Eltek Flatpack 2 User Manual

Installation & Commissioning, Operation & Maintenance Manual

Eltek Australia Pty Ltd Unit 1, 22 Narabang Way, Belrose, NSW, 2085, Australia Telephone: +61 2 9479 4200 Facsimile: +61 2 9479 4292

Installation & Commissioning + Operation & Maintenance manual for FlatPack2 SEF29-X-149, ‘150, ‘156 and A111171.000, A112040.000 and A112041.000 systems REVISION CONTROL Rev

Date

Revision Description

Orig

Check

H

25/10/06

Added extra wall mounting option.

GT

BD

I

29/11/07

Added system for this manual

AL

J

14/04/11

Changed logo and fax number

RB

K

14/06/11

Added Ethernet connection

RB

L

23/11/11

4 Battery Shelves, SP18-RRU, SP18 DA

M

07/03/12

Updated to manufacturing version

App

DA

This manual is in process of revision if you require updated manual please contact with Eltek Australia engineering department

DOCUMENT DISTRIBUTION CONTROL Copy No:

1

Controlled:

X

Uncontrolled:

TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 1 of 64


Eltek Australia Pty Ltd ACN072 645 446 ABN 90 072 645 446 Unit 1, 22 Narabang Way Belrose NSW 2085 Phone: (02) 9479 4200 Fax: (02) 9479 4292 E-Mail (Sales Dept.): E-Mail (Service Dept.): E-Mail (all departments):

[email protected] [email protected] [email protected]


Page 2 of 64


TABLE OF CONTENTS 1.

SCOPE ............................................................................................................................................................... 5

2.

SYSTEM OVERVIEW .................................................................................................................................... 5

3.

REQUIREMENTS ......................................................................................................................................... 14

4.

PACKING LIST ............................................................................................................................................. 16

5.

SYSTEM CONFIGURATION ...................................................................................................................... 17

6.

UNPACKING.................................................................................................................................................. 18

7.

CABINET ASSEMBLY ................................................................................................................................. 19 7.1 SPECIALISED WALL MOUNTING KIT ................................................................................................................. 20

8.

FLOOR INSULATION .................................................................................................................................. 22

9.

EARTH CABLING ........................................................................................................................................ 23

10.

CONNECTING THE BATTERIES ....................................................................................................... 24

11.

EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS. ................................. 26

12.

EXPANSION RACK ALARM CONFIGURATION ............................................................................ 28

13.

INSTALATION & REFRESHING VOLTAGES OF BATTERIES .................................................. 29

14.

EXPANSION RACK INSTALLATION CHECK LIST ....................................................................... 30

15.

INSTALLATION AND OPERATION OF RECTIFIER MODULES ................................................ 31

15.1 VISUAL INDICATIONS..................................................................................................................................... 32 15.2 PLUGGING IN RECTIFIERS .............................................................................................................................. 33 15.3 IDENTIFICATION OF DIFFERENT RATED RECTIFIERS ....................................................................................... 33 15.4 REPLACING AND INSTALLING RECTIFIER MODULES ........................................................................................ 34 16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER (ETHERNET CONNECTION) ..................................................................................................................................................... 35 17.

OPERATION OF THE SMARTPACK CONTROLLER .................................................................... 38

17.1 FRONT PANEL OPERATION............................................................................................................................. 38 17.2 OPERATING MENUS, (MENU MODE) .............................................................................................................. 40 17.3 FRONT KEYPAD MENU TREE FOR SMARTPACK CONTROLLER: ........................................................................ 41 USER ..................................................................................................................................................................... 41 Service ......................................................................................................................................................... 41 18.

REMOTE ALARM CONNECTIONS.................................................................................................... 42

18.2 DIGITAL INPUTS. ............................................................................................................................................ 45 19.

+24 V DC/DC CONVERTER .................................................................................................................. 47

20.

AC MAIN SUPPLY INSTALLATION .................................................................................................. 49

21.

DC DISTRIBUTION INSTALLATION ................................................................................................ 51

LOAD CABLE INSTALLATION CONSIDERATIONS .................................................................................................... 52 22.

TEMPERATURE COMPENSATION ................................................................................................... 52


Page 3 of 64


23.

COMMISSIONING ................................................................................................................................. 54

PRE-START / INITIAL CHECKS ............................................................................................................................... 54 SYSTEM START-UP ................................................................................................................................................ 54 CHECKING THE ALARMS ....................................................................................................................................... 55 DEFAULT -48V SYSTEM SETTINGS ........................................................................................................................ 58 24.

GENERAL MAINTENANCE CHECKS ............................................................................................... 58

25.

MODULE MAINTENANCE .................................................................................................................. 59

26.

GENERAL PROCEDURES.................................................................................................................... 59

27.

SYSTEM COMPONENTS MINIMUM OPERATING LIFE ............................................................. 59

28.

USING SMART SUITE SOFTWARE ................................................................................................... 60

28.1 INSTALLATION OF SMART SUITE SOFTWARE ................................................................................................. 63 SETTING UP COMMUNICATION BETWEEN PC AND SMARTPACK ............................................................................. 63 28.2 USING SMARTSUITE: A START UP GUIDE. ...................................................................................................... 63 29.

