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351433.0

33

Installation Guide

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Installation Guide Flatpack MicroPower Outdoor Cabinet, Art. 351433.033, v1-2005-08

Page 2 of 28

Information in this document is subject to change without notice and does not represent acommitment on the part ofEltek Energy AS.

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 withoutthe explicit written permission of ELTEK Energy.

Copyright : Eltek Energy AS, Norway 2005NS-EN ISO 9001:1994 Certifcate no: 900005QNS-EN ISO 14001:1996 Certifcate no: 900005E.This product holds a CE mark and satisfies all requirements covering relevant standards anddirectives.

EMC EN61000-6-2 Industrial Environment EN61000-6-3 Residential, Commercial and Light Industry ETS 300386 v1.3.1 Telecommunication Equipment

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

Art. No. 351433.033 Issue 1, 2005 August

Published 2005-08-18

ESB.

Flatpack PSB 3kW, 48VDC (Outdoor Power Cabinet) has part no. 105417

POWER DISTRIBUTION

CENTER FOR

COMMUNICATIONS EQUIPMENT

9N73

Certificate no: 900005ECertificate no: 900005

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Page 3 of 28

TABLE OF CONTENTS

1 DESCRIPTION OF FLATPACK PSB 3KW, 48VDC 4

IMPORTANT NOTICES 4

OVERVIEW GENERAL ARRANGEMENT,INPUT AND DISTRIBUTION ARRANGEMENT 5

BLOCK DIAGRAM 5

ACINPUT TERMINAL BLOCKS 6

DCDISTRIBUTION AND LVBD DEVICE 7

2 INSTALLATION PROCEDURES 8

SAFETY PRECAUTIONS 8

MECHANICAL INSTALLATION 9 Organize the installation site 9 Get the installation tools ready 9 Prepare AC mains supply 9 Remove packaging and check equipment 10 Lifting the cabinet 10 Position and fasten the cabinet 11 Wind resistance 12 Preventing condensation 12 Mount the batteries on the shelf. 13 Fixing point for temperature sensor 13

ELECTRICAL INSTALLATION 14 Cable access for outdoor MicroPower cabinet and battery cabinet 17 Block Diagram 18 About Negative DC Distribution 19

About AC, DC Earthing Systems 19 Rectifier Installation Handles and Locking Mechanism 20 Commissioning 20 Installation and maintenance instruction for filter mat for MicroPowerCabinet 21

3 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS 23

ALARM RELAY SPECIFICATION 23 About Fail-Safe Operation Mode 24 Connections for Internal system wiring 24

TEMPERATURE COMPENSATION SLOPE 25

CHARGING VOLTAGE DEFAULT VALUE 25

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Page 4 of 28

1 Description of Flatpack PSB 3kW, 48VDC

This Installation Guide contains information about how to install the Flatpack PSB 3kW,48VDCsystem, for the outdoor power cabinet (fan cooled).

Important notices

WARNING:

Cabinet must not be lifted using eyebolts when batteries are fittedDEVICE

HAZARD

To be installed only in restricted access areas or the like, inaccordance with articles 110-16, 110-17, and 110-18 of the NationalElectrical Code, ANSI/NFPA 70.

For supply connectors use wires suitable for at least 75C

Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.

Use copper conductors only.

The over voltage protection kit contains a class C protection. This requires an external class B

protection on the systems mains feed.

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Page 5 of 28

FlatpackTelecom

equipment

Telecomequipment

Overview General Arrangement, Input and distribution arrangement

The Flatpack PSB 3kW, 48VDC is a DC power supply system based on the Flatpack 150048V rectifier. The system contains AC terminal blocks, DC distribution, Flatpack Power Rackand Flatpack 1500 rectifier modules. The system is designed for cable entry trough locknutsunderneath. The cabinet size is 590x427x775mm, (23,2 x 16,8 x 30,5) (WxDxH).

Figure 1Flatpack PowerRack SystemGeneralArrangement

Block Diagram

Figure 2. Block diagram.

