qstart-installation-operation-commissioning and maintenance
TRANSCRIPT
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
1/28
Quick Start GuideInstallation, Operation, Commissioning and Maintenance
DC Power Supply SystemIntegrated, Cabinetized and Outdoor Applications
Flatpack2, PS System
356804.103
MiscellaneousCommunicationo CAN Bus Termination ( 9)o Installing PowerSuite PC software ( 9)AC Mainso 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 Monitoringo Battery Symmetry Connections (16 )o Terminals & Pin-out Location, Battery Interface Card ( 17)Alarms & Monitoringo 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)
Introductiono The Flatpack2 Product Range (2 )o Brief System Description (2 )
Installationo Installing Smartpackand Rectifier Modules ( 3)o Installation steps; mechanical, electrical (4-5)
Commissioningo Pre-start check (6 )o Commissioning steps, Startup (6-7)
Operationo Front keys and display ( 8)o Software Menus ( 8)
Check Lists pullout formso Installation Check Listo Circuit Distribution Listo Commissioning Procedureo Maintenance Procedure
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
2/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-012
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 powersystem 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 partof the system.
Introduction
Flapack2System, Integrated4U and 1U Distributions
Flapack2System, Cabinetized Flapack2SystemOutdoorCabinet
Flatpack2Cabinetized
Battery string #1
AC mains
supplyselector
SymmetryAlarm &
Temp. Sensor
LVLD
LVBD
Fuse Alarm
AC Fuses,external
(230VAC or400VAC
Telecomequipment
AC Supply(Single- or
three-phase)
Alarm Outputs NC-C-NODigital Inputs
BatteryFuses
Load Fuses& MCBs
Smartpack(Ctrl. Unit)
Flatpack2(rectifiers)
PowerSuiteApplication
CAN Bus
USB cable
DCdistribution
DC Supply(24V, 48Vor 60V*)
*Available from 2006
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
3/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 3
Installing Smartpackand Rectifier Modules
Installation
Handle inunlocked position
Flatpack2rectifier
Smartpackcontroller
Handle in locked position
Hole to release thehandles springmechanism
Removing Blind Panels
1. Release the panels upper left and right corners byinserting a small screwdriver into the panels 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 byusing you hand to pull the panel loose
Mounting Blind Panels
1. Insert the panels upper edge bypressing gently so that its upper locking tabs engage
2. Lock the panels lower edge bypressing with your hand so that the blind panels lower tabs lock
into position.
Screwdriver torelease the lockingtabs
Blind panels upperlocking 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 Smartpackand Flatpack2Modules
Note that cables are plugged to the Smartpacks rear panel. When
mounting the controller, you must plug the cables before step 2. When
removing it, unplug the cables duringstep 2.
1. Unlock the handles byinserting 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 makesproper contact (forSmartpack, 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 Smartpackmodule
3. Lock the handles bypushing 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
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
4/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-014
Installation Steps
Installation
Check off in theInstallation Check List, that you find in the pullout section of
this folder. Also, refer to the systems 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 topo 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 AccessLocations (RAL)
2 Prepare the installation tools
o Use insulated tools suitable for telecom installations3 Prepare AC Supply: AC input cable(s) and fuses
o Correct type AC supply is availableo External AC fuses have correct ratingo AC input cable(s) are sized correctly
EMCregard
200 mm
600 mm
For external AC fuses and AC input cable ratings, refer to your sites AC
supply specification. Read also ourexternal AC fuse recommendations
in 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 locatedbehind the upper dummy panels
o Battery shelves (if any) are placed behind the lower panels6 Position and fasten the cabinet or subassembly
o Cabinets are floor-mounted on levelled surface. Adjust the legs ifnecessary. 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 upwardso Do not terminate the battery cables yet!
Electricshock
Devicehazard
Flatpack2PSS, batteries, Doc.Chart, Spec. Drawings, CD-ROM
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
5/28
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 systems specific drawings)
8 Make the system completely voltage free
o Switch OFF or remove all load fuses (MCB1, MCBx), batteryfuses (Fb1, Fbx) and the AC supply fuses, in external fuse
boards
9 AC Connections
o Check AC configuration: the AC terminals are correct configuredto 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 Circuitso 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 DCoutput rail, and the other directly to the MCB or load fuse
11 DC Connections Alarm & Signal Circuits
o Refer to your systems connection drawings and configuration, orto the Miscellaneous, Alarms & Monitoring section (Factory
Settings)
o Terminate Alarm Circuit cables to the relay output terminalso 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 shelfs 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 viaPowerSuite
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) OuterTerminal
+0V OuterTerminal
Link 2(DC Earth)
CommonDC RailEGBattery
Fuse
Intercell Links
BatteryCable S
ym
metry1
2-1
Chassis
Card Art.200576
+-
15 pins D-Sub(male)
Temp.sensorT
emp.Sensorcable1
Block1
- ++-+-+-
Block4Block3
Electricshock
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
6/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-016
The commissioning ofFlatpack2 PS System consists of following stages:
I. Perform a pre-start check before the PS system is switched ONII. 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 theFlatpack2 PSsystem, verify the following:
1. System installation is completedo Ensure a correctly performed system installation, with correct polarity on all