ATTACHMENTS .................................................................................................................................... 64


Page 4 of 64


1. SCOPE This Installation and Commissioning Manual provides simple instructions as to the installation requirements for the Eltek -48 Volt DC Flatpack2 systems. All maintenance & installation work must be carried out by suitably trained personnel. This manual also includes Operation & Maintenance information and technical data regarding the Flatpack2, Smartpack controller and DC/DC converters (factory fitted option.) 2.

SYSTEM OVERVIEW

The Flatpack2 Mobile systems are 18kW -48V DC power system comprising of:      

1 Main System Cabinet (fig 2.2, 2.3, 2.4, 2.7 & 2.8) Up to 9 FlatPack2 -48V 2kW or 1.8kW rectifiers 1 Smartpack Control Module 4, 5 or 6 Battery strings Expansion Battery Cabinet (optional, fig 2.5, 2.6 & 2.9) Up to 4 off +24V 1.1kW DC/DC converters (factory fitted option in 600D rack only)

The Main System Cabinet is available in 2 configurations, a 600 deep cabinet option and a 400 deep cabinet option. The 600 deep cabinets can accommodate up to 6 strings of 100Ah 12FFT100 batteries or 4 strings of 190Ah SBS190 batteries, and the 400 deep cabinets can accommodate up to 5 strings of 100Ah 12FIT100 batteries. If required, the main system cabinets for either option can be supplemented with a battery expansion cabinet for increased battery capacity. Details of the expansion battery cabinets are given later in this manual. The system is also available with an optional DC/DC converter rack to supply +24V supply as needed. This extra rack can deliver up to 4.4kW at 24V and has an extendable alarm output. It input is supplied via an MCB on the -48V load distribution, with the 24V output given via a top mounted Anderson connector. Anderson connector for battery expansion rack

Output cable management rail +48VDC bar (SPC)

AC mains input

Bulk feed point for external battery connection (Available only in SP18&SP18-RRU) Monitor fail PCB

Alarm PCBs

Battery Alarm for the Expansion rack


Serial Number

Page 5 of 64


Fig 2.2, Front and side views of an A111105.000 (SEF29-X-156). 2200(H)x 600(W)x 600(D)


Page 6 of 64


Fig 2.3, Front and side views of an A1110886.00x (SEF29-X-149). 2200(H)x 600(W)x 400(D)


Page 7 of 64


Fig 2.4, Front and side views of an A111160.00x (SEF29-X-150). 2200(H)x 600(W)x 600(D)


Page 8 of 64


Fig 2.5, Front and side views of an A451028.000 (SEB5-12FIT100-002) battery cabinet. 2200(H)x 600(W)x 400(D)


Page 9 of 64


Fig 2.6, Front and side views of an A461032.000 (SEB6-12FFT100-002) battery cabinet. 2200(H)x 600(W)x 600(D)


Page 10 of 64


Fig 2.7, Front and side views of a SP18-RRU A112040.000. 2200(H)x 600(W)x 600(D)


Page 11 of 64


Fig 2.8, Front and side views of a SP18 A112041.000. 2200(H)x 600(W)x 600(D)


Page 12 of 64


Fig 2.9, Front and side views of a SP18 Battery Expansion Rack A401049.000 2200(H)x 600(W)x 600(D) TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 13 of 64


3.

REQUIREMENTS

Installation:   

Termination or configuration of the AC Mains connection is only to be performed by a licensed electrical installer. Standard tools used by an authorized Electrician A torque wrench for installing the battery cables nuts.

The system should only be installed into locations that have restricted access to personnel. Note: All tools should be insulated

For communication with the controller:   

A laptop computer running either windows 2000 or windows XP. SmartSuite software on CD (supplied with system) Standard A-B type USB cable.


Page 14 of 64


WARNINGS



     

Communications Grade valve regulated gas recombination lead acid cells and monoblocs are electrically live at all times and must be treated with care. The products are generally capable of supplying high short circuit currents even if the case or lid is damaged. Remember that the battery is electrically live at all times and cannot be isolated in the conventional sense, although the voltage at any point can be reduced by removal of appropriate inter battery links. Take care that short circuits are not caused by accidentally dropping or touching metal objects onto the cell or monoblocs terminals.

Before connecting batteries and cables remove all metallic objects such as rings, watches etc from your hands and wrists to avoid causing a short circuit.

Do not smoke or permit open flames near batteries. Avoid any activity near the batteries that may cause sparks.

If the rectifier module is damaged in any way or develops a fault it should be replaced immediately. This should only be done by appropriately qualified personnel. Refer to the operations manual for instructions.

The equipment contains voltages that may be lethal. The AC distribution front cover plate should not be removed without first isolating the AC supplies. AC supply connection should only be done by appropriately qualified personnel.

Allow for adequate ventilation around the units. A 5 –10 mm clearance should be kept between the batteries as they may expand in high temperatures.

Be aware that the rectifier is rated for high temperature operations. Therefore care must be taken when handling the modules as they can reach temperatures of 60oC


Page 15 of 64


4.

PACKING LIST

A fully equipped Flatpack2 system is dispatched from Eltek in a number of packages. Each package is clearly marked indicating its content. The packages include the following. 1 x Rectifier Cabinet box Including: Rectifier Cabinet, Manual on CD, lifting eye bolts, floor insulation kit and dyna bolts/dynasets. May contain up to 9 x 2kW FlatPack2 rectifiers already fitted. (see packing list). 1 x Battery Cabinet box (if ordered) Including: Battery Cabinet, Floor Insulation Kit, dynabolts and battery rack to rectifier rack DC power connection cable with Anderson connectors, earth cable & alarm extension cable. (See packing list on box.) Batteries crates Each Crate contains batteries (Monoblocs) as required, including solid links & washers.