BTS breaker

Heater Kit

(option)

Battery Shelf OVP Kit(option)

2-pol AC breaker

(option)

Control card withalarm terminalsand LVBD device

Flatpack 1500 rectifiermodules

Temp. Probe

DC distributionRack 1x2u

BTS2*

BTS1

2-pole ACbreaker*

MicroPower

Outdoor cabinet

OVP*

Heater*

Outdoor batterycabinet*

Battery breaker

ACterminalblocks

*Optional Kits

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Page 6 of 28

AC Input Terminal blocks

The AC terminal blocks are factory configured for mains supply type: 230V AC, 1 phase. TheAC DIN rail is designed for mounting of an over voltage protection (OVP) kit and an internal

2-pole AC input breaker. See the respective manuals for further information.

L1 N

PE N L1Figure 3 Example picture AC input terminals, L1 & N with OVP and AC breaker installed.

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DC Distribution and LVBD device

The system is configured for negative distribution. The standard distribution is equippedwith 1 battery breaker (Fb1) and 1 BTS load breaker (F1). The load breaker is a double poletype. If both poles are connected in parallel with the copper fish-plate the breaker will berated at 32A. If the bottom fish-plate is removed and only 1 pole is used for the load, thebreaker is rated at 16A.

Between Fb1 and F1 there is free space for a second BTS load breaker and a terminal blockfor an external battery back-up. Both the second BTS load breaker and the battery terminalblock are options delivered with their respective kits.

See the installation manual for both kits for further info.

TRIP

60A

CBI

I

0

CURVE U2

10 kA

80V

QY-1(13)-D

TRIP

32A

CBI

I

0

CURVE U2

10 kA

80V

QY-2(13)-D

51mm

+ +

Costumer connections

F1

+VE

Fb1

-48VBattery

-48V Load

0V

Load andBattery

BASIC BUILD

Figure 4 DC distribution.

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Page 8 of 28

2 Installation Procedures

This section describes how to install the Flatpack PSB 3kW, 48VDC. A step-by-stepprocedures will guide you through the installation.

For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and controlunit, please refer to the Operation Guides for the respective modules.

Safety Precautions

The equipment described in this manual must only beinstalled by authorized personnel, and only operated bypersons who have attended a suitable Eltek Energytraining course.

The equipment represents an energy hazard and failureto observe this could cause terminal injury and invalidateour warranty.

There are hazardous voltages inside the rectifier system.As the rectifier units incorporate large chargedcapacitors, it is dangerous to work inside the systemeven if the mains supply is disconnected.

Products into which our components are incorporatedhave to comply with a number of requirements.

Installation is to be in accordance with therecommendations herein.

Please read the manual carefully before using theequipment.

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Mechanical Installation

Organize the installation site

Begin preparing the installation site, tools, AC supply cables and fuses, etc

Check that clearances in front and over the cabinet are sufficient for cooling andto facilitate operation and cable entry. Also, ensure that the site is ventilatedadequately in a non-explosive atmosphere.

Get the installation tools ready

Always use insulated tools suitable for telecom installations (screwdrivers,wire cutters, spanner and socket wrenches, etc.)

Prepare AC mains supply

Prepare the following AC input cables and external AC inputbreaker:

TOOLSrecommended tools needed on the

installation of OEM systemsPhillips No.3 Battery shelf

Flat screwdriver 3mm

Flat screwdriver 4,5mm

Flat screwdriver 6mm

All Terminal clamps, screw or springclamps

Flat screwdriver < 3mm Release of rectifiers+ spring connectionsto alarm/controller card

Posidrive No2 (Flat screwdrivers also suited) OVP, BTS and AC fuses

Socket wrench 10mm Common earth and battery poles

NOTE! An external breakeris required on all sites.This must be turned OFFunder all installation.

External AC Fuse & AC Input Cables(Recommended ratings for certain output power values)

AC Mains Type 3.6kW incl usive heater

230VAC, 1 phase 30A C char.2x4sqrmm cable - Max 30m

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Page 10 of 28

Remove packaging and check equipmentEltek Energys products include semiconductors andcircuits which are protected against over-voltage and electro static discharge (ESD), tocomply with applicable parts of the EMC directive. Whenhandling circuit boards, you must use special aids and

handling methods which prevent damage, inaccordance with NS-ISO-9001.

Check that you have received all the parts cabinet, modules,batteries (if applicable), documentation, etc. and inspect them forphysical or transit damages; contact Eltek Energyotherwise. Protectall the parts.