connections, has been carried out (Installation Check Listfilled in)
o All cabling and copper bars are securely terminated and supportedo All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
2. Battery and load fuses are disconnectedo Verify that all battery and load MCBs/ fuses are switched OFF or removed
3. AC input cable(s) and AC Earth wire (PE) are terminatedo Make sure that the AC input cable(s) are connected to correctly configured AC terminalso Verify that the AC input cable(s) and external AC fuses are sized and rated as specifiedo Check that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)
4. Site specific parameters and settings are knowno Read the system specific drawings and documentation
5. AC supply and all MCBs, fuses are switched OFFo 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 thenmeasure 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 IfFlatpack2 rectifier modules are installed, unlock the handles and pull themodules partially out (fan housing visible), but do NOT physically remove them
from the power shelves
o IfFlatpack2 rectifier modules are not yet mounted, release their handles and insertthem partially into the correct position in the shelves
2. Switch ON the systemo Switch ON the AC input supply (external AC fuses) to the PS cabinet
3. Measure and verify that theAC input voltage is correcto Measure the AC input voltage at the cabinets mains connection boxo Verify the AC voltage is within range
Commissioning
Devicehazard
Device
hazard
I
II
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
7/28
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 theSmartpackand all rectifier modules are working: LEDs are ONo Verify correct operation, by monitoring the modules LED lamps and display:
No alarms are present on rectifiers; The Smartpackdisplays 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 Smartpackcontrollero StartPowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite
Refer to chapter InstallingPowerSuitePC Application, page 9, if required
o On the toolbar, click the Connect button to establish connection
7. Measure and adjustDC output voltageo Read the DC output voltage on the controllers displayo 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 MCBso If required, adjust the voltage using the controllers front keys or viaPowerSuite
8. Verify the alarm relays are working correctly (alarm relay test)o Run the alarm relay test using the controllers front keys (refer to page 8) or via
PowerSuite (select the menu Go > Output Test)
9. Make sure theSystem Setup is in accordance with configurationo Verify system settings using the controllers front keys or viaPowerSuiteo 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.AdjustDC output voltage to equal measured battery voltageo Measure the battery voltage is within range (check connections have correct polarity)o Adjust DC output voltage using the controllers 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 partiallyout (fan housing visible). Do NOT physically remove them from the power shelveso Switch ON all battery fuses or MCBs
12.Adjust DC output voltage again to equal the nominal battery voltageo Adjust DC output voltage using the controllers front keys or viaPowerSuite 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 IIo Wait for about 2 min., and check using thePowerSuite 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 displayedo Switch ON all load MCBs/ fuseso Verify correct operation: rectifiers and controller display no alarms
Devicehazard
Devicehazard
III
Commissioning
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
8/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-018
Front Keys and display, menus, etc.
Operation
Flatpack2Rectifier Module front panel
Power LED is OFF (mains unavailable), Flashing
(controller accessing information) orON (powered).Warning LED is ON (derating or similar minor
warning), Flashing (over-voltage mode) orOFF (OK)
Alarm LED is ON (shutdown or similar major alarm)
orOFF (OK, no alarm)
Flatpack2rectifier
AlarmLED Lamp (red)
PowerLED Lamp (green)
WarningLED Lamp (yellow)
Software Menus
Service menu
NomVolt BoostVolt LowBatt1
oltAdjustment LowBatt2 HighBatt1 HighBatt2 LVD 1 LVD 2
oltCalibration ------ VoltCal
ChangePassword -- Password SetBoostTime--------
Start/StopBoost
Auto Boost Conf. -- Enable/Disable & AutoBThrs
Nxt Test DateTimeEnd 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 / TempCompChange Date/Time
Alarm Output 1RelayTest Alarm Output 2
Batt Contactor
Load ContactorAlarm Output nnBattLifeTime Rst 1v0
Level 2 Level 3
TheX
vXreferences,
ifany,ontherighthandoftheoption,arenotshowninthedisplay.
Theyo
nlyindicateinwhichsoftwarevesjon(x)theoptionwas
firstimplemented.
SmartpackControl Unit front keys, display, etc
Display: is in Status Mode (displays the systems
status) or inMenu 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 enterMenu Mode (Level 1), you
access the User Options. You may also scroll down to
password protected Service Options. Default password
should be changed.
User menu
AlarmResetNomVoltBoostVoltLowBatt1
VoltageInfo LowBatt2HighBatt1HighBatt2LVD 1
LVD 2DisplayMessages Message SoftwareInfoSerialNumber 1v01
NoOfRects. NnRectCurrent 1v0
Rectifier Info RectSerialNumber 1v0
Rect.PrimaryVolt 1v0
Rectifier Status 1v0
Rectifier Temp 1v0
NoOfPhases nnMains Info Mains Status
Mains VoltageTemp Level Info - Level 1v0
Level 2 Level 3
TheXvXreferences,
ifany,ontherighthandoftheoption,arenotshowninthedisplay.
Theyonlyindicateinwhichsoftwarevesjon(x)the
optionwasfirstimplemented.
PowerLED Lamp (green)
WarningLED Lamp (yellow)
Alarm
LED Lamp (red)
Graphical
Display16 char. x 2 linesLCD display
Up arrow keyDown arrow key
Enter keyUSB0ype B port
Smartpackcontrol unit
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
9/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 9
CAN Bus TerminationFlatpack2 systems are shipped from factory with the CAN bus already terminated with 120resistors.
To ensure a correct bus communication and avoid data reflection, you must always terminate
the CAN bus with two 120 resistors, one at each end of the line. The figure shows aFlatpack2system communicating via the CAN bus.
