing Smartpack and Rectifier Modules
Installation
Handle in unlocked position
Flatpack2 rectifier
Smartpack controller
Handle in locked position
Hole to release the handle’s spring mechanism
Removing Blind Panels 1. Release the panel’s upper left and right corners by
inserting a small screwdriver into the panel’s upper left gap and carefully press down and out to release the locking tabs. Repeat on the upper right gap.
2. Remove the blind panel by using you hand to pull the panel loose
Mounting Blind Panels 1. Insert the panel’s upper edge by
pressing gently so that its upper locking tabs engage 2. Lock the panel’s lower edge by
pressing with your hand so that the blind panel’s lower tabs lock into position.
Screwdriver to release the locking tabs
Blind panel’s upper locking tabs
Device hazard
CAUTION: - The modules may be warm, but do not hand-carry them by their handles - Open the handles before inserting them into the power shelves (hot-pluggable)
Electricshock
Mounting or Removing Smartpack and Flatpack2 Modules Note that cables are plugged to the Smartpack’s rear panel. When mounting the controller, you must plug the cables before step 2. When removing it, unplug the cables during step 2.
1. Unlock the handles by
inserting a screwdriver into the holes to release the spring mechanism
2. Insert or remove the module by sliding it fully into the power shelf, so that the module makes proper contact (for Smartpack, plug cables first) or using both handles to pull the module loose. Support from underneath before the unit is completely free. Unplug the cables, when removing the Smartpack module
3. Lock the handles by pushing the handles up into their housings (locked position). Then, the module will be securely locked in the shelf, or ready for transport
4. Mount blind panels in unused module locations
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 4
Installation Steps
Installation
Check off in the Installation Check List, that you find in the pullout section of this folder. Also, refer to the system’s specific drawings.
Preparing the Installation Site
Begin preparing the following:
1 Organize the installation site o Min. clearances for cabinet access: 60 cm in front, 20 cm on top o Levelled surface able to support 600 kg (cabinetized systems) o Explosive atmospheres are to be avoided. Ensure suitable
ventilation o 60V systems are only to be installed in Restricted Access
Locations (RAL) 2 Prepare the installation tools
o Use insulated tools suitable for telecom installations 3 Prepare AC Supply: AC input cable(s) and fuses
o Correct type AC supply is available o External AC fuses have correct rating o AC input cable(s) are sized correctly
EMCregard
200 mm
600 mm
For external AC fuses and AC input cable ratings, refer to your site’s AC supply specification. Read also our external AC fuse recommendationsin section “Miscellaneous”. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.
Mechanical Installation Power is OFF!
Carry out the following: 4 Remove packaging and check equipment
o Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc.
o Inspect the equipment for physical damage (report any damages) o Leave rectifier modules in their packaging or in the selves, if
factory installed. To be installed under commissioning 5 Remove top cover and dummy front panels
o Cable entry from the top. Connection terminals are located behind the upper dummy panels
o Battery shelves (if any) are placed behind the lower panels 6 Position and fasten the cabinet or subassembly
o Cabinets are floor-mounted on levelled surface. Adjust the legs if necessary. If the cabinet must be fastened, unscrew the legs and use suitable bolts to fasten it to the floor
o Subassemblies are fastened in existing 19” or in ETSI cabinets, using brackets. Mount the support & heat deflecting plate under the lower power shelf
7 Mount the batteries on the shelves o Start (if applicable) placing the batteries on the lower shelf first,
and continue upwards o Do not terminate the battery cables yet!
Electricshock
Devicehazard
Flatpack2 PSS, batteries, Doc. Chart, Spec. Drawings, CD-ROM
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 5
Installation
Electrical Installation Power is OFF!
Carry out the following: (Refer to the system’s specific drawings)
8 Make the system completely voltage free o Switch OFF or remove all load fuses (MCB1, MCBx), battery
fuses (Fb1, Fbx) and the AC supply fuses, in external fuse boards
9 AC Connections o Check AC configuration: the AC terminals are correct configured
to the external AC supply, otherwise reconfigure the terminals o Connect the AC Earth wire (PE) to the terminals AC Earth (PE) o Connect the AC input cable(s) to the terminals. Cable and
terminal block labeling are to correspond 10 DC Connections ⎯ Load Circuits
o Terminate DC Earth (TE), and check that the common DC Output Rail is connected to “Telecom Earth” (TE) at only one place (at the cabinet or at a central distribution point). Se chapter about AC, DC earthing systems
o For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB or load fuse
11 DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration, or
to the “Miscellaneous, Alarms & Monitoring” section (Factory Settings)
o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output
terminals 12 DC Connections ⎯ Battery Cables
Careful! Use correct polarity. For each battery shelf: (refer to the figure in this page)
(In cabinetized systems, steps b, d and f are usually performed in factory)
a Mount 3 intercell links to connect in series 4 battery blocks b-c Connect battery cables to fuses and common DC rail, and to
the shelf’s outer terminals; black (+); blue (-) d-e Connect battery symmetry cables, if applicable, to the input
terminals, and to the center terminal of the battery string (+) and to the -48V outer terminal. Deviation from factory settings requires Symmetry reconfiguration via PowerSuite
f-g Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the temperature sensor (at the end of the cable) to a suitable place in the middle of the installed battery bank
— (-48V) Outer
Terminal +
0V Outer Terminal
Link 2(DC Earth)
Common DC Rail EG Battery
Fuse
Intercell Links
Battery Cable S
ymm
etry
1
2-1
Chassis
Card Art.200576
+ -
15 pins D-Sub (male)
Tem
p. s
enso
r Tem
p. S
enso
r cab
le 1
Block1
- ++ - + - + -
Block4 Block3
Electricshock
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 6
The commissioning of Flatpack2 PS System consists of following stages:
I. Perform a pre-start check before the PS system is switched ON II. Switch ON the system with disconnected load; adjust output voltage
III. Adjust the nominal output voltage with connected batteries and load
Pre-Start Check Power is OFF! Check off in the Commissioning Procedure, that you find in the pullout section of this folder.
If you have just finished the system installation successfully and filled in the Installation Check List, jump over the Pre-Start Check and continue with stage II.
Before you switch ON the Flatpack2 PS system, verify the following:
1. System installation is completed o Ensure a correctly performed system installation, with correct polarity on all
connections, has been carried out (Installation Check List filled in) o All cabling and copper bars are securely terminated and supported o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
2. Battery and load fuses are disconnected o Verify that all battery and load MCBs/ fuses are switched OFF or removed
3. AC input cable(s) and AC Earth wire (PE) are terminated o Make sure that the AC input cable(s) are connected to correctly configured AC terminals o Verify that the AC input cable(s) and external AC fuses are sized and rated as specified o Check that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)
4. Site specific parameters and settings are known o Read the system specific drawings and documentation
5. AC supply and all MCBs, fuses are switched OFF o Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF
Commissioning Steps, Startup Check off in the Commissioning Procedure, that you find in the pullout section of this folder.