To facilitate transport, standard Flatpack outdoor MicroPowerdeliveries consist of two strong packages on pallets: onecontains batteries, the other the cabinet.

Lifting the cabinetOpen the cabinet door and demount the 2 screws in the front.

Take off the roof.

Fix straps to the eye-bolts. Close the door again so the doordoes not swing during lifting. Lift the cabinet via the straps with

lifting equipment to its intended position. Balance the weight.

Remove the straps and remount the roof once the cabinet hasbeen moved and fixed to its installation position.

CAUTION: The product can be damaged, perform poorly or havereduced lifecycle if exposed to incorrect treatment during transport,installation or servicing.Device

hazard

Special treatment of circuitboards

(ESD-sensitive equipment)

Unscrew these 2screws and takethe roof off.

Eye-bolts.

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Page 11 of 28

Position and fasten the cabinetFlatpack PSB 3kW, 48VDC, Outdoor Power Cabinet has different mountingpossibilities; Pole mounting, Wall mounting and Floor mounting options areavailable. Please refer to the Installation guides for the respective mounting kit.

Pole

Pole mounting kit makes it possible to mount theMicropower OutdoorCabinet to a pole with minimum diameter 60mm and maximum diameter115mm.

Floor

The floor mounting kit is intended for mounting the Micropower OutdoorCabinet to a pad/floor.

480mm

545mm

410,5mm250mm

200mm

505mm

Figure 5 Drilling template floor mounted plinth.

Wall

The Micropower Outdoor cabinet can be mounted to a wall with the wallmounting kit.

Upper wall mount bar

Lower wall mount bar

400mm

505mm

530mm

Hole for wall

Hole for cabinet

160mm

Top of cabinet

85mm

Bottom of cabinet

Figure 6 Drilling template wall mounting kit.

Two M8 screw holesfor fixing thecabinet to the linth

Four M8 holesfor fixing theplinth to the

ground

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Page 12 of 28

Wind resistanceCabinets are tested according to GR 487.

Depending upon the geographic location of a cabinet, exposure to high wind speedwind gusts is often a threat. Unbalanced forces may be applied to pole or wallmounted cabinets resulting in a turning moment. Pole or wall mounted cabinets arecapable of resisting the turning moment resulting from a 67m/s wind gust acting on

half of the front or rear of the cabinet surface, without damage to the mountinghardware.

Plinth mounted cabinets are capable of resisting the overturning moment resultingfrom a wind gust of 67m/s perpendicular to the largest vertical surface.

Preventing condensationCondensation might be a problem in case the cabinet is left unpacked overnightwithout powering it up. In order to avoid condensation put drying agent next tothe system and pull a plastic bag over the cabinet. It is important to cover theroof (air outlet) and the air inlet gills on the door.

The system is packed in a plastic bag at delivery. This bag can be wrappedaround the system. Only fresh drying agent should be put inside. Use tapeand/or rubber bands to tighten the plastic bag to the cabinet.

Figure 7 Cabinet wrapping. Drying agent

Adhesive tape

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Page 13 of 28

Mount the batteries on the shelf.Lift and position the batteries (PRSB system only) on the shelf.Fit the inter-links between the batteries.

Do not terminate the battery cables yet.

Use lifting straps for heavy batteries; Read the site specificdrawings for the type and number of batteries.

Fixing point for temperature sensor

It is recommended to place the temperature sensor in the middle of thebattery bank. Fix the sensor with a cable tie to the inter-link betweenbattery number 2 and 3.

Figure 8. The temperature sensor fixed with a cable tie to the inter-link betweenbattery no. 2 and 3.

Electricshock

WARNING: The batteries represent a major energy hazard. To avoidshort-circuit of battery poles, you must always remove metallic objects uninsulated tools, rings, watches, etc. from the vicinity of thebatteries.

Temperaturesensor

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Electrical Installation

For location of components, see Figure 1 -page 5.

Installation Comments OK

1. PREPARATIONTo ease access to the DIN rail, located at the bottom of the OutdoorMicroPower cabinet, it might be necessary to remove the factorymounted battery shelf.

Remove four PAN screws minding the nuts for square hole inrack.

Pull battery shelf out.