The Smartpackdynamically 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 Smartpacks ID numbers (1, 2) are assigned by DIP switches on the controllers side.
Terminate the CAN bus with only two 120 resistors, one at each end of the line. The figureshows twoFlatpack2 systems communicating via the CAN bus.
Installing PowerSuitePC ApplicationThePowerSuite software application enables you to configure and operate theFlatpack2 Power
Supply System from a personal computer.
Communication Miscellaneous
120
Flatpack2DC Power System
End-of-LineResistor
End-of-LineResistor
120
CAN bus(twisted-pair internal CAT5 cable)
USB A-B cable(standard)
01 02 n
1
120
Flatpack2DC Power System 2
120
Flatpack2DC Power System 1
End-of-LineResistor
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 twiceNew hardware
is ready to use
3
IfPowerSuite 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).
PowerSuites newest version is always available on our FTP server. Call your Elteks contact person.
Flatpack2system configuration from a PC running MS Windows XP
2. Switch SmartpackON and plug USB cable (Part 202073)to Smartpackand to any available USB port in the PC 2
1. Install PowerSuiteInsert the CD in your PC drive, start the PowerSuite installation and follow & accept the wizard default steps toinstall .Net software and PowerSuite
1
4. Start PowerSuite and establish connectionSelect Start > All Programs > Eltek > PowerSuite. On the toolbar, click Connect button. On the Connectiondialogue box, click the Connect button
4
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
10/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-0110
External AC Fuses Recommended RatingThe sites AC supply quality is of great importance. In general, a site with better AC supply
quality (stable nominal voltage) may use smaller breakers.
205V
ACInputs
AC Mains No of Power Current Ext. FuseType Shelves Max. (A) Type
1 21.6 25A-C2 43.1 50A-C3 43.1 50A-C
400VAC +N3 phase
4 64.7 80A-C
1 37.4 40A-C
2 56.1 63A-C
3 74.8 80A-C
230VAC3 phase
4 112.2 125A-C
1 43.0 50A-C230VAC1 phase 2 86.0 100A-C
2ACPowerShelves
2ACinputspershelf,each
feeding2rectifiers
AC Mains No of Power Current Ext. FuseType Shelves Max. (A) Type
1 21.6 25A-C400VAC +N3 phase 2 32.3 40A-C
1 29.5 32A-C230VAC3 phase 2 56.1 63A-C
1 43.1 50A-C230VAC1 phase 2 86.2 100A-C
4ACPowerShelves
4ACinputspershelf,each
feeding1rectifier
185VA
CInputs
4ACPowerShelves
4ACinputspershelf,each
feeding1rectifier
AC Mains No of Power Current Ext. FuseType Shelves Max. (A) Type
1 23.9 25A-C400VAC +N3 phase 2 35.8 40A-C
1 32.7 40A-C230VAC3 phase 2 62.1 63A-C
1 47.8 50A-C230VAC1 phase 2 95.6 100A-C
2ACPowerShelves
2ACinputspershelf,each
feeding2rectifiers
AC Mains No of Power Current Ext. FuseType Shelves Max. (A) Type
1 23.9 25A-C2 47.8 50A-C3 47.8 50A-C
400VAC +N3 phase
4 71.7 80A-C
1 41.4 50A-C
2 62.1 63A-C
3 82.9 100A-C
230VAC3 phase
4 124.3 125A-C
1 48.0 50A-C230VAC1 phase 2 96.0 100A-C
External AC FusesRecommended Ratings
1AC Feed to 1 Flatpack2rectifier
AC Mains Ext. Fuse TypeType FS=I FS=0
185VAC 25A-C 13A-B
205VAC 25A-C 10A-B
FS=I (Fuse Selectivity: Internal)which means that the Flatpack2rectifiers internal fuse will trip be-fore the external AC fuse.
FS=0 (Fuse Selectivity: none) thesefuse types may be used when it isirrelevant whether the internal orthe external fuse trips first.
Note: Always replace a rectifier
with blown internal AC fuse with anew module, and send the mal-functioning module for servicing.
Miscellaneous AC Mains
Use the recommendations in the205VAC table, if you are sure theavailable AC mains voltage will notdrop below 205VAC.
OR
If you are unsure or know thatthe voltage may drop below
205VAC
use the 185VAC tablerecommendations.
Only difference between the 205 and the185VAC recommendation tables
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
11/28
PULLOUT
CheckL
istsPullout
Pulloutthepagesw
iththegrayouterba
nd,
andusethe
maschecklists
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
12/28
INSTALLATIONCHECKLIST
SystemDataFlatpack2PSSystemFlatpack2PowerSupplySystem,type:ArticleNo.:
Site,name:
SerialNo.:Software,versionNo.:Rectifiers,type&numberof:
ACInputVoltage,measured:BatteryType:BatteryCapacity:Installationcarriedoutby,name:
SitePreparations
CARRYOUTFOLLOWING:OK1.Organizetheinstallationsite
oCheckmin.clearancesforcabinetaccess:frontaccess,60cm,topaccess,20cmoCheckthatthelevelledsurfaceisabletosupport600kg(cabinetizedsystems)oEnsuretheinstallationsiteissuitablyventilatedandinanon-explosiveatmosphere.60VsystemsinRALareas
2.PreparetheinstallationtoolsoCheckthatinsulatedtoolssuitablefortelecominstallationsareused
3.PrepareACSupply:ACinputcable(s)andfusesoChecktheACsupplyisthecorrecttype,andthattheexternalACfusesandACinputcable(s)aresuitablyrated
MechanicalInstallationPowerisOFF!