After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you will switch ON the Flatpack2 PSS — while the batteries and load are disconnected ⎯ then measure the output voltage, and adjust it if required. Carry out the following:
Startup and No-Load Adjustments Power is ON!
1. Disconnect all rectifier modules, without removing them (keep original location) o Read how to install modules, on page 3 in this guide. Also, read about the correct
rectifier position on page 15, and then, o If Flatpack2 rectifier modules are installed, unlock the handles and pull the
modules partially out (fan housing visible), but do NOT physically remove them from the power shelves
o If Flatpack2 rectifier modules are not yet mounted, release their handles and insert them partially into the correct position in the shelves
2. Switch ON the system o Switch ON the AC input supply (external AC fuses) to the PS cabinet
3. Measure and verify that the AC input voltage is correct o Measure the AC input voltage at the cabinet’s mains connection box o Verify the AC voltage is within range
Commissioning
Device hazard
Device hazard
I
II
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 7
4. Mount all Flatpack2 rectifier modules in the power shelves (keep original location)
o Push all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯ to plug them in the same shelf location. Lock their handles. Refer also to page 15
o Mount blanking panels over unused positions
5. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON o Verify correct operation, by monitoring the modules’ LED lamps and display:
No alarms are present on rectifiers; The Smartpack displays fuse alarms
6. Connect a PC to the PS system (to facilitate operation) o Plug a standard USB A-B cable between the PC and the Smartpack controller o Start PowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite
Refer to chapter “Installing PowerSuite ⎯ PC Application”, page 9, if required o On the toolbar, click the “Connect” button to establish connection
7. Measure and adjust DC output voltage o Read the DC output voltage on the controller’s display o With a multi-meter, measure the DC output voltage at the most accessible point, e.g.
between the common DC rail and the lower connection of one of the priority load MCBs o If required, adjust the voltage using the controller’s front keys or via PowerSuite
8. Verify the alarm relays are working correctly (alarm relay test) o Run the alarm relay test using the controller’s front keys (refer to page 8) or via
PowerSuite (select the menu Go > Output Test)
9. Make sure the System Setup is in accordance with configuration o Verify system settings using the controller’s front keys or via PowerSuite o Use the opportunity to enter site related information, number of used AC phases,
type of batteries, etc.
Load Adjustments Power is ON! Now, you can begin with stage III, where you will adjust again the output voltage to the battery voltage, and connect the batteries and the load. Carry out the following:
10. Adjust DC output voltage to equal measured battery voltage o Measure the battery voltage is within range (check connections have correct polarity) o Adjust DC output voltage — using the controller’s front keys (refer to page 8) or via
PowerSuite— to equal the measured battery voltage. (Important adjustment to avoid arcing when connecting the batteries)
11. Unplug all rectifiers but one, and connect the battery fuses /MCBs (CAUTION: Have only one rectifier connected, when switching ON the battery fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.)
o Disconnect all rectifiers but one, by unlocking the handles and pulling them partially out (fan housing visible). Do NOT physically remove them from the power shelves
o Switch ON all battery fuses or MCBs
12. Adjust DC output voltage again to equal the nominal battery voltage o Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to
equal the nominal battery voltage (or the nominal load voltage, when not using batteries)
13. Plug in again all rectifiers, and verify the rectifiers’ current sharing o Connect all rectifiers again by pushing them firmly inwards ⎯ Repeat step 4, in stage II o Wait for about 2 min., and check — using the PowerSuite application —that each of the
rectifiers delivers the same output current. A deviation of 1A is acceptable.
14. Connect the load breakers and verify that no alarms are displayed o Switch ON all load MCBs/ fuses o Verify correct operation: rectifiers and controller display no alarms
Devicehazard
Devicehazard
III
Commissioning
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 8
Front Keys and display, menus, etc.
Operation
Flatpack2 Rectifier Module — front panel Power LED is OFF (mains unavailable), Flashing (controller accessing information) or ON (powered). Warning LED is ON (derating or similar minor warning), Flashing (over-voltage mode) or OFF (OK) Alarm LED is ON (shutdown or similar major alarm) or OFF (OK, no alarm)
Flatpack2 rectifier
AlarmLED Lamp (red)
PowerLED Lamp (green)
WarningLED Lamp (yellow)
Software Menus
Service menu <ServiceOption> NomVolt ↓↑
BoostVolt ↓↑
LowBatt1 ↓↑ VoltAdjustment LowBatt2 ↓↑
HighBatt1 ↓↑
HighBatt2 ↓↑
LVD 1 ↓↑
LVD 2 ↓↑ VoltCalibration ------ VoltCal ↓↑ ChangePassword -- Password ↓↑ SetBoostTime-------- ↓↑ Start/StopBoost Auto Boost Conf. -- Enable/Disable & AutoBThrs ↓↑
Nxt Test DateTime
End Volt ↓↑ Batt Test Setup MaxTestDur ↓↑
Test int ↓↑
Guard time ↓↑ Start/Stop Test Charge Curr Lim. --- Enable/Disable & Max C.Curr ↓↑ Battery Setup -------- NumOfString ↓↑ Output Control------- VoltageCtrl / TempComp Change Date/Time
Alarm Output 1 RelayTest Alarm Output 2
Batt Contactor Load Contactor Alarm Output nn
BattLifeTime Rst 1v0
Level 2 Level 3
The
”XvX
” ref
eren
ces,
if a
ny, o
n th
e rig
ht h
and
of th
e op
tion,
are
not
sho
wn
in th
e di
spla
y.
They
onl
y in
dica
te in
whi
ch s
oftw
are
vesj
on (x
) the
opt
ion
was
firs
t im
plem
ente
d.
Smartpack Control Unit — front keys, display, etc Display: is in Status Mode (displays the system’s status) or in Menu Mode (displays the menu structure). Operation: Press on the key to change from Status Mode to Menu Mode. Press the or keys to scroll up or down and navigate to find menu options (function or parameter). Press then the key to select the function. Menus: When you “enter” Menu Mode (Level 1), you access the User Options. You may also scroll down to password protected Service Options. Default password <0003> should be changed.