2. CABLE ENTRYCable entry is from bottom of cabinet. See Figure 9. The cableglands are mounted the wrong way in order to avoid transportdamages to them.

Demount all the cable glands and mount them the correctway.

Remove the metal disc in the cable glands to be used. Leavethis metal disc in all un-used cable glands in order to ensurefull IP protection.

Make a cut in the rubber sealing inside the glands. Make thecut smaller than the cable diameter. See picture to the left.

Pull the cables through the glands. All cables should bepulled at least 10mm too far inside the cabinet and then bepulled a little bit back again. This will lock the cable in thegland and ensure full IP protection.

Cut along thedashed lines

Cable gland

WARNING: Opening the equipment may cause terminal injury even if

the mains AC supply is disconnected. Hazardous voltages may bepresent inside, as large capacitors may still be charged. Electric

shock

CAUTION: For safety reasons, the commissioning and configuration of the equipment

is only to be performed by Elteks personnel or by authorized and qualified persons;

otherwise the warranty may be invalidated.

Please, read the user documentation carefully before installing and using the equipment,

as installation and operation is to be performed as described.

Qualified

personnel

Pre installation Post installation

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Page 15 of 28

3. ACCONNECTIONS Switch OFF the AC input power (external MCB), before

connecting the mains cables.

Connect the external AC ground wire (min. 4 mm/max. 10mm)to the mains Protective Earth (E) terminal block.

Connect the AC cables (min. 4 mm/max. 10mm) to theterminal blocks. Do not power up the system until the wholeinstallation is complete.

Mains input

282/284

WAGO

281/282

L1

L1

282/284

WAGO

281/282

N N

PE L N

E

4. LOAD CONNECTIONS Turn OFF the Load/BTS MCB.

Customer connection is at the bottom of all MCBs. Connect theload cable to the double pole breaker F1. For 35A load connect tothe cable to the copper link. For 16A load remove the copper linkand connect the cable to either of the F1 poles.

-48VBattery -48V BTSLoad

0V Loadand Battery

TRIP

60A

CBI

I

0

CURVE U2

10kA

80V

QY-1(13)-D

TRIP

32A

CBI

I

0

CURVE U2

10kA

80V

QY-2(13)-D

+ +

F1

+VE

Fb1

5. BATTERY CONNECTIONS Connect the loose end of the battery cables to the battery

terminals; blue cable to the negative terminal and black cable tothe positive terminal.

Connect all battery inter-links. Fix the temperature sensor to thebattery bank. For location of temperature sensor see `Fixing

point for temperature sensor` Figure 8.

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COMMISSIONING Comments

6.POWER UPSwitch ON external (and internal, if additional AC breaker kitis installed) AC breaker. Measure and verify that the AC inputvoltage is correct.

7.MOUNT ALLRECTIFIER MODULES

IN THE POWER

SHELVES

Make sure that rectifiers are firmly plugged in, and all handlesin locked position. Ensure all rectifiers are ON and no alarmsare present.

8.TURN ON THE LOADBREAKER

Measure and verify that the output voltage is correct.

9.TURN ON THEBATTERY FUSES

Check that the batteries are connected correctly beforeturning the battery breaker on.

MAINTENANCE Comments

10.VERIFY THAT THEEQUIPEMENT IS FREE

FROM DAMAGE, DUSTOR DIRT

Carefully vacuum clean or remove any accumulation of dustcorrosion or dirt. Especially notice to clean the grill in front ofthe filter mat. See Installation and maintenance instructionfor filter mat for MicroPowerCabinet.

11.ALL CABLING ANDCOPPER BARS ARE

SECURELY

TERMINATED AND

SUPPORTED

Correct any loose connections, excessive cable temperature,defective insulation, etc.

12.ALL RECTIFIERMODULES ARE ON,NO ALARM PRESENT

Replace faulty rectifiers.

13.RECTIFIERS LOADCURRENT SHARING

Verify that the LEDs illuminated on each rectifiers bar graphare equal (1LED).