Page 16 of 64


5.

SYSTEM CONFIGURATION

The different configurations of the Flatpack2 system and expansion battery cabinets are listed below: Part #

Dimensions

A1110886.00x (SEF29-X-149)

2200(H)x600(W)x400(D)

Battery Type

Max # strings

Notes

12FIT100

5

Can accommodate up to 10 strings using the SEB512FIT100-002 Cabinet. Battery Expansion To suit SEF29-X-149

A451028.000 (SEB5-12FIT100.002)

2200(H)x600(W)x400(D)

12FIT100

5

A111160.00x

2200(H)x600(W)x600(D)

12FFT100

6

Can accommodate up to 12 strings using the SEB612FFT100-002 Cabinet.

A111105.000 (SEF29-X-156)

2200(H)x600(W)x600(D)

12FFT100

5

A461032.000 (SEB6-12FFT100.002)

2200(H)x 600(W)x600(D)

12FFT100

6

2200(H)x600(W)x600(D)

SBS190(Default)

4(Default)

PWL100 (Optional)

6(Optional)

SBS190(Default)

4(Default)

PWL100 (Optional)

6(Optional)

SBS190(Default)

5

As SEF29-X150, but with a DC/DC converter rack factory fitted Battery Expansion To suit SEF29-X-150 / SEF29-X-156 Can accommodate up to 9 (or 11) strings using the A401049.000 SP18 battery expansion rack Can accommodate up to 9 (or 11) strings using the A401049.000 SP18 battery expansion rack Battery Expansion To suit A112040.000 A112041.000

(SEF29-X-150)

A112040.000

A112041.000

A401049.000

2200(H)x600(W)x600(D)

2200(H)x600(W)x600(D)

PWL100 (Optional)

Fig 5.1 System Part numbers


Page 17 of 64


Component name Smartpack Controller Smartpack Controller Flatpack2 Rectifier Flatpack HE Rectifier DC/DC Converter SP18-RRU Label Kit

Part number 242100.100 242100.118(later type) 241115.002 241115.105 241114.503 A641031.000

Fig 5.2 Component Part numbers 6.

UNPACKING

All equipment is suitable for being moved with a normal pallet truck whilst packed. When unpacked, cabinets may weigh 145kg and are heavier at the top end of the cabinet.

CAUTION: THESE UNITS ARE TOP HEAVY, AND CAN TIP OVER UNEXPECTEDLY IF NOT HANDLED WITH CARE. Appropriate lifting equipment should be used, and suitable care must be taken while handling these units. The most appropriate method of moving the racks is with the use of a hand trolley. Some packaging material should be placed between the trolley and the rack to avoid damage to the rack. It is however recommended that the complete boxes be positioned as close as possible to the actual location where the system is to be installed.

If lifting using eye bolts, a spreader bar must be used.

Lifting Cables

Spreader bar, used to prevent eyebolts from bending inwards Eyebolt, placed in the wall mounting brackets bolt positions Cabinet

Fig 6.1 Lifting arrangement for the cabinet, using eyebolts and spreader bar.


Page 18 of 64


7.

CABINET ASSEMBLY

The Cabinets will arrive packed in a box. The following are step by step instructions for assembling this cabinet. 1. Inspect the installation site and determine where the system will be located. Position the packages close to the final systems destination. 2. Each package will have affixed to it a complete packing list listing the contents of each package and the quantity. Check to ensure that you have all items marked on the packing list. 3. Unpack the cabinet from its box. 4. Follow the floor fixing instructions in the next section to fix the cabinet in position. 5. Attach the cabinet to the wall using wall mounting brackets as below.

600mm Cabinet example

400mm Cabinet example

Fig 7.1 Wall mounting brackets. Note: the distance between the top of the cabinet and the wall will be 100mm larger for the 600mm cabinet type than for the 400mm cabinet, due to the greater battery depth.


Page 19 of 64


7.1 Specialised Wall mounting kit This section details the mounting of an optional wall mounting kit, for mounting in transportable huts.

Contained with the kit (Part number): 2 wall mount brackets (MB300) 12 ‘top hat’ washers (XZ045) 2 short wall insulators (KZ207) 2 Long wall insulators (KZ208)

Fig 7.2

Fig 7.3 Assembled brackets with insulators & ‘hat washers’ in place. Remove the ‘X’ brace from all shelves. Drill a counter sunk hole here to correspond with the holes in the vertical wall mount. Two extra holes will need to be drilled in each of the top five shelves. (See TG6308 in attachments for a drawing) The existing cross brace attachment hole can be used as the 2nd mounting position.

61mm

Fig 7.4 TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 20 of 64


Each vertical bracket uses 4 ‘hat washers’ & one long wall insulator to insulate from the wall.

Place the short edge of the bracket against the wall in the location shown to align with the holes drilled in the rear of the battery shelves.

Remove the ‘X’ bracing from all shelves.

Use the short wall insulator with 2 hat washers to insulate the top ‘L’ bracket from the wall. The insulator is installed between the wall & bracket; shown here beside the ‘L’ bracket. Fig 7.5 TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 21 of 64


8.