User menu <UserOption> AlarmReset
NomVolt
BoostVolt
LowBatt1
VoltageInfo LowBatt2
HighBatt1
HighBatt2
LVD 1
LVD 2
DisplayMessages Message ↓↑
SoftwareInfo
SerialNumber 1v01
NoOfRects. Nn
RectCurrent 1v0
Rectifier Info RectSerialNumber 1v0
Rect.PrimaryVolt 1v0
Rectifier Status 1v0
Rectifier Temp 1v0
NoOfPhases nn
Mains Info Mains Status
Mains Voltage
Temp Level Info - Level ↓↑ 1v0
Level 2 Level 3
The
”XvX
” ref
eren
ces,
if a
ny, o
n th
e rig
ht h
and
of th
e op
tion,
are
not
sho
wn
in th
e di
spla
y.
They
onl
y in
dica
te in
whi
ch s
oftw
are
vesj
on (x
) the
opt
ion
was
firs
t im
plem
ente
d.
PowerLED Lamp (green)
Warning LED Lamp (yellow)
AlarmLED Lamp (red)
Graphical Display
16 char. x 2 lines LCD display
”Up” arrow key ”Down” arrow key
”Enter” key
USB0ype B port
Smartpack control unit
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 9
CAN Bus Termination Flatpack2 systems are shipped from factory with the CAN bus already terminated with 120Ω resistors.
To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120Ω resistors, one at each end of the line. The figure shows a Flatpack2 system communicating via the CAN bus.
The Smartpack dynamically software-assigns ID numbers to rectifiers. The controller registers the rectifiers’ ID numbers, or CAN bus address (01, 02…), together with their Serial Numbers. The Smartpack’s ID numbers (1, 2…) are assigned by DIP switches on the controller’s side. Terminate the CAN bus with only two 120Ω resistors, one at each end of the line. The figure shows two Flatpack2 systems communicating via the CAN bus.
Installing PowerSuite ⎯ PC Application The PowerSuite software application enables you to configure and operate the Flatpack2 Power Supply System from a personal computer.
Communication Miscellaneous
120Ω
Flatpack2 DC Power System
End-of-Line Resistor
End-of-LineResistor
120Ω
CAN bus(twisted-pair internal CAT5 cable)
USB A-B cable(standard)
01 02 n
1
120Ω
Flatpack2DC Power System 2
120Ω
Flatpack2DC Power System 1
End-of-Line Resistor
End-of-LineResistor
01 02 n n+1 n+2 m
1 2
3. Wait for Windows to install USB driversFollow & accept the wizard default steps to automatically install the USB drivers; the wizard runs twice New hardware
is ready to use 3
If PowerSuite fails communicating via the standard COM port, find the COMx assigned to Smartpack (My Computer/ Properties / Hardware/ Device Manager) and configure PowerSuite to communicate via this COMx (read the instructions in the installation CD).
PowerSuite’s newest version is always available on our FTP server. Call your Eltek’s contact person.
Flatpack2 system configuration from a PC running MS Windows XP
2. Switch Smartpack ON and plug USB cable (Part 202073)to Smartpack and to any available USB port in the PC 2
1. Install PowerSuite Insert the CD in your PC drive, start the PowerSuite installation and follow & accept the wizard default steps to install “.Net” software and PowerSuite
1
4. Start PowerSuite and establish connection Select “Start > All Programs > Eltek > PowerSuite”. On the toolbar, click “Connect” button. On the Connection dialogue box, click the “Connect” button
4
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 10
External AC Fuses ⎯ Recommended Rating The site’s AC supply quality is of great importance. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.
205V
AC In
puts
AC Mains No of Power Current Ext. Fuse Type Shelves Max. (A) Type
1 21.6 25A-C 2 43.1 50A-C 3 43.1 50A-C
400VAC +N3 phase
4 64.7 80A-C 1 37.4 40A-C2 56.1 63A-C3 74.8 80A-C
230VAC 3 phase
4 112.2 125A-C1 43.0 50A-C 230VAC
1 phase 2 86.0 100A-C
2AC
Pow
er S
helv
es
2 A
C in
puts
per
she
lf, e
ach
feed
ing
2 re
ctifi
ers
AC Mains No of Power Current Ext. Fuse Type Shelves Max. (A) Type
1 21.6 25A-C 400VAC +N3 phase 2 32.3 40A-C
1 29.5 32A-C230VAC 3 phase 2 56.1 63A-C
1 43.1 50A-C 230VAC 1 phase 2 86.2 100A-C
4AC
Pow
er S
helv
es
4 A
C in
puts
per
she
lf, e
ach
feed
ing
1 re
ctifi
er
185V
AC In
puts
4AC
Pow
er S
helv
es
4 A
C in
puts
per
she
lf, e
ach
feed
ing
1 re
ctifi
er
AC Mains No of Power Current Ext. Fuse Type Shelves Max. (A) Type
1 23.9 25A-C 400VAC +N3 phase 2 35.8 40A-C
1 32.7 40A-C230VAC 3 phase 2 62.1 63A-C
1 47.8 50A-C 230VAC 1 phase 2 95.6 100A-C
2AC
Pow
er S
helv
es
2 A
C in
puts
per
she
lf, e
ach
feed
ing
2 re
ctifi
ers
AC Mains No of Power Current Ext. Fuse Type Shelves Max. (A) Type
1 23.9 25A-C 2 47.8 50A-C 3 47.8 50A-C
400VAC +N3 phase
4 71.7 80A-C 1 41.4 50A-C2 62.1 63A-C3 82.9 100A-C
230VAC 3 phase
4 124.3 125A-C1 48.0 50A-C 230VAC
1 phase 2 96.0 100A-C
External AC Fuses Recommended Ratings
1AC Feed to 1 Flatpack2 rectifier
AC Mains Ext. Fuse Type Type FS=I FS=0
185VAC 25A-C 13A-B 205VAC 25A-C 10A-B FS=I (Fuse Selectivity: Internal) which means that the Flatpack2 rectifier’s internal fuse will trip be-fore the external AC fuse. FS=0 (Fuse Selectivity: none) these fuse types may be used when it is irrelevant whether the internal or the external fuse trips first. Note: Always replace a rectifier with blown internal AC fuse with a new module, and send the mal-functioning module for servicing.
Miscellaneous AC Mains
Use the recommendations in the 205VAC table, if you are sure the available AC mains voltage will not drop below 205VAC.
OR If you are unsure ⎯ or know that the voltage may drop below 205VAC ⎯ use the 185VAC table recommendations.