CARRYOUTFOLLOWING:OK4.Removepackagingandcheckequipment
oCheckyouhavereceivedalltheparts,correctcabinet,documentation,batteries(ifapplicable),etcoInspecttheequipmentforphysicaldamage(reportanydamages)oLeaverectifiermodulesintheirpackagingorintheselves,iffactoryinstalled.(commissioningtask)
5.Removetopcoveranddummyfrontpanels
oCheckthatcableentryfromthetopispossible
6.PositionandfastenthecabinetorsubassemblyoCabinetsonlevelledsurface,adjustthelegs.Ifnecessary,unscrewthelegsandfastenthecabinettoflooroSubassembliesinexisting19orinETSIcabinets,usingbrackets.Mountthesupport&heatdeflectingplate
7.MountthebatteriesontheshelvesoStart(ifapplicable)onthelowershelffirst,andcontinueupwardsoDonotterminatethebatterycablesyet!
ElectricalInstallationPowerisOFF!
CARRYOUTFOLLOWING:OK8.Makethesystemcompletelyvoltagefree
oSwitchOFForremoveallloadfuses(MCB1,MCBx),batteryfuses(Fb1,Fbx)andexternalACsupplyfuses9.ACConnections
oCheckACconfiguration:TheACterminalsarecorrectconfiguredtotheexternalACsupplyoConnecttheACEarthwire(PE)totheterminalsACEarth(PE)oConnecttheACinputcable(s)totheterminals.Cableandterminalblocklabelingaretocorrespond
10.DCConnectionsLoadCircuitsoTerminateDCEarth(TE):CommonDCOutputRailisconnectedtoTEatonlyoneplaceoForeachDCload,connectoneofthecablestothecommonDCoutputrail,andtheotherdirectlytotheMCB
11.DCConnectionsAlarm&SignalCircuitsoRefertoyoursystemsconnectiondrawingsandconfiguration,ortotheFactorySettingsintheQuickStartGuideoTerminateAlarmCircuitcablestotherelayoutputterminalsoTerminateSignalCircuitcablestothedigitalinput/outputterminals
12.DCConnectionsBatteryCablesCareful!Usecorrectpolarity.Foreachbatteryshelf,
oMount3intercelllinkstoconnectinseries4batteryblocksoConnectbatterycablestofusesandcommonDCrail,andtotheshelfsouterterminals;black(+);blue(-)
oConnectbatterysymmetrycables,ifapplicable,totheinputterminalsoConnectthetemperaturesensorcable,ifapplicable,totheD-Subplugorinputterminal,andfixthesensor(atthe
endofthecable)toasuitableplaceinthemiddleoftheinstalledbatterybank
ApprovalResponsibleofinstallation,sign.:Date:Approvedbycustomer,sign.:
EMCregard
Electricshock
Devicehazard
Electricshock
Form17
3-g
b-v1-C
01
_356804
-103_qstart-in
st-comm-o
per_fla
tpack2-p
ss.d
oc_
mfm_2
006-01-0
6
EltekEnergyASTel.+4732203200
Internet:www.eltekenergy.comE-Mail:[email protected]
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
13/28
CIRCUITDISTRIBUTIONLIST
SystemDataFlatpack2PSS,type:ArticleNo.:
Site,name:
CIRC.NO.FUSEKNIFE
TYPEMCB
LVLDCONTROLLED
DESCRIPTIONFUSEAMPERE
CABLEmm
2
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
LOAD
BATT.
Form172-g
b-v2-C
01
_356
804-1
03_qstart-in
st-comm-o
per_fla
tpack2-p
ss.d
oc_mfm
_2
006-01-0
6
EltekEnergyASTel.+4732203200
Internet:www.eltekenergy.comE-Mail:[email protected]
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
14/28
CIRCUITDISTRIBUTIONLIST
CIRC.
NO.
FUSEKNIFE
TYPEMCB
LVLDCONTROLLED
DESCRIPTIONFUSEAMPERE
CABLEmm
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.
LOAD
EltekEnergyASTel.+4732203200
Internet:www.eltekenergy.comE-Mail:[email protected]
Form172-g
b-v2-C
01
_356
804-1
03_qstart-in
st-comm-o
per_fla
tpack2-p
ss.d
oc_mfm
_2
006-01-0
6
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
15/28
Form171-g
b-v2-C
01
_356804-1
03_qstart-in
st-comm-o
per_fla
tpack2-p
ss.d
oc_mfm
_2
006-01-0
6
EltekEnergyASTel.+4732203200
Internet:www.eltekenergy.comE-Mail:[email protected]
WARNING:Maintenanceworkonliveequipmentisonlytobeperformedbyauthorizedandqualifiedpersonsusinginsulatedtools.Hazardousvoltagesinsidemaycauseterminalinjury. Electric
shock
MAINTENANCEPROCEDURE
SystemDataFlatpack2PSSystemFlatpack2PowerSupplySystem,type:ArticleNo.:
Site,name:
SerialNo.:Software,versionNo.:Rectifiers,type&numberof:
ACInputVoltage,measured:BatteryType:BatteryCapacity:Maintenancecarriedoutby,name:
SystemInspectionPowerisON!CARRYOUTFOLLOWING:OK
1.Sitespecificparametersandsettingsareknown.Usermanualsandsitespecificconnection&arrangementdrawingsareavailable.