FLOOR INSULATION

All cabinets include an insulation kit, which isolates the racks from earth. One insulation kit consists of appropriate insulation plates, 4 insulation washers, 4 round washers and 4 M8 dynabolts/dynasets. The insulating plate can be used as a template to mark the positions of the holes on the concrete floor. After the holes have been drilled, position the insulating plate between the cabinet and the cabinet floor. Bolt through the 4 holes in the bottom battery tray using the dynabolts/dynasets provided. Note: the insulating plate may be provided in separate pieces that need to be positioned on the floor.

Nut Washer Cabinet

Insulating Washer

Dyna-bolt/ Dyna-set

Insulating Plate

Concrete Floor

Fig 8.1 Dynabolt Fixing

556mm

400mm 288mm

600mm Fig 8.2 Floor template and insulating plates 400mm option TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 22 of 64


563mm

600mm 540mm

600mm Fig 8.3 Floor template and insulating plates, 600mm option 9.

EARTH CABLING

Each cabinet should be bound to earth using links. There is one 95mm² earth cable shipped with each cabinet (Except SP18-RRU system). Ensure this converter cubicle bond is bonding the cabinet M8 bolt to the positive common bar (SPC) inside the cabinet. Also ensure flat and spring washers are used and the links are secure. External earthing should be done to relevant company standards. Also connect the battery extension cabinet, if being used, to the SPC inside the rectifier cabinet with the 95mm² earth cable supplied with the extension cabinet. There is also a M6 bolt that is connected to the protective earth on the AC input terminals that needs no further connections .


Page 23 of 64


10.

CONNECTING THE BATTERIES

The FlatPack2 system is supplied with a 100A battery circuit breaker with auxiliary for each string. The battery CB’s are located on the left-hand side of each battery shelf. System is supplied with cables from the battery CB’s to the battery trays already fitted. Ensure that the battery CB’s are turned OFF before connecting the batteries. NOTE: For battery shelves not being used, ensure cable ends remain insulated with heat shrink provided. Installation Steps 1. Before commencing the installation, ensure that each battery is in good condition and has not been damaged during transport. 2. Monoblocs are heavy; and accordingly the recommended lifting equipment should be used. 3. Remove retaining strap. 4. Position the batteries on shelves as per fig 10.1. We suggest that one monobloc be lifted into place at a time. Leave a clearance space of between 5 – 10 mm between the batteries. Slide the batteries gently back to the rear of the system to avoid any risk of damaging them on the rear of the shelf. 5. Particular care should be taken when placing on the shelves to ensure the correct positioning of the +ve and –ve terminals. 6. Connect inter battery flexible cables and inter tier links. To ensure a low resistance joint clean the flat contact making surfaces of the terminal posts and connectors with a soft clean cloth. The links do not normally require cleaning and can be fitted without any operation. However in some cases the links could show encrustation and this should be removed using Scotchbrite or fine grade abrasive paper. Do not use a wire brush and be especially careful not to break through the lead plating. Apply a light coating of grease to the contact – mating surfaces and place a solid connector strap or flexible link in position. Tighten the nuts firmly: 7-8 Nm for a Stud type terminal; (12FIT100 [M6], SBS190 [M6]), 8-10 Nm for a socket type terminal (12FFT100 [M8]) using an insulated torque wrench. (A non-torque insulated wrench is supplied with the batteries. This should be used only when the installer is familiar with battery installations and knows from experience what level of torque needs to be applied) Lightly smear grease on the washer and nut. WARNING: Particular care should be taken to ensure the batteries are not shortcircuited during this procedure. 7. Place terminal boots and battery link caps on all battery terminals. 8. Place the battery numbering labels in place starting at the first battery (on the bottom shelf) and working to the last. Replace the battery 9. Wait 24 Hours and re-torque the battery terminals. You will find the following colour coding on the battery cables. Blue (–) negative and Red (+) Positive 

The system must not be located in an explosive atmosphere, i.e. in the presence of flammable gases and fumes. Suitable ventilation for the battery must be provided.


Page 24 of 64


Battery Circuit breaker. Retaining bracket

(Cables / links are not shown) Fig 10.1 Front view of batteries, showing spacing & battery circuit breaker position Note: the solid battery links have slots that allow the batteries to be easier positioned and connected, but may allow the batteries to come too close together if not installed correctly. Please enure that there is proper spacing maintained between the batteries to allow for ventilation of heat.


Page 25 of 64


11.

EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS.

The Flatpack2 system can be supplied with an expansion battery cabinet. The following table outlines which expansion cabinet is supplied with which system. Part #

Dimensions

Type of battery

Number of battery shelves

A451028.000 (SEB5-12FIT100.002)

2200(H)x 600(W) x 400(D)

12FIT100

5

A461032.000 (SEB6-12FFT100.002)

2200(H)x 600(W) x 600(D)

12FFT100

6

A401049.000

2200(H)x 600(W) x 600(D)

SBS190 12FFT100

5

To suit System

A1110886.00x (SEF29-X-149) A111160.00x (SEF29-X-150) A112040.000 A112041.000

To install extra strings of batteries: 1. Position expansion cabinet and fix it to the floor in the same manner as the rectifier cabinet. 2. Ensure that all the individual string MCB’s are turned OFF 3. Install the batteries as detailed in section 10. 4. Double check all the string MCB’s are OFF and connect the flying lead with the Anderson connector to the existing rectifier cabinet as in fig.11.2 below. 