Only difference between the 205 and the 185VAC recommendation tables
PU
LLOU
T
Check Lists Pu
llout
Pull o
ut th
e pag
es with
the g
ray outer b
and,
and u
se them
as check lists
INSTALLATION CHECK LIST System Data Flatpack2 PS System Flatpack2 Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:
Site Preparations CARRY OUT FOLLOWING: OK
1. Organize the installation site o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm o Check that the levelled surface is able to support 600 kg (cabinetized systems) o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas
2. Prepare the installation tools o Check that insulated tools suitable for telecom installations are used
3. Prepare AC Supply: AC input cable(s) and fuses o Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated
Mechanical Installation Power is OFF! CARRY OUT FOLLOWING: OK
4. Remove packaging and check equipment o Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc o Inspect the equipment for physical damage (report any damages) o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
5. Remove top cover and dummy front panels o Check that cable entry from the top is possible
6. Position and fasten the cabinet or subassembly o Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor o Subassemblies in existing 19” or in ETSI cabinets, using brackets. Mount the support & heat deflecting plate
7. Mount the batteries on the shelves o Start (if applicable) on the lower shelf first, and continue upwards o Do not terminate the battery cables yet!
Electrical Installation Power is OFF! CARRY OUT FOLLOWING: OK
8. Make the system completely voltage free o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses
9. AC Connections o Check AC configuration: The AC terminals are correct configured to the external AC supply o Connect the AC Earth wire (PE) to the terminals AC Earth (PE) o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
10. DC Connections ⎯ Load Circuits o Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place o For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB
11. DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration, or to the Factory Settings in the Quick Start Guide o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output terminals
12. DC Connections ⎯ Battery Cables Careful! Use correct polarity. For each battery shelf,
o Mount 3 intercell links to connect in series 4 battery blocks o Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-) o Connect battery symmetry cables, if applicable, to the input terminals o Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the
end of the cable) to a suitable place in the middle of the installed battery bank
Approval Responsible of installation, sign.: Date: Approved by customer, sign.:
EMC regard
Electric shock
Device hazard
Electric shock
Form 173-gb-v1-C
01_356804-103_qstart-inst-comm
-oper_flatpack2-pss.doc_mfm
_2006-01-06
Eltek Energy AS Tel. +47 32 20 32 00
Internet: www.eltekenergy.com E-Mail: [email protected]
CIRCUIT DISTRIBUTION LIST System Data Flatpack2 PSS, type: Article No.:
Site, name:
CIRC. NO. FUSE
KNIFE TYPE
MCB LVLD
CONTROLLED DESCRIPTION FUSE
AMPERE CABLE
mm2
Fb1 Fb2 Fb3 Fb4 Fb5 Fb6 F1 F2 F3 F4 F5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Continue
LOA
D
BA
TT.
Form 172-gb-v2-C
01_356804-103_qstart-inst-comm
-oper_flatpack2-pss.doc_mfm
_2006-01-06
Eltek Energy AS Tel. +47 32 20 32 00
Internet: www.eltekenergy.com E-Mail: [email protected]
CIRCUIT DISTRIBUTION LIST
CIRC. NO. FUSE KNIFE
TYPE MCB
LVLD CONTROLLED
DESCRIPTION FUSE AMPERE
CABLE mm
2
31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66.
LOA
D
Eltek Energy AS Tel. +47 32 20 32 00
Internet: www.eltekenergy.com E-Mail: [email protected]
Form 172-gb-v2-C
01_356804-103_qstart-inst-comm
-oper_flatpack2-pss.doc_mfm
_2006-01-06
Form 171-gb-v2-C
01_356804-103_qstart-inst-comm
-oper_flatpack2-pss.doc_mfm
_2006-01-06
Eltek Energy AS Tel. +47 32 20 32 00
Internet: www.eltekenergy.com E-Mail: [email protected]
WARNING: Maintenance work on live equipment is only to be performed by authorized and qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury. Electric
shock
MAINTENANCE PROCEDURE System Data Flatpack2 PS System Flatpack2 Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:
System Inspection Power is ON! CARRY OUT FOLLOWING: OK 1. Site specific parameters and settings are known.
User manuals and site specific connection & arrangement drawings are available.
2. The battery bank has been fully charged in advance. At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration
3. The equipment is free from damage, dust or dirt; verify. Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.
4. All cabling and copper bars are securely terminated and supported. Correct any loose connections, excessive cable temperature, defective insulation, etc.
5. The Smartpack & all rectifier modules are ON, no alarm present; verify. Otherwise, correct and put the PS system in normal mode of operation.
6. All rectifier’s functionality & Smartpack’s keys and display work OK; verify Correct possible abnormalities before continuing.
7. Connect the PS system to a PC (install the PowerSuite application if required) The PowerSuite program in the PC enables system configuration from the PC.
8. Rectifiers’ load current sharing; verify. Use the PowerSuite PC application to check all rectifiers output the same amount of current (±1A)
9. Display the stored log of Alarm Messages. Using the keypad on the Smartpack controller or from the PC.
System Adjustment CARRY OUT FOLLOWING: OK 1. DC Output Voltage Calibration; ensure correct display readings.
If measured DC output voltage at the load terminals deviates more than ±1% from the display reading, calibrate the output voltage from the Smartpack’s keypad or the PC.
2. Load & Battery Current Calibration; verify correct display readings. Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery current. If the calculated total values deviate more than ±1% from the display readings, calibrate the current from the PC (calibration value>50% of system’s max. capacity)
3. DC Output Voltage Adjustment; measure and adjust. Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery manufacturer. (Voltage measurements to be done at the DC rail, with little load current)
4. Alarm Relay Test; verify all alarm relays are working correctly. From the Smartpack’s keypad or PC use the Relay Test function; verify activation of external equipment
5. Battery bank control; measure and verify battery specifications. Follow the recommendations of the actual battery manufacturer.
Approval Responsible of maintenance control, sign.: Date: Approved by customer, sign.:
COMMISSIONING PROCEDURE System Data Flatpack2 PS System Supplier’s Order No.: Flatpack2 Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:
Pre-Start Check Power is OFF! CHECK FOLLOWING: OK 1. Flatpack2 system installation is completed; The Flatpack2 Installation Check List is filled in.