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Page 17 of 28

Cable access for outdoor MicroPower cabinet and battery cabinet

Figure 9 View on inside of cabinet base

APPLICATION POWER CABINET BATTERY CABINET

AC input HOLE E1, CABLE DIA 13.0 TO20.0mm

FOR 3X4.0mmSQ OR 3X6.0mmSQ

HOLE J1, CABLE DIA 9.0 TO 16.0mm

FOR 3X2.5mmSQ

BTS1 HOLES G1 &G2, CABLE DIA 5.0 TO10.0mm ------

BTS2 HOLES G3 &G4, CABLE DIA 5.0 TO10.0mm ------

BATTERY HOLES F2 &F3, CABLE DIA 7.0 TO12.0mm HOLES F2 &F3, CABLE DIA 7.0 TO12.0mm

ALARM HOLES G5, CABLE DIA 5.0 TO10.0mm ------

GROUND HOLES F1, CABLE DIA 7.0 TO12.0mm HOLES F1, CABLE DIA 7.0 TO12.0mm

DC CONTROL HOLES H1 & H2, CABLE DIA 2.0 TO 5.0mm HOLES H1 & H2, CABLE DIA 2.0 TO 5.0mm

SPARE HOLES E2 & E3, CABLE DIA 13.0 TO 20.0mm HOLES E2 & E3, CABLE DIA 13.0 TO 20.0mm

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Page 18 of 28

Block Diagram

Figure 10. Block diagram of Micropower Outdoor Cabinet with all options installed.

Alarm

Interface

Board

PENL

OVP

(option)

12

11

10987654321

Flatpack

PowerSystem

L PE

N

+ -

Mains

Input

16

15

14

13

FAN

T

Temperature

sensor

+ -

2polemains

inputbreaker

(Option)

L PE

N

+ -

LVBD

BatteryHeater

(option)

C

OM3(RJ45)

19

18

17

J1(RJ45)

8

4321

Con4

Con1

4321

Con6

N

L

In-line

fuse

F2

F1

+VE

(option)

Fb1

-Ext.batt

+Fan

-Battery

-ExternalBattery

-BTS2

-BTS1

+Battery

+BTS1

+BTS2

Fext2

-Fan

-DCsupplyext.

+DCsupplyext.

+ExternalBattery

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Page 19 of 28

About Negative DC Distribution

About AC, DC Earthing Systems

The AC earth is connected to the systems chassis. Also the positive DC output from therectifiers is connected to chassis. If required this DC earth connection to chassis can beremoved in order to separate AC earth and DC earth. All DC outputs must then beconnected to Telecom earth (TE).

Figure 11

In 48VDC power supply systems for Telecomequipment, it is common practice to use a positive DC

rail as a common positive output. On the other hand,the negative DC outputs are distributed over allload breakers/fuses. This practice is denominated asNegative DC Distribution.

Negative DCDistribution

CommonDC Rail +

DC

Load

wires

PE (Protective Earth)TE (Telecom Earth)

EG (Exchange Ground)

Flatpack PSS

PE

AC Mains EG

.

AC Mains

In ut

DC Load

Circuit

Link 2

DC Earth

Link 1

(AC Earth)

TE

Chassis

Chassis

Common

DC Rail

Common earth

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Page 20 of 28

Rectifier Installation Handles and Locking Mechanism

The Flatpack 1500 rectifier module is equipped with handles that serve two purposes:

1.1.1.1 Locking the module into position

Open both handles, insert and plug the module into powershelf. Then lock it into position by rotating the handles upwardsand pushing them firmly home; failure to do so will prevent themodule from making proper contact.

Figure 12 Module with released handles

1.1.1.2 Pulling the module out

Unlock and release the handles by insertinga small screwdriver into the upper holes,thus releasing the spring mechanisms. Donot use excessive force. The handles willrelease and pop out. When both handles arereleased, use them to pull the module out.

Do not hold or carry the rectifier by itshandles.

Figure 13Releasing the module handles

Commissioning

For information regarding system commissioning, please read manual Quick Start GuideFlatpack PS System, art.no. 356803.103.

Handle in locked position

Upper hole torelease the spring

mechanism

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Page 21 of 28

Installation and maintenance instruction for filter mat for MicroPowerCabinet

1. Open the front door of the cabinet by operating the swing handle.

Figure 14. Door with filter

2. Pull the filter mat out of the rectangular aperture at the inside of the front door.

Figure 15. Pull out the filter

3. Fit the filter mat into the aperture in the opposite way of item 2.

Figure 16. Fit the new filter

Please consider the right direction of the filter. The side with thehigher density (harder surface) is to fit towards the door side and is notvisible to the user.