For SP18 and SP18-RRU systems, there is a bulk feed point supplied in the system for direct connection of battery rack without using Anderson connector. (Fig 11.1)

Figure 11.1 Bulk Feed Point for External Battery Connection TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 26 of 64


5. Once the battery strings are in place turn on the strings of batteries one by one. Pause between turning each string on to let the system equalize with the string. 6. Check the string voltage and the battery current on the Smartpack display. There should be a small positive current flowing to the batteries. Each expansion battery cabinet is fitted with a flying lead with an Anderson connector on one end to connect to the +ve/-ve bus bars in the system cabinet as shown below: (SP18 Expansion rack has additional bulk feed connection) Rectifier Cabinet

Battery Cabinet Flying Lead with Anderson Connector

Battery CB alarm. Earth cable

Figure 11.2 When connecting extra batteries to the system, the controller needs to be updated manually. Use the keypad menu in Section 17 to change the battery charge current limit setting if no PC is available. The battery charge current limit should be set to = [25% of the C10 rating of the battery] x [the number of strings installed], which in the case of 12FFT100 & 12FIT100 batteries is 25A x [the number of strings.]


Page 27 of 64


12.

EXPANSION RACK ALARM CONFIGURATION

The battery alarms provide signals to the Smartpack control module via auxiliary switch’s on each battery circuit breaker. The purpose of this signal is to initiate an alarm condition if the battery CB has tripped. This a normally closed loop which if broken, will create an alarm Alarm Interconnection cables Each system cabinet is supplied with an alarm interconnection cable that connects the system cabinet to the expansion battery cabinet. The alarm interconnection cable is a 2000mm long, 2 way cable. Installation Steps for Expansion Cabinet alarm wiring There is a four way terminal block fitted in the rectifier cabinet on the LHS under the distribution. When an external battery cabinet has been installed remove the link wire on the top of the terminals:1. Connect one end of the 2 core alarm interconnection cable to the two terminals located in the top LHS of the cabinet. 2. Run the cable through the top cover of the cabinet to the terminal block located in the top of the battery cabinet. 3. Secure the alarm cable wiring with cable ties.

Figure 12.1 Battery Alarm Schematic showing expansion battery cabinet


Page 28 of 64


13.

INSTALATION & REFRESHING VOLTAGES OF BATTERIES

If the batteries are in service on a temperature compensated power supply in temperatures above an ambient of 20°C, the service life of the battery will be affected. See table 13.1 below. Ambient temperature (deg C) 20 25 30 35 40 45 50

Expected life (% of nominal) 100 70 50 35 25 18 15

Table 13.1

To check if a refresh is needed, follow the below procedure. 1. Check the open circuit voltage of each battery. The minimum monobloc open circuit voltage that the battery can be considered as not requiring refresh is 12.72V. Any monoblocs that are below this voltage will have to be refreshed as below. Above this value, they may be considered acceptable for use & do not need to be refreshed. 2. Put the batteries on a float voltage charge of 54.48V for a period of 48 hours at 20degC. 3. After float charging leave the batteries to settle for a further 48 hours. 4. Check the open circuit voltages of the monoblocs. The minimum monobloc open circuit voltage after refresh is 12.72V. Any monoblocs that are below this voltage cannot be considered as serviceable.


Page 29 of 64


14.

EXPANSION RACK INSTALLATION CHECK LIST

Check these points 1. Check that the cabinet is fixed to the wall securely. 2. Check that the battery connections are all of correct polarity. 3. Check that the terminal boots and battery link caps are fitted on all the batteries. 4. Check that the Anderson flying lead is connected. 5. Check that the battery rack expansion rack earth cable is securely connected to the common positive bar (SPC) inside the rectifier cabinet. 6. Check that battery string voltage is between -48 and -55 V. 7. Check that the MCB alarm cabling to the main rack is installed and terminated.


OK

      

Page 30 of 64


15.

INSTALLATION AND OPERATION OF RECTIFIER MODULES

If for any reason any of the rectifiers have to be removed, or additional rectifiers are being fitted, please refer to the following procedure. See also section 25, for important information regarding rectifier operation and positioning. It is to be noted that the FlatPack2 rectifier module is a “Hot” plug rectifier allowing expandability and serviceability without power shutdown. The current share functionality of the modules ensures all modules deliver the same amount of current. The FlatPack2 rectifier cabinet accommodates up to 9 rectifier modules. Installing rectifiers 1. Unpack the rectifier modules from their packaging. 2. Refer to section 15.3: for information regarding the correct rectifier positioning. 3. With the system on, slide each module into place, but do not push the rectifier all the way home at this point. Make sure the pull out handles have been released as shown in figs 15.1 and 15.2 below, then push the unit into place and lock the rectifier into position by pushing the handles firmly into their housing. Hole to release the handles spring mechanism

Handle in locked position

Fig. 15.1 To remove a rectifier, follow the steps below: 1. Unlock and release the handles by inserting a small screw driver into the holes in the upper corners of the rectifier front panel and carefully push it downwards. The handle will release and pop out.

Handle in unlocked position

2.

Fig. 15.2 Use the handles to pull the rectifier loose.

During continuous operation, the metal case of the rectifier unit can become hot. There is no danger of contact burns occurring, but care should still be taken when handling recently unplugged rectifiers.