All cabling is securely terminated with correct polarity 2. All battery and load MCBs/ fuses are disconnected
3. AC input cable(s) and AC earth wire (PE) are terminated
4. Site specific parameters and settings are known
5. AC supply and all MCBs/ fuses are switched OFF
Start-up, No-Load & Load Adjustments Power is ON! CARRY OUT FOLLOWING: OK 1. Disconnect all rectifier modules, without removing them (keep original location)
2. Switch ON the system (external AC fuses ON)
3. AC input voltage is correct; Measure and verify
4. Insert all Flatpack2 rectifiers in their original locations in the power shelves
5. The Smartpack and all rectifier modules are working, LEDs are ON; Verify
6. Connect a PC to the PS system Install the PowerSuite software, if required
7. DC output voltage; Measure and adjust
8. Alarm relay test; Verify all alarm relays are working correctly 9. System Setup is in accordance with configuration Enter site spec. info in PowerSuite 10. Adjust DC output voltage to equal measured battery voltage Check correct polarity! 11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs 12. Adjust DC output voltage to equal nominal battery or load voltage 13. Plug in again all rectifiers, and verify the rectifiers’ current sharing 14. Connect all load MCBs/ fuses, and verify no alarms are displayed
Approval Responsible of commissioning, sign.: Date: Approved by customer, sign.:
Device hazard
I
II
Device hazard
III
Device hazard
Form 170-gb-v4-C
01_356804-103_qstart-inst-comm
-oper_flatpack2-pss.doc _mfm
_2006-01-06
Eltek Energy AS Tel. +47 32 20 32 00
Internet: www.eltekenergy.com E-Mail: [email protected]
PU
LLOU
T
Check Lists Pu
llout
Pull o
ut th
e pag
es with
the g
ray outer b
and,
and u
se them
as check lists
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 11
Identifying Power Shelves, 4AC or 2AC Flatpack2 rectifiers are accommodated in one or several power shelves. Two types of power shelves are available:
• 4AC Power Shelves, or single AC feed (4 AC inputs per shelf, each feeding 1 rectifier)
• 2AC Power Shelves, or dual AC feed (2 AC inputs per shelf, each feeding 2 rectifiers)
You can identify the type of power shelves used by your system by reading the shelf’s label, or by looking at the shape of the shelf’s AC mains terminals, at its rear. (Also viewable by removing the rectifier in the shelf’s 4th position)
Mains Reconfiguration, Integrated Systems 1U Distr. The AC mains terminals of Flatpack2 integrated systems with 1U DC distribution units are located on the power shelf’s rear.
Find out whether your system is implemented with 4AC or 2AC powers shelves (read the Identifying Power Shelves section, page11) and terminate the AC mains cable according to the type of AC mains to be used, as shown in the actual example below.
4AC
Pow
er S
helv
es
Sin
gle
AC
feed
: 4 A
C in
puts
per
sh
elf,
each
feed
ing
1 re
ctifi
er L1 L2 PE
Υ MainsThree-phase & N, 400VAC
L3 N
PE(CON12) L1(CON11) L2(CON10) PE(CON15)L1(CON14)L2(CON13)
PE(CON18) L1(CON17) L2(CON16) PE(CON21)L1(CON20)L2(CON19)
L (L1) N (L2) PE
Mains One-phase, 230VAC
PE(CON12)L1(CON11)L2(CON10)PE(CON15)L1(CON14)L2(CON13)
PE(CON18)L1(CON17)L2(CON16)PE(CON21)L1(CON20)L2(CON19)
L1 L2
∆ MainsThree-phase, 230VAC
L3
PE(CON12)L1(CON11)L2(CON10)PE(CON15)L1(CON14)L2(CON13)
PE(CON18)L1(CON17)L2(CON16)PE(CON21)L1(CON20)L2(CON19)
2AC
Pow
er S
helv
es
Dua
l AC
feed
: 2 A
C in
puts
per
sh
elf,
each
feed
ing
2 re
ctifi
ers
L (L1) N (L2) PE
Mains One-phase, 230VAC
CON13(PE)
CON9(L1 1/2)
CON11(L1 3/4)
CON10(L2 1/2)
CON12(L2 3/4)
Power Shelf
L1 L2 PE
Υ MainsThree-phase & N, 400VAC
L3 N
CON13 (PE)
CON9 (L1 1/2)
CON11 (L1 3/4)
CON10 (L2 1/2)
CON12 (L2 3/4)
Power Shelf Power Shelf
CON13(PE)
CON9(L1 1/2)
CON11(L1 3/4)
CON10(L2 1/2)
CON12(L2 3/4)
L1 L2 PE
∆ MainsThree-phase, 230VAC
L3
2AC Power Shelves
4AC Power Shelves
Flatpack2 System, 1U DC Distr.
AC Mains &PE terminals
Power Shelf (rear view)
AC Mains Miscellaneous
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 12
Mains Reconfiguration, Cabinetized & Integrated 4U To reconfigure the AC mains feed of Flatpack2 DC power systems ⎯ cabinetized or integrated with 4U DC distribution units ⎯ you have to rewire the internal cables of the system’s AC Mains connection box.
1. Find out first whether your system is implemented with 4AC or 2AC powers
shelves (read the Identifying Power Shelves section, page11).
2. Rewire then the internal cables of your system’s AC Mains connection box, according to the type of AC mains to be used, as shown in the actual example in this section.
Miscellaneous AC Mains
4AC Power Shelves Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier
L3
X:******
Flapack2 DC Power System
(To internal connections)
AC Mains Cable
Chassis
L1L2 PE
Υ Mains Three-phase & N, 400VAC
N
PS1:C
ON
20P
S1:C
ON
19PS
1:CO
N17
PS
1:CO
N16
PS1:C
ON
14P
S1:C
ON
13PS
1:CO
N11
PS
1:CO
N10
PS
2:CO
N19
PS
2:CO
N16
PS
2:CO
N13
PS
2:CO
N10
PS2:C
ON
20PS
2:CO
N17
PS2:C
ON
14PS
2:CO
N11
AC
Mai
ns
conn
ectio
n bo
x
Rewire the box
as shown
X:******
Flapack2 DC Power System
(To internal connections)
AC MainsCable
Chassis
L1L2 PE L3
∆ MainsThree-phase, 230VAC
PS1:C
ON
20P
S1:C
ON
19PS
1:CO
N17
PS
1:CO
N16
PS1:C
ON
14P
S1:C
ON
13PS
1:CO
N11
PS
1:CO
N10
PS
2:CO
N19
PS
2:CO
N16
PS
2:CO
N13
PS
2:CO
N10
PS2:C
ON
20PS
2:CO
N17
PS2:C
ON
14PS
2:CO
N11
AC
Mai
ns
conn
ectio
n bo
x
Rewire the box
as shown
AC
Mai
ns
conn
ectio
n bo
x
X:******
Flapack2 DC Power System
(To internal connections)
AC MainsCable
Chassis
PE L (L1)N (L2)
MainsOne-phase, 230VAC
PS1:C
ON
20P
S1:C
ON
19PS
1:CO
N17
PS
1:CO
N16
PS1:C
ON
14P
S1:C
ON
13PS
1:CO
N11
PS
1:CO
N10
PS
2:CO
N19
PS
2:CO
N16
PS
2:CO
N13
PS
2:CO
N10
PS2:C
ON
20PS
2:CO
N17
PS2:C
ON
14PS
2:CO
N11
Rewire the box
as shown
AC Mains Connection Box
PS1:C
ON
20P
S1:C
ON
19PS
1:CO
N17
PS
1:CO
N16
PS1:C
ON
14P
S1:C
ON
13PS
1:CO
N11
PS
1:CO
N10
PS
2:CO
N19
PS
2:CO
N16
PS
2:CO
N13
PS
2:CO
N10
PS2:C
ON
20PS
2:CO
N17
PS2:C
ON
14PS
2:CO
N11
Rewire the internal cables
For externalAC Mains
cable
For external AC Mains cable
Internal connection point (power shelf # and connector #) for each cable
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 13
About AC, DC Earthing Systems To prevent the risk of electric shock, all cabinet’s chassis are to be electrically connected to AC Earth (PE). Also, it is a common practice for telecom equipment to have its common DC output rail (+ or -) connected to a separate “Telecom Earth” (TE) or DC Earth.