2.Thebatterybankhasbeenfullychargedinadvance.Atleastfor12hourssincestart-upormainsfailure.Enablescorrectmeasurements&calibration
3.Theequipmentisfreefromdamage,dustordirt;verify.Carefullyvacuumcleanorremoveanyaccumulationofdust,corrosionordirt.
4.Allcablingandcopperbarsaresecurelyterminatedandsupported.Correctanylooseconnections,excessivecabletemperature,defectiveinsulation,etc.
5.TheSmartpack&allrectifiermodulesareON,noalarmpresent;verify.Otherwise,correctandputthePSsysteminnormalmodeofoperation.
6.Allrectifiersfunctionality&SmartpackskeysanddisplayworkOK;verifyCorrectpossibleabnormalitiesbeforecontinuing.
7.ConnectthePSsystemtoaPC(installthePowerSuiteapplicationifrequired)ThePowerSuiteprograminthePCenablessystemconfigurationfromthePC.
8.Rectifiersloadcurrentsharing;verify.UsethePowerSuitePCapplicationtocheckallrectifiersoutputthesameamountofcurrent(1A)
9.DisplaythestoredlogofAlarmMessages.UsingthekeypadontheSmartpackcontrollerorfromthePC.
SystemAdjustmentCARRYOUTFOLLOWING:OK
1.DCOutputVoltageCalibration;ensurecorrectdisplayreadings.IfmeasuredDCoutputvoltageattheloadterminalsdeviatesmorethan1%fromthedisplayreading,calibratetheoutputvoltagefromtheSmartpackskeypadorthePC.
2.Load&BatteryCurrentCalibration;verifycorrectdisplayreadings.Measurewithaclip-onammeterthebatterycurrent&everyloadcircuitcurrent.Calculatethetotalload&battery
current.Ifthecalculatedtotalvaluesdeviatemorethan1%fromthedisplayreadings,calibratethecurrentfromthePC(calibrationvalue>50%ofsystemsmax.capacity)
3.DCOutputVoltageAdjustment;measureandadjust.Measureand,ifrequired,adjusttheoutputvoltagetothenominalvoltagerecommendedbythebatterymanufacturer.(VoltagemeasurementstobedoneattheDCrail,withlittleloadcurrent)
4.AlarmRelayTest;verifyallalarmrelaysareworkingcorrectly.FromtheSmartpackskeypadorPCusetheRelayTestfunction;verifyactivationofexternalequipment
5.Batterybankcontrol;measureandverifybatteryspecifications.Followtherecommendationsoftheactualbatterymanufacturer.
ApprovalResponsibleofmaintenancecontrol,sign.:Date:Approvedbycustomer,sign.:
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
16/28
PULLOUT
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
17/28
COMMISSIONINGPROCEDURE
SystemDataFlatpack2PSSystemSuppliersOrderNo.:Flatpack2PowerSupplySystem,type:ArticleNo.:
Site,name:
SerialNo.:Software,versionNo.:Rectifiers,type&numberof:
ACInputVoltage,measured:BatteryType:BatteryCapacity:Commissioningcarriedoutby,name:
Pre-StartCheckPowerisOFF!
CHECKFOLLOWING:OK1.Flatpack2systeminstallationiscompleted;TheFlatpack2InstallationCheckListisfilledin.
Allcablingissecurelyterminatedwithcorrectpolarity
2.AllbatteryandloadMCBs/fusesaredisconnected
3.ACinputcable(s)andACearthwire(PE)areterminated
4.Sitespecificparametersandsettingsareknown
5.ACsupplyandallMCBs/fusesareswitchedOFF
Start-up,No-Load&LoadAdjustmentsPowerisON!
CARRYOUTFOLLOWING:OK1.Disconnectallrectifiermodules,withoutremovingthem(keeporiginallocation)
2.SwitchONthesystem(externalACfusesON)
3.ACinputvoltageiscorrect;Measureandverify
4.InsertallFlatpack2rectifiersintheiroriginallocationsinthepowershelves
5.TheSmartpackandallrectifiermodulesareworking,LEDsareON;Verify
6.ConnectaPCtothePSsystemInstallthePowerSuitesoftware,ifrequired
7.DCoutputvoltage;Measureandadjust
8.Alarmrelaytest;Verifyallalarmrelaysareworkingcorrectly
9.SystemSetupisinaccordancewithconfigurationEntersitespec.infoinPowerSuite
10.AdjustDCoutputvoltagetoequalmeasuredbatteryvoltageCheckcorrectpolarity!
11.Unplugallrectifiersbutone,andconnectallbatteryfuses/MCBs
12.AdjustDCoutputvoltagetoequalnominalbatteryorloadvoltage
13.Pluginagainallrectifiers,andverifytherectifierscurrentsharing
14.ConnectallloadMCBs/fuses,andverifynoalarmsaredisplayed
ApprovalResponsibleofcommissioning,sign.:Date:Approvedbycustomer,sign.:
Devicehazard
I
II
Devicehazard
III
Devicehazard
Form17
0-g
b-v4-C
01
_356804-1
03_q
start-in
st-comm-o
per_fla
tpack2-p
ss.d
oc_mfm
_2
006-01-0
6
EltekEnergyASTel.+4732203200
Internet:www.eltekenergy.comE-Mail:[email protected]
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
18/28
PULLOUT
CheckLi
stsPullout
P
ulloutthepageswiththegrayouterband,
andusethem
aschecklists
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
19/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 11
Identifying Power Shelves, 4AC or 2ACFlatpack2 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 1rectifier)
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 shelfs label, or by looking at the
shape of the shelfs AC mains terminals, at its rear. (Also
viewable by removing the rectifier in the shelfs 4th
position)
Mains Reconfiguration, Integrated Systems 1U Distr.The AC mains terminals ofFlatpack2 integrated systems with 1U DC distribution units arelocated on the power shelfs 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.