Page 31 of 64


Fig. 15.3 Flatpack2 front view

The Flatpack2 is intended for use as a stand-alone unit or in systems with multiple modules and an external alarm / control module. The Flatpack2 will operate in a default mode if the control module fails The Flatpack2 Rectifier Module has the following LED indications:  “Power” (green) indicates whether the power supply is OFF, ON, or communicating.  “Alarm” (red) indicates an alarm situation.  “Notice” (yellow) indicates an atypical situation. 15.1 Visual Indications LED Power (green)

Status

Description

ON Flashing OFF

Rectifier is powered Smartpack controller accessing information on the rectifier Mains are unavailable  Rectifier is in Shut-down Mode due to low mains (0 – 85VAC) or high internal temperature (+75 °C or higher)

Alarm (red)

ON

 Interna    CAN bus failure No alarm situation is present

OFF 

Notice (yellow)

Flashing

Rectifier is in Derating Mode (reduced output power) due to high internal temperature (+45 to 75 °C) or low input voltage (lower than 185VAC) or fan failure  The remote Current Limit is activated  The rectifier is communication with the controller over a current sharing / current limiting issue  AC input voltage is out o  Rectifier in stand-alone mode (or loss of communication with the Smartpack controller Rectifier is in Over-voltage Protection Mode

OFF

No atypical situation is present

ON


Page 32 of 64


15.2 Plugging in Rectifiers 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”. This ID number (or CAN bus address) and the rectifier’s serial number are stored in both SmartPack and Rectifier modules. 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 and serial numbers, 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.

During continuous operation, the metal case of the rectifier unit can become hot. There is no danger of contact burns occurring, but all care should still be taken when handling recently unplugged rectifiers.

15.3 Identification of different rated rectifiers Three different types of Flatpack2 rectifiers are compatible these systems; a 1.8kW rectifier & a 2.0kW rectifier and a 2.0kW HE rectifier. These interoperate fully, including alarms & current sharing (current sharing is by a percentage of total output). The only functional difference between the 1.8kW and 2.0kW rectifiers is their maximum power output. For easy identification, the 1.8kW rectifier has a silver front, the 2kW rectifier has a light blue front and 2kW HE rectifier has a black front. HE and 2000W label

Silver Black 1.8kW 2.0kW

Blue 2kW

‘2000w’ label

Fig. 15.4 Flatpack2 1.8kW & 2kW and 2kW HE rectifiers.


Page 33 of 64


15.4 Replacing and installing rectifier modules

 If a upgrading a system with additional rectifiers: Place the new rectifiers into the next highest rectifier position, in order. See table below. Their existence will be automatically logged by the controller, no further configuration is required.

 If a replacing a faulty rectifier and a replacement rectifier is immediately available: 1. Unclip handles of faulty rectifier as shown above and pull out rectifier. 2. Fit the new rectifier into the position left by the faulty rectifier. 3. Eliminate any rectifier alarm by performing a ‘rectifier recount’ [rectifier reset, under rectifier info] that resets the number of rectifiers using the front keypad, under user menu (see section 17.3)

 If a replacing a faulty rectifier and a replacement rectifier is not immediately available: 1. Unclip handles of faulty rectifier as shown above and pull out rectifier. 2. Remove the highest ID rectifier (important) and fit into the vacant faulty rectifier position, in order to maintain continuity. 3. Eliminate any rectifier alarm by performing a ‘rectifier recount’ [rectifier reset, under rectifier info] that resets the number of rectifiers using the front keypad, under user menu (see section 17.3) NOTE: The highest ID rectifier is now reassigned to the ID of the faulty rectifier in the system 4. When a new rectifier is obtained, fit it into the highest vacant ID position. Its existence will be automatically logged by the controller (as in the above scenario, ‘upgrading a system with additional rectifiers’.)

Smartpack (controller)

ID1

ID4

ID7

(Blank)

ID2

ID5

ID8

(Blank)

ID3

ID6

ID9


Page 34 of 64


16.

INSTALLING AND REMOVING THE SMARTPACK CONTROLLER (ETHERNET CONNECTION) The Smartpack controller is physically held in place using similar method as the Flatpack2 rectifiers: It incorporates handles that serve both to lock the module into position and to pull it out of its housing. CAUTION: Do not hand-carry the controller by its handles. Cables are plugged to the controller’s rear panel. If in the event that the Smartpack needs to be removed for any reason the following procedure should be used: 1. Release the handles (using similar method as the Flatpack2 rectifiers as described above) 2. Grasp the Smartpack by the handles at either side of the unit and pull the unit out. The connection cables are attached to the rear of the controller via several ‘D’ type connectors. Pull out the controller enough to access the rear of the unit, and unplug the cables as detailed over page. NOTE: make a record of which positions the connectors were removed from for future reference.

Open the handles before inserting the controller into the power shelf. To refit the Smartpack: 1. Carefully reconnect the cables to the appropriate positions in the rear of the controller. 2. Slide the controller unit into place making sure that all cables are not overly bent. 3. Fasten the unit by firmly pushing the handles into their housing. Removing the Smartpack controller

Open the handles (insert a screwdriver into the holes to release the spring mechanism) Remove the module

Use both handles to pull the module gently loose; support it from underneath; hidden cables are connected to the rear panel.