AC Earth (PE) and DC Earth (TE) are connected to chassis via “Link 1” and “Link 2”. Remove the links (“floating earth”) for compliance with other local earthing systems.
Common Positive DC Output Rail is usual in 48 and 60V DC supply systems: Negative DC Distribution. Common Negative DC Output Rail is usual in 24V systems: Positive DC Distribution.
AC Mains Miscellaneous
2AC Power Shelves Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
PS1:C
ON
11P
S1:C
ON
12P
S1:C
ON
9P
S1:C
ON
10PS
2:CO
N11
PS
2:CO
N12
PS
2:CO
N9
PS
2:CO
N10
PS3:C
ON
11P
S3:C
ON
12P
S3:C
ON
9P
S3:C
ON
10PS
4:CO
N11
PS
4:CO
N12
PS
4:CO
N9
PS
4:CO
N10
X:******
Flapack2 DC Power System
(To internal connections)
AC Mains Cable
Chassis
L1 L2 PE
Υ Mains Three-phase & N, 400VAC
L3 N
AC
Mai
ns
conn
ectio
n bo
x
Rewire the box
as shown
X:******
Flapack2 DC Power System
(To internal connections)
AC MainsCable
Chassis
L1L2 PE L3
∆ MainsThree-phase, 230VAC
L1
N
L3
L2
AC
Mai
ns
conn
ectio
n bo
x
Rewire the box
as shown
X:******
Flapack2 DC Power System
(To internal connections)
AC MainsCable
Chassis
PE L (L1)N (L2)
MainsOne-phase, 230VAC
PS
1:CO
N11
PS
1:CO
N12
PS
1:CO
N9
PS
1:CO
N10
PS
2:CO
N11
PS
2:CO
N12
PS
2:CO
N9
PS
2:CO
N10
PS
3:CO
N11
PS
3:CO
N12
PS
3:CO
N9
PS
3:CO
N10
PS
4:CO
N11
PS
4:CO
N12
PS
4:CO
N9
PS
4:CO
N10
AC
Mai
ns
conn
ectio
n bo
x
Rewire the box
as shown
CabinetPE
AC Mains Common DC Rail EG
.
AC
Mai
ns In
put
(L1,
L2,L
3,N
)
DC Load Circuit
Link 2(DC Earth)
Link 1 (AC Earth)
TE
Chassis
Chassis
PE (Protective Earth) TE (Telecom Earth) EG (Exchange Ground)
Common DC Rail —
DC
Loa
d w
ires
+
+
+ +
Positive DC Distribution
—
—
——
Negative DCDistribution
Common DC Rail +
DC
Loa
d w
ires
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 14
Mains Phases versus Rectifier ID Phase Balancing & Monitoring When Flatpack2 systems are fed with a 3-phase AC Mains input circuit, each rectifier is internally connected to the 230VAC phases, in such a pattern that loads the 3 phases evenly.
The distribution of rectifiers among the phases is implemented both via internal wiring to the power shelves, and how the shelf’s back-wiring card routes the phases to each rectifier position. There are two types of shelves: 4AC and 2AC power shelves. Read also the Identifying Power Shelves section, page11.
Plug-and-Play Rectifiers versus Phase Monitoring
When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller assigns the next available ID number to the rectifier, starting with “01”. The controller registers the rectifier’s Serial Number and ID number.
When a previously installed (hot plugged) Flatpack2 rectifier is inserted in a power shelf, the Smartpack controller “recognizes” the module, and assigns the same ID to the rectifier. In other words, the controller and the rectifier “remember” the assigned ID number, even after removing and reinserting the rectifier in the shelf.
To achieve a more controlled ID assignment, you should always insert & hot-plug new Flatpack2 rectifiers in the power shelves, one module at a time, starting with shelf position 1, 2, 3, and so on. The sequence is indifferent after positions 9. You find more information on page 15.
This position-versus-ID number relationship is very important for the correct monitoring of the mains three phases, as the Smartpack controller always uses rectifier ID01, 02 and 03 to monitor the Mains phase 1, 2 and 3 respectively. If these rectifiers malfunction, rectifier ID 04, 05 and 06 will automatically take over.
For example: accidentally inserting a rectifier with ID02 in a power shelf position internally connected to mains phase 1, will cause the controller to monitor phase 1 “thinking“ it monitors phase 2.
Miscellaneous AC Mains
∆ Mains Three-phase, 230VAC
L1
L2 L3 230VAC
AC Mains
02
05
08
n
Phase 2
03 06 09 n Pha
se 3
01 04 07 n Pha
se 1
Flatpack2 rectifier
Υ Mains Three-phase & N, 400VAC
ID number (Assigned CAN bus address)
230V
AC
L1
L2
L3
Mains400VAC, 3ph+N
N 01 04 07 n Pha
se 1
030609nPha
se 3
Pha
se 2
02 05 08 n
Load Balancing of Mains Phases Even distribution of Flatpack2 rectifiers on the Mains phases
Mains One-phase, 230VAC
01 02 03 n N(L2)
230VAC
AC Mains
L(L1)
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 15
Correct Rectifier Positions in Power Shelves
Flatpack2 DC power systems are normally shipped from factory with empty power shelves. The rectifier modules are shipped in separate packaging, and you have to install the modules in the correct position in the power shelves, with respect to their ID number (or CAN bus address). Do not relocate already pre-installed rectifiers.