4ACPowerShelve
s
SingleACfeed:4ACinputsper
shelf,eachfeeding1rectifier
L1 L2 PE
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
MainsOne-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)
2ACPowerShelves
DualACfeed:2ACinputsper
shelf,eachfeeding2rectifiers
L (L1) N (L2) PE
MainsOne-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
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
Flatpack2System, 1U DC Distr.
AC Mains &PE terminals
Power Shelf(rear view)
C Mains Miscellaneous
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
20/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-0112
Mains Reconfiguration, Cabinetized & Integrated 4UTo reconfigure the AC mains feed ofFlatpack2 DC power systems cabinetized or integrated
with 4U DC distribution units you have to rewire the internal cables of the systems AC Mainsconnection box.
1. Find out first whether your system is implemented with 4AC or 2AC powersshelves (read the Identifying Power Shelves section, page11).
2. Rewire then the internal cables of your systems 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 ShelvesSingle AC feed: 4 AC inputs per shelf, each feeding 1 rectifier
L3
X:******
Flapack2DC Power System
(To internal connections)
AC MainsCable
Chassis
L1L2 PE
MainsThree-phase & N, 400VAC
N
PS1:CON20
PS1:CON19
PS1:CON17
PS1:CON16
PS1:CON14
PS1:CON13
PS1:CON11
PS1:CON10
PS2:CON19
PS2:CON16
PS2:CON13
PS2:CON10
PS2:CON20
PS2:CON17
PS2:CON14
PS2:CON11
ACMains
connectionbox
Rewirethe box
as shown
X:******
Flapack2DC Power System
(To internal connections)
AC MainsCable
Chassis
L1L2 PE L3
MainsThree-phase, 230VAC
PS1:CON20
PS1:CON19
PS1:CON17
PS1:CON16
PS1:CON14
PS1:CON13
PS1:CON11
PS1:CON10
PS2:CON19
PS2:CON16
PS2:CON13
PS2:CON10
PS2:CON20
PS2:CON17
PS2:CON14
PS2:CON11
ACMains
connectionbox
Rewirethe box
as shown
ACMains
connectionbox
X:******
Flapack2DC Power System
(To internal connections)
AC MainsCable
Chassis
PE L (L1)N (L2)
MainsOne-phase, 230VAC
PS1:CON20
PS1:CON19
PS1:CON17
PS1:CON16
PS1:CON14
PS1:CON13
PS1:CON11
PS1:CON10
PS2:CON19
PS2:CON16
PS2:CON13
PS2:CON10
PS2:CON20
PS2:CON17
PS2:CON14
PS2:CON11
Rewirethe box
as shown
AC MainsConnection Box
PS1:CON20
P
S1:CON19
PS1:CON17
P
S1:CON16
PS1:CON14
P
S1:CON13
PS1:CON11
P
S1:CON10
P
S2:CON19
P
S2:CON16
P
S2:CON13
P
S2:CON10
PS2:CON20
PS2:CON17
PS2:CON14
PS2:CON11
Rewire theinternalcables
For externalAC Mains
cable
For externalAC Mainscable
Internalconnection point(power shelf # andconnector #) foreach cable
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
21/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 13
About AC, DC Earthing SystemsTo prevent the risk of electric shock, all cabinets 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.
C Mains Miscellaneous
2AC Power Shelves
Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
PS1:CON
11
PS1:CON12
PS1:CON
9
PS1:CON10
PS2:CON
11
PS2:CON12
PS2:CON
9
PS2:CON10
PS3:CON
11
PS3:CON12
PS3:CON
9
PS3:CON10
PS4:CON
11
PS4:CON12
PS4:CON
9
PS4:CON10
X:******
Flapack2DC Power System
(To internal connections)
AC MainsCable
Chassis
L1L2 PE
MainsThree-phase & N, 400VAC
L3N
ACMains
connectionbox
Rewirethe box
as shown
X:******
Flapack2DC Power System
(To internal connections)
AC MainsCable
Chassis
L1L2 PE L3
MainsThree-phase, 230VAC
L1
N
L3
L2
ACMains
connectionbox
Rewirethe box
as shown
X:******
Flapack2DC Power System
(To internal connections)
AC MainsCable
Chassis
PE L (L1)N (L2)
MainsOne-phase, 230VAC
PS1:CON
11
PS1:CON12
PS1:CON9
PS1:CON10
PS2:CON
11
PS2:CON12
PS2:CON9
PS2:CON10
PS3:CON
11
PS3:CON12
PS3:CON9
PS3:CON10
PS4:CON
11
PS4:CON12
PS4:CON9
PS4:CON10
ACMains
connectionbox
Rewirethe box
as shown
CabinetPE
AC MainsCommonDC RailEG
.