Fig. 16.1


Page 35 of 64


WARNING: the rear cables from the system carry live -48V voltages. If completely disconnecting the controller from the system, ensure that the cable to CON5 is removed last, as this cable provides the controller with its 48V power. When removing, be careful that the male plug doesn’t make contact with any metallic material that can cause a short circuit on the pins. There is no danger to personnel.

Early controllers rear view:

Later controllers with Ethernet connection (242100.118) rear view:

Ethernet port

For connection to the internet for remote monitoring, connect CAT5 cable to the back of the Smartpack and route the cable out through the letterbox aperture at the top rear of the power rack. Refer to Webpower section of accompanying CD for information on setting up the network connection. NOTE: Do not plug networked cables in to the CAN1 connector, this will damage the CAN bus internally on the controller.


Page 36 of 64


Removing the cables for replacement purposes:

Remove the controller until the rear connectors are exposed.

Unplug the cables, leaving CON5 (red surrounds) until last.

Reverse the procedure when reconnecting the new controller Fig. 16.2 Note, CON 3 is unused, and CON 4 is only used for connection of the temperature compensation probe.


Page 37 of 64


17.

OPERATION OF THE SMARTPACK CONTROLLER

The Smartpack unit controls, monitors and regulates each FlatPack rectifier module and provides battery & system surveillance in order to protect and optimize the battery lifetime. If the alarm module is removed, voltage control / regulation will be lost and system voltage will equal to default rectifier voltage. 17.1 Front Panel Operation This chapter describes the Smartpack controller’s keys and indicators, and how to operate the Flatpack2 DC power system from the controller’s front panel. Description of Keys, Display and Indicators The Smartpack controller’s front panel consists of two functional areas: the presentation area (LCD display and LED lamps) and the control area (keys).

`

LED indicators The Smartpack controller has the following LED indications:  “Power” (green LED) indicates that the power supply is ON or OFF  “Alarm” (red LED) indicates an alarm situation (major alarm)  “Notice” (yellow LED, or minor warning) indicates an atypical situation.

LCD Display The graphic display is an important part of the power supply system’s user interface. The display can be shown in Status Mode (displays the system’s status) or in Menu Mode (displays the menu structure). Depending on the display’s mode, the upper line shows the output voltage or menu options, while the lower line displays battery and load current, alarms, or information about which key to press.


Page 38 of 64


Front Keys You can control the whole Flatpack2 DC power system via a network of software menus accessed with the controller’s front keys. o Press the

key to change from Status Mode to Menu Mode.

o Press the or keys to scroll up or down and navigate to find menu options (function or parameter). o Press then the

key to select the function.

Modes of Operation The controller’s display is either in Status Mode or in Menu Mode. Status Mode When the front keys are not in operation, the display is in Status Mode. The following information is then scrolled through the display: The upper line continuously displays the battery voltage. The lower line continuously scrolls the following information:  Battery Current  Load Current  Active alarms  Other messages Menu Mode When the front keys are in operation, the controller’s display switches to Menu Mode and the following information is scrolled through the display:  

The upper line shows the name of the active menu or sub-menu The lower line indicates which key to press Notice: If no keys are pressed within 30 seconds the display will automatically switch from Menu Mode to Status Mode.


Page 39 of 64


17.2 Operating Menus, (Menu Mode) The Flatpack2 DC power system’s functionality is accessed via a network of software menus and submenus, enabling you to configure and control the whole power system. The functionality is divided in two different hierarchical menu structures: the User Options menus and the Service Options menus (password protected, only authorized personnel have access to them). Special, not so frequently used options — such as calibration and adjustments — are accessible in the Service Options sub-menus. User Options When you “enter” Menu Mode, you access the User Options. How to browse the display menus:

o

o o

To enter Menu Mode Press on the key to change from Status Mode to Menu Mode Browsing “down” to a menu option Press the key, to scroll down within the same menu level, and find menu options (functions or parameters) Selecting a menu option Press the key to select the displayed menu option or parameter Browsing “up” to a menu option or level Press the key to scroll up to the previous menu option, and out to the previous menu level. Service Options When you enter Menu Mode, you access the User Options. You may then scroll down to the password protected Service Options. The Service Option’s password is factory-programmed to <0003>. If the wrong password is entered three times, the controller will be locked out for a period of time. Notice: If no keys are pressed within 30 seconds the display will automatically switch from Menu Mode to Status Mode.


Page 40 of 64


17.3 Front keypad menu tree for Smartpack controller: Service

User

Password = Service password

Alarm Reset

Alarm Reset

Voltage Info

NomVolt

VoltAdjustment

NomVolt

BoostVolt

LowBatt1 BoostVolt Volt Calibration

VoltCal LowBatt2

LowBatt1 Change Password

Password HighBatt1

LowBatt2 SetBoostTime

BoostTime

Start/StopBoost

StartBoost/StopBoost

High Batt2 HighBatt1 LVD1 High Batt2 Auto Boost Cfg

Enable/Disable LVD2

LVD1 Threshold LVD2 Batt. Test Setup Display messages

Display messages

Serial Number

Controller S/N

Sw Info

SwInfo

Rectifier Info

NoOfRects. Nn RECTIFIER RESET

RectCurrent

RectSerialNumber

Nxt Test Date Time

Start/Stop Test

StartTest/StopTest

End Volt

Charge Curr Lim

Enable/Disable

Max Test Duration

Max ChargeCurr

Test Interval

Battery Setup

NumOfString

Guard Time

OutputControl

Temp.Comp

Change Date/Time

VoltageControl

Rect.PrimaryVolt

Rectifier Status

Relay Test

Alarm Output 1 Alarm Output 2

Rectifier Temp Batt Contactor Mains Info

NoOfPhases nn

Load Contactor

Mains Status

Alarm Output nn

Mains Voltage BattLifeTime Rst Temp Level Info

BattLifeTime Rst

Temp Level Info

Fig 17.1 TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 41 of 64


18.