For first time installations of rectifiers in Flatpack2 systems, follow the scheme below:
1. Find out your system’s power shelf type, by reading the Identifying Power Shelves section, page11
2. Find out if your system’s AC mains feed is <230VAC, 3 phase> or <400VAC, 3 phase and N>
3. Insert & hot-plug the rectifiers in the power shelves, one module at a time, allowing a 2s delay between them and starting with shelf position 1, 2, 3, and so on. Follow one of the four figures below:
Smartpack Located in Distribution Shelf
Correct Rectifier Position in 4AC Power Shelves Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier
∆ Mains Three-phase, 230VAC
Υ Mains Three-phase & N, 400VAC
and
01 02
05 06
09 ---
03 04
07 08
--- --- --- --- --- ---
Position 1
Position 4
ID number (Assigned CAN bus address)
Flatpack2rectifier
Position 8
Position 9
Smartpack controller
Correct Rectifier Position in 2AC Power Shelves Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
∆ MainsThree-phase, 230VAC
Υ MainsThree-phase & N, 400VAC
and
01 04
03 06
08 ---
02 05
07 ---
09 --------- --- --- ID number
(Assigned CAN bus address)
Position 1
Position 4
Flatpack2rectifier
Position 8
Position 9
Smartpackcontroller
AC Mains Miscellaneous
Smartpack Located in Power Shelf
Correct Rectifier Position in 4AC Power Shelves Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier
∆ Mains Three-phase, 230VAC
Υ Mains Three-phase & N, 400VAC
and
02
05 06
09 07
03 01
04 08
--- --- --- --- --- ---
Position 1 Position 8
Smartpack controller
Position 9 ID number (Assigned CAN bus address)
Flatpack2rectifier
Position 4
Correct Rectifier Position in 2AC Power Shelves Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
∆ MainsThree-phase, 230VAC
Υ MainsThree-phase & N, 400VAC
and
01
03 06
08 ---
02 05
04 07
09 --------- --- --- ID number
(Assigned CAN bus address)
Position 1
Position 4
Flatpack2rectifier
Position 8
Position 9
Smartpackcontroller
Phase 1 Phase 2 Phase 3
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 16
Battery Symmetry Connections Connections Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors CON4 and CON3), enabling symmetry measurement of:
• 8 battery strings using the Mid-Point Measurement Method
• 4 battery strings using the more accurate Double Mid-Point Measurement Method
• 2 battery strings using the even more accurate Block Measurement Method
You can implement any of these methods using one or two Battery Connection Kits (refer to the illustration next page) and the appropriate number of Battery Symmetry Kits, which contain a single cable strand with suitable cable eyes, etc.
Battery Terminology
Battery Block, Battery String and Battery Bank
48V Battery Bank
Battery String #1 (48V)Batt.
Battery Block (12V)
Battery String #2 (48V)
Notice that, if you open the serial switches in card, Art. 200576 ⎯ setting all to OFF (up) ⎯ you have to connect the + and – wires of every symmetry input.
Miscellaneous Battery Monitoring
Battery Symmetry Block Measurement
Four measurements per string (Serial measurement)
—(-48V) Outer
Terminal+
0V Outer Terminal
Intercell Links
X:****
Block1
- + + - +-+-
Block4 Block3
Card, Art. 200576Serial Switches
Set all 4 switches ON (down)
7
Sym
met
ry 4
+
2-1
Sym
met
ry 1
+-
5
Sym
met
ry 3
+
3
Sym
met
ry 2
+
Battery Symmetry Double-point Measurement
Two measurements per string, from the middle to the outer terminals
—(-48V) Outer
Terminal+
0V Outer Terminal
Intercell Links
X:****Card, Art. 200576 Serial Switches
Set all 4 switches ON
(down)
3
Sym
met
ry 2
+
2-1
Sym
met
ry 1
+ -
Block1
- + + - + -+-
Block4 Block3
Bat
t. S
ymm
etry
Kit,
Art.
200
830
Cable Eyes
Sin
gle
Cab
le S
trand
Exam
ples
of B
atte
ry S
ymm
etry
Con
nect
ions
48
V D
C S
uppl
y S
yste
ms
Battery Symmetry Mid-point Measurement
One measurement per string
—(-48V) Outer
Terminal+
0V Outer Terminal
Intercell Links
2-1X:****
Sym
met
ry 1
+ -
Card, Art. 200576 Serial Switches
Set all 4 switches OFF (up)
Block1
- + + - + -+-
Block4Block3
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 17
Terminals & Pin-out Location, Battery Interface Card The Smartpack controller’s battery monitoring signals are accessible on D-Sub connectors CON4 and CON3, on the controller’s rear panel.
Using the Battery Connection Kit ⎯ which consists of a Battery Interface Card (Art. 200576) and a standard 15 pins D-Sub cable ⎯ you can make the signals on CON4 accessible at any suitable location inside your system, e.g. near the battery blocks.
When extra battery monitoring signals are required, you can use an extra Battery Connection Kit connected to the controller’s CON3.
For detailed information about the card’s pin-out location and terminal block connections, refer to the figures in this section.
For temperature monitoring of the battery compartment, we recommend the use of the Temperature Sense Kit, instead of connecting the sensor cable directly to the terminals, pin 9-10.
The Temperature Sense Kit is connected to the Battery Interface Card (Art. 200576), or directly to the controller’s CON3 or CON4, if unused.
Terminals & Pin-out Location
Battery Interface Card, Art. 200576 14
1
Serial Switch
For Temp. Sense Kit
CON3A or CON4A
X***/X**** X**/X*
1
Alarm Outputs & Digital Inputs Card, Art. 105954
System Connections Card, Art. 200625
Smartpack
Battery ConnectionsCard, Art. 200576
Battery ConnectionsCard, Art. 200576
Battery Monitoring Miscellaneous
15 pins D-Sub cable
Card Art.200576
Battery Connection Kit
Temp. sensor
Temp. Sensor cable
Temperature Sense Kit
In
1.5 mm2, max. wire section
Battery Connections (Internal) Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
(Internal Connections)
4 3 2 1
5
9 8 7 6
10
14 13 12 11
X:**** Batt. Symmetry 1 +
−+−+−+−
Batt. Symmetry 2
Batt. Symmetry 3
Batt. Symmetry 4
(Fro
m in
tern
al
batte
ries)
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperature sensor
+−Temperature Sense 1
(NA)
(NA)
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperature sensor
15-pins D-Sub female
(Alternative use of Temp. Sense Kit, instead of connecting to X:****, 9-10)
Temperature Sense 1
X**/X*15-pins D-Sub male
1 5
11 15
Card Art.200576
To S
mar
tpac
k,C
ON
4
CON3A or CON4A 15-pins D-Sub female
1 11
5 15
In
1.5 mm2, max.wire section
Battery Connections (Internal) Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
(Internal Connections)
4 3 2 1
5
9 8 7 6
10
14 13 12 11
X:*** +−+−+−+−
(Fro
m in
tern
al
batte
ries)
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperature sensor
+−
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperature sensor
15-pins D-Sub female
(Alternative use of Temp. Sense Kit, instead of connecting to X:***, 9-10)
Temperature Sense 2
X**/X*15-pins D-Sub male
1 5
11 15
Card Art.200576
To S
mar
tpac
k,C
ON
3
CON3A or CON4A 15-pins D-Sub female
1 11
5 15
The Temperature Sense Kits may also be connected directly to the Smartpack controller’s CON3 or CON4, if these connectors are unused.