Figure 17. Direction of filter.

Wrinkled surface towardsthe door.

Smooth surface visiblefrom inside of door.

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Page 22 of 28

Make sure that the grill in front of the filter is free from damage,carefully vacuum clean or remove any accumulation of dust and dirt.

The filter should be replaced by a new one with same density and materialquality (EU5 grade acc. to EN 779, Eltek part nr.200892).

Under normal operational conditions (normal industrial pollution) werecommend to change the filter on a yearly period.

Under ambient conditions with high pollution and near the coast werecommend to change the filter twice a year or shorter.

The pollution of the filter can be detected by durable increase of the internalcabinet temperature without any failure of the fan or/and the change of thecolour of the mat from white to grey/dark grey.

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Page 23 of 28

3 Alarm Relay Outputs and Signal Connections

The alarm relays are operated in fail-safe, i.e. the relays are energized when there is noalarm. If several external devices are going to the same digital input, they must beconnected in series.The description below describes the pin out in normal state, i.e. the NO output is open in

normal operation and shorts to the COM output in the alarm-state.

Alarm relay specification

Figure 18. Alarm relay outputs

CON 4 Pin Assignments For Analog Controller card- Micro Power

Pin Signal Function Pin Signal Function

1

2

3

NO

Com

NC

Relay 1:

Low Voltage Alarm

420,5Vdc

10

11

12

NO

Com

NC

Relay 4:

Low Temp Alarm

Below -5C 1-2C

4

5

6

NO

Com

NC

Relay 2:

Module Fail Alarm

13

14

15

NO

Com

NC

Relay 5:

Mains abnormal alarm

Below85Vac or above 300Vac

7

8

9

NO

Com

NC

Relay 3:

High Temp Alarm

Over 40C 1-2C

16

17

NO

Com

Relay 6:

LVBD Control

Disconnect at 390,5Vdc

18

19

NO

Com

Relay 7:

Fan Control

Fan ON: +25C 1-2C

Fan OFF: +18C1-2C

Nominal switching capacity 2A/30V DC

Maximum switching power 60W (resistive load)

Maximum switching voltage 220V DC

Maximum switching current 2A DC

CON 41-15 alarm relays 16-19 Control relays

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Page 24 of 28

About Fail-Safe Operation Mode

All Flatpack PSS alarm outputs use the Fail-Safe Operation Mode (relay coils energizedin the systems normal operation mode). In order to implement fail-safe digital inputscircuits, the external relay coil must be energized and the contact closed in thesystems normal mode of operation.

Figure 19

Connections for Internal system wiring

Figure 20

Correct Use of Alarm Outputs (example)

+

-

NO

Relay X(De-energized coil)

Alarm

CON 6 Pin Assignments

For Analog Controller card- Micro Power

Pin Signal Function

1

2

+

-

Temperature Probe

Red

Blue

3

4

+

-

System Voltage

Red

Blue

CON 1 Pin Assignments

For Analog Controller card- Micro Power

Pin Signal Function

1

2

L

N

AC Mains

3

4

N

L

Heater Control

Heater ON: +5C

Heater OFF: +15C

NC

COM

+

-NO

Relay X(Energized coil)

Normal

NC

COM

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Page 25 of 28

Temperature compensation slope

The MicroPower alarm interface board controls the battery charging voltage according to theambient temperature measured by the temperature sensor. The charging voltage dropswhen the temperature rises in order to protect the batteries from damage.

0C 10C 20C 30C 40C 50C 60C

48V

50V

52V

54V

56V

58V

Chargevoltage

Ambient temperature

-10C

Figure 21. Temperature compensated battery charging.

Charging voltage default value

Charging voltage default value is set to 54,48VDC at 20C, with slope 96mV/C (4mV/Cper cell).

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Main Office:

Eltek Energy AS

P.O. Box 2340 StrmsN-3003 DRAMMENNorway

Phone: 47 32 20 32 00Fax: 47 32 20 32 10

E-Mail: mailto:[email protected]

[email protected]

Internet: www.eltekener .com

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