REMOTE ALARM CONNECTIONS

The Smartpack controller incorporates 6 alarm relay outputs and provides both normally open and normally closed states on the output relay. See table 18.1 for pin connections.

Relay Output Card 1

Relay Output Card 2

Relay Output Card 3 (SP18, SP18-RRU)

PLEASE NOTE: Normal operation is when the system is energized and there are no alarms present on the system.

Monitor fail

DCDC converter alarm terminal block. Black: common. White: normally closed (failsafe) Brown: normally open.

Battery fuse alarm extension. Fig 18.1 Alarm terminal blocks


Page 42 of 64


ALARM

CONTACT

Mains Fail

COM

RELAY #

5

NC

High Load / Low Load

1

7

NC

8

2

COM

10 11 12

NC

Off Normal

9 9

3

COM NO

Rectifier Fail

TB2

10

NC

Battery Fuse/CB fail

6

NO

NO High Float / Low Float

TB PIN #

4

COM

13

NO

14

NC

15

5

COM

16

NO

17

NC

18

6

COM

TB1

19 20

NO NC Monitor Fail

External PCB

NO COM

Figure 18.2 Output relay pin out assignment for SP18 and SP18-RRU Systems ALARM

CONTACT

Mains Fail

NO

Mains Fail

COM

Mains Fail

NC


NO


COM


NC

High Float / Low Float

NO


COM

RELAY #

RELAY OUTPUT CARD #

1

1

PIN # 5 6 7 8

2

1

9 10 9

3

2

10


NC

11

Load / Battery CB fail

NO

12


COM


NC

14

Rectifier Fail

NO

15

Rectifier Fail

COM

Rectifier Fail

NC

17

Off Normal / BCM

NO

18

Off Normal / BCM

COM

Off Normal / BCM

NC

Monitor Fail

NO

Monitor Fail

COM

Monitor Fail

NC

4

5

6

2

2

2

13

16

19 20

External PCB located LHS, above Smartpack controller

Table 18.3 Output relay PIN connection for other systems TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 43 of 64


Normally closed Normally open Common

Figure 18.4 Top view of monitor fail PCB showing connection points for monitor fail alarm

Alarm name

Trigger

Failed AC supply

Total loss of any one phase or all phases AC supply to the system.

Battery CB tripped Load CB tripped High Load voltage High Float voltage Low Load voltage Low Float voltage Failed Rectifier

Failure of any battery CB Failure of any load fuse System voltage is above 57.0Vdc System voltage is above 55.70Vdc System voltage is below 48Vdc System voltage is below 52.8Vdc Loss of output and input information from a rectifier, Loss of communication between Smartpack controller and rectifier Smartpack output failure

System monitor failure

Table 18.5 Alarm trigger conditions


Page 44 of 64


18.2 Digital inputs. For SP18 / SP18-RRU Systems: The alarm PCB also has up to six digital inputs that can be used on, two of which are pre set for Generator Feed and Off Normal (but disabled). Input 1: Generator input. Input 2: Off normal input. Alarm Input 1 Input 1 Input 2 Input 2

State TB Pin + 1 2 2 + 3 2 4

Alarm Input 3 Input 3 Input 4 Input 4 Input 5 Input 5 Input 6 Input 6

State TB Pin + 1 1 2 + 3 1 4 + 5 1 6 + 7 1 8 Figure 18.6 Alarm PCB showing digital input pin outs Input voltage range 0-75V Terminal impedance 200kΩ Operating current between terminals 30mA Figure 18.7 Digital input specification

Input 1: Generator input (Disabled). When operating on AC mains, the digital input is left open, (its normal state.) If this input is closed (shorted), the controller will assume that it is now operating from a generator. The controller will then limit the battery charge current down to a small value in order to limit the strain introduced on the generator. In this way, the generator can be used to supply only the load, and not be burdened by also trying to recharge discharged batteries at the same time.

Input 2: Off normal input (Disabled). When in a normal state the digital input is left open. If this input is closed (shorted), the controller will extend an off normal alarm on the alarm relay output (relay 6.), This could be used in combination with a switch to indicate someone is on site. Input 3: Spare Connection. Input 4: Load MCB fail alarm. When a load MCB is in the off position and alarm will be generated and sent to the Smartpack which will change the state for relay #4. (see Fig 13-3) TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 45 of 64


Input 5: Used for external load fuse alarm (Disabled). Input 6: Spare Connection. For more information, refer to Quick Start Guide: Flatpack2, PS System (356804.103).

For other Systems: The Smartpack controller accepts up to 6 inputs to the system, 2 are used. Input 1: Generator input. Normally closed. Input 2: Off normal input. Normally closed.

Alarm Input 1 Input 1 Input 2 Input 2

State TB Pin + 1 1 2 + 3 1 4 Pin 1