ACMainsInput
(L1,L2,L3,N)
DC LoadCircuit
Link 2(DC Earth)
Link 1(AC Earth)
TE
Chassis
Chassis
PE (Protective Earth)TE (Telecom Earth)EG (Exchange Ground)
Common DC Rail
DCLoad
wires
+
+
++
Positive DCDistribution
Negative DCDistribution
Common DC Rail +
DCLoad
wires
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
22/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-0114
Mains Phases versus Rectifier ID Phase Balancing & MonitoringWhen 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 shelfs 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 Smartpackcontroller
assigns the next available ID number to the rectifier, starting with 01. The controller registers
the rectifiers Serial Number and ID number.
When a previously installed (hot plugged)Flatpack2 rectifier is inserted in a power shelf, the
Smartpackcontroller 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
MainsThree-phase, 230VAC
L1
L2L3230VAC
ACMains
02
05
08
n
Phase 2
030609nPhase3
01 04 07 n Phase1
Flatpack2rectifier
MainsThree-phase & N, 400VAC
ID number(AssignedCAN busaddress)
230V
AC
L1
L2
L3
Mains
400VAC, 3ph+N
N 01 04 07 n Phase1
030609nPhase3
Phas
e2
02 05 08 n
Load Balancing of Mains Phases
Even distribution ofFlatpack2rectifiers on the Mains phases
MainsOne-phase, 230VAC
01 02 03 nN(L2)
230VAC
ACMains
L(L1)
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
23/28
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. Therectifier 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 systems power shelf type, byreading the Identifying Power Shelves section, page11
2. Find out if your systems AC mains feed is or
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:
SmartpackLocated 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, 230VACMains
Three-phase & N, 400VACand
01 02
05 06
09---
03 04
0708
------
------
------
Position 1
Position 4
ID number
(Assigned CANbus address
Flatpack2rectifier
Position 8
Position 9
Smartpackcontroller
Correct Rectifier Position in 2AC Power Shelves
Dual AC feed: 2 AC inputs per shelf, each feeding 2 recti fiers
Mains
Three-phase, 230VACMains
Three-phase & N, 400VACand
0104
03 06
08---
02 05
07 ---
09---
------
------ ID number
(Assigned CANbus address
Position 1
Position 4
Flatpack2rectifier
Position 8
Position 9
Smartpackcontroller
C Mains Miscellaneous
SmartpackLocated 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, 230VACMains
Three-phase & N, 400VACand
02
0506
0907
03 01
04 08
------
---------
---
Position 1 Position 8
Smartpackcontroller
Position 9 ID number(Assigned CANbus address
Flatpack2rectifier
Position 4
Correct Rectifier Position in 2AC Power Shelves
Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
Mains
Three-phase, 230VACMains
Three-phase & N, 400VACand
01
0306
08---
02 05
04 07
09---
---------
--- ID number(Assigned CANbus address
Position 1
Position 4
Flatpack2rectifier
Position 8
Position 9
Smartpackcontroller
Phase 1 Phase 2 Phase 3
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
24/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-0116
Battery Symmetry Connections ConnectionsEach Smartpack controller is equipped with 8 battery symmetry inputs (on connectors
CON4 and CON3), enabling symmetry measurement of:
8 battery strings
using theMid-Point Measurement Method 4 battery strings
using the more accurateDouble Mid-Point Measurement Method
2 battery stringsusing the even more accurateBlock Measurement Method
You can implement any of these methods using one or twoBattery Connection Kits (refer
to the illustration next page) andthe appropriate number ofBattery 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
BatteryString #1(48V)Batt.
BatteryBlock (12V)
BatteryString #2(48V)
Notice that, if you open the serial switches in card, Art.200576 setting all to OFF (up) you have to connectthe + and wires of every symmetry input.
Miscellaneous Battery Monitoring
Battery SymmetryBlock Measurement
Four measurements per string(Serial measurement)
(-48V) Outer
Terminal
+0V OuterTerminal
Intercell Links
X:****
Block1
- ++-+-+-
Block4Block3
Card, Art. 200576Serial Switches
Set all 4 switchesON (down)
7
Symmetry4
+
2-1
Symmetry1
+-
5
Symmetry3
+
3
Symmetry2
+
Battery SymmetryDouble-point Measurement
Two measurements per string, from themiddle to the outer terminals
(-48V) Outer
Terminal
+0V OuterTerminal
Intercell Links
X:****
Card, Art. 200576
Serial Switches
Set all 4switches ON
(down)
3
Symmetry2
+
2-1
Symmetry1
+-
Block1
- ++-+-+-
Block4Block3
Batt.
SymmetryKit,
Art.2
00830
CableEyes
SingleCableStra
nd
ExamplesofBatterySymmetryConnec
tions
48VDCSupplySystems
Battery SymmetryMid-point Measurement
One measurement per string
(-48V) Outer
Terminal
+0V OuterTerminal
Intercell Links
2-1
X:****
Symmetry1
+-
Card, Art. 200576Serial Switches
Set all 4switchesOFF (up)
Block1
- ++-+-+-
Block4Block3
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
25/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 17
Terminals & Pin-out Location, Battery Interface CardThe Smartpack controllers battery monitoring signals are accessible on D-Sub connectors
CON4 and CON3, on the controllers rear panel.
Using the Battery Connection Kitwhich consists of a BatteryInterface Card(Art. 200576) and a standard 15 pins D-Sub cable
you can make the signals on CON4 accessible at any suitablelocation inside your system, e.g. near the battery blocks.