Batt. Symmetry 5
Batt. Symmetry 6
Batt. Symmetry 7
Batt. Symmetry 8
Temperature Sense 2
Batt Current 2
Batt Fuse Fail 2
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 18
Standard Alarm Relays & Digital Inputs Connections
The alarm outputs in Flatpack2 systems use the Fail-Safe Operation Mode (relay coils energized in the system’s normal operation mode). When the system is in alarm mode, the alarm relay coils are de-energized.
The figure shows the position of the relay contacts when the relay coils are de-energized (PS system in alarm mode)
In order to implement monitored fail-safe digital inputs circuits, the external relay coil must be energized and the contacts closed in the system’s normal mode of operation.
Terminals & Pin-out Location, Alarm Interface Card The Smartpack controller’s alarm and digital input monitoring signals are accessible from the controller’s rear panel, on mini power connector CON1 (2 outputs & 2 inputs) and on D-Sub connector CON2 (4 outputs & 4 inputs).
Using the Alarm Interface Card (Art. 105954) and two interface cables, you can make the signals on CON1 & 2 accessible at any suitable location inside your system.
For detailed information about the card’s pin-out location and terminal block connections, refer to the figures in this 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)
Standard Relays & Digital Inputs
Correct Use of Digital Inputs (example)
Normal ModeExternal Relay Y(Energized coil)
+—
Digital Input X (Normal mode)
Alarm Mode External Relay Y
(De-energized coil) +
—Digital Input X (Activated)
Flatpack2 PS System
Correct Use of Alarm Outputs (example) Flatpack2 PS System
—
+
NC
NOCom
Normal ModeRelay X
(Energized coil)
+—
Alarm Mode
Relay X (De-energized coil) NC
NOCom
Miscellaneous Alarms & Monitoring
Terminals & Pin-out Location
Alarm Outputs & Digital Inputs Card, Art. 105954(or Art. 200916 when X** and CON2A are not mounted)
CON2A CON1A
110 20 1
X* X**
Alarm Outputs & Digital Inputs Card, Art. 105954
System Connections Card, Art. 200625
Smartpack
Battery Connections Card, Art. 200576
Battery Connections Card, Art. 200576
4 3 2 1
5
9 8 7 6
10
X:*
(Customer Connections)
Input Circuit 1
Input Circuit 2
Alarm Circuit 1
Alarm Circuit 2
OutIn
(To
and
from
ex
tern
al e
quip
men
t)
1.5 mm2, max.wire section
Relay 2 Mains Alarm
Relay 1Common Alarm
+−
NO COM
NC
NO COM
NC
+−
Digital Input 1
Digital Input 2
Alarm Outputs & Digital InputsVoltage free relay outputs and Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
Input Circuit 3
Alarm Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6
Alarm Circuit 4
Alarm Circuit 5
Alarm Circuit 6
4 3 2 1
5
9 8 7 6
10
14 13 12 11
15
X:**
16 17 18 19 20
+−
+−
+−
+−
NO COM
NC
NO COM
NC
NO COM
NC
NO COM
NC
Digital Input 3
Digital Input 4
Digital Input 5
Digital Input 6
Relay 3 Fuse Alarm
Load & Battery
Relay 5Low Battery Alarm
Relay 6 Rectifier Alarm
(To
exte
rnal
equ
ipm
ent)
(Fro
m e
xter
nal e
quip
men
t)
Card Art.105954 1
To S
mar
tpac
k,C
ON
25
To S
mar
tpac
k,C
ON
19
Relay 4High Battery Alarm
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 19
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.
LVD Latching Contactors Connections
Flatpack2 systems’ LVBD and LVLD functionality (Low Voltage Battery Disconnect; LV Load Disconnect) is implemented by the Smartpack controlling magnetically latching contactors.
The coil of latching contactors is not energized in any state. They change state from open to close, or vice versa, when a reversed pulse is applied to the coil.
Internal Connections Miscellaneous
System Connections Card, Art. 20062511 1 CON5A
JP1 JP2
X*****
Terminals & Pin-out Location
Alarm Outputs & Digital Inputs Card, Art. 105954
System Connections Card, Art. 200625
Smartpack
Battery Connections Card, Art. 200576
Battery Connections Card, Art. 200576
Latching Contactor
Y
X
Latching Contactors, LVD1 & LVD2
A latching contactor changes state only when a reversed pulse voltage is applied to its coil
+ Pulse
ON
- Pulse
OFF
Correct Use of Latching Contactors (example)
PCB Art. 200625
10
8 9
X:*****
+
—
LVD1A
LVD2A LVD Common
Smartpack Unit
Flatpack2 PS System (internal)
11
LVD Common
Latching Contactor LVD2
Y
X
Latching Contactor LVD1
Y
X
+
4 3 2 1
5
9 8 7 6
10 11
X:***** Power Input
−+−+−
10156
712
139+, Neg.D.
11−,Pos.D.1+/−3+/−
2+/−
Batt. Fuse Fail 1Load Fuse Fail 1
Batt. Current 1
LVD1A LVD Common LVD1
OutIn
Term
inal
Boa
rd, A
rt. 2
0062
5 (T
o S
mar
tpac
k, C
ON
5)
(Internal Connections)
Syst
em C
onne
ctio
ns
JP2
LVD2ALVD Common LVD2(To latching contactors LVD1 & LVD2)
Head Office Eltek Energy AS PO Box 2340 Strømsø; N-3003 Drammen; Norway
Tel:+47 32 20 32 00 — Fax:+47 32 20 32 10 E-mail: [email protected] Internet: www.eltekenergy.com
Copyright © Eltek Energy AS, Norway 2005This document may be changed without notice
Art. No. 356804.103, Issue 3, 2006 JanPublished 2006-01-06
This product is CE marked andcomplies with all current requirementsfor relevant standards and directives.