When extra battery monitoring signals are required, you can use an
extraBattery Connection Kitconnected to the controllers CON3.
For detailed information about the cards 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 totheBattery Interface Card (Art. 200576), or
directly to the controllers CON3 or CON4,
if unused.
Terminals & Pin-out Location
Battery Interface Card, Art. 200576
141
Serial Switch
For Temp.Sense Kit
CON3A or CON4A
X***/X****
X**/X*
1
Alarm Outputs & DigitalInputs Card, Art. 105954
System ConnectionsCard, 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 mm , max.wire section
Battery Connections (Internal)Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
(Internal Connections)
4321
5
9876
10
14131211
X:****Batt. Symmetry 1 +
+
+
+
Batt. Symmetry 2
Batt. Symmetry 3
Batt. Symmetry 4(Fromi
nternal
batteries)
(Froma
reawith
internalbatteries)
Temperaturesensor
+
Temperature Sense 1
(NA)
(NA)
(Froma
reawith
internalbatteries)
Temperaturesensor
15-pinsD-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
ToSmartpack,
CON4
CON3A orCON4A15-pinsD-Sub female
1 11
5 15
In
1.5 mm , max.wire section
Battery Connections (Internal)Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
(Internal Connections)
4
321
5
9876
10
14131211
X:***+
+
+
+
(Fromi
nte
rnal
batterie
s)
(Froma
reawith
internalbatteries)
Temperaturesensor
+
(Froma
reawith
internalbatteries)
Temperaturesensor
15-pinsD-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
ToSmartpack,
CON3
CON3A orCON4A15-pinsD-Sub female
1 11
5 15
The Temperature Sense Kits may also be connected directly to theSmartpackcontrollers 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
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
26/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-0118
Standard Alarm Relays & Digital Inputs Connections
The alarm outputs in Flatpack2 systems use the Fail-SafeOperation Mode (relay coils energized in the systems
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 systems normal mode of operation.
Terminals & Pin-out Location, Alarm Interface CardThe Smartpack controllers alarm and digital input monitoring signals are accessible from the
controllers 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 canmake the signals on CON1 & 2 accessible
at any suitable location inside your system.
For detailed information about the cards
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 ModeExternal 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 ModeRelay 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)
CON2ACON1A
110 201
X* X**
Alarm Outputs & DigitalInputs Card, Art. 105954
System ConnectionsCard, Art. 200625
Smartpack
Battery ConnectionsCard, Art. 200576
Battery ConnectionsCard, Art. 200576
4321
5
9876
10
X:*
(Customer Connections)
Input Circuit 1
Input Circuit 2
Alarm Circuit 1
Alarm Circuit 2
OutIn
(Toandfrom
externalequipment)
1.5 mm , max.wire section
Relay 2Mains Alarm
Relay 1Common Alarm
+
NOCOM
NC
NOCOM
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
43
21
5
9876
10
14131211
15
X:**
16171819
20
+
+
+
+
NOCOM
NC
NOCOM
NC
NOCOM
NC
NOCOM
NC
Digital Input 3
Digital Input 4
Digital Input 5
Digital Input 6
Relay 3Fuse Alarm
Load & Battery
Relay 5Low Battery Alarm
Relay 6Rectifier Alarm
(Toexternalequipment)
(Frome
xternaleq
uipment)
Card Art.105954
ToSmartpack,
CON2
ToSmartpack,
CON1
Relay 4High Battery Alarm
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
27/28
Quick Start Guide Flatpack2 PS System 356804.103, v3-2006-01 19
Terminals & Pin-out Location, System Interface CardFlatpack2 systems are shipped from factory with the CON5 signals already connected.
Some of the Smartpackcontrollers internal system signals are accessible on D-Sub connectorCON5, on the controllers 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 cards 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. 200625
111 CON5A
JP1 JP2
X*****
Terminals & Pin-out Location
Alarm Outputs & Digital
Inputs Card, Art. 105954
System ConnectionsCard, Art. 200625
Smartpack
Battery ConnectionsCard, Art. 200576
Battery ConnectionsCard, Art. 200576
Latching Contactor
Y
X
Latching Contactors, LVD1 & LVD2
A latching contactor changes state only when areversed pulse voltage is applied to its coil
+ Pulse
ON
- Pulse
OFF
Correct Use of Latching Contactors (example)
PCB Art.200625
10
89
X:*****
+
LVD1A
LVD2A
LVD Common
SmartpackUnit
Flatpack2 PS System (internal)
11
LVD Common
LatchingContactor
LVD2Y
X
LatchingContactor
LVD1Y
X
+
4321
5
9876
1011
X:*****
Power Input+
+
10
156
712
13
9+, Neg.D.
11,Pos.D.
1+/3+/
2+/
Batt. Fuse Fail 1
Load Fuse Fail 1
Batt. Current 1
LVD1ALVD Common LVD1
OutIn
TerminalBoard,Art.2
00625
(ToSmartpack,
CO
N5)
(Internal Connections)
SystemC
onnec
tions
JP2
LVD2ALVD Common LVD2
(To latching contactorsLVD1 & LVD2)
-
7/29/2019 QStart-Installation-Operation-Commissioning and Maintenance
28/28
Head OfficeEltek Energy ASPO Box 2340 Strms; N-3003 Drammen; Norway
Copyright Eltek Energy AS, Norway 2005This document may be changed without notice
This product is CE marked andcomplies with all current requirementsfor relevant standards and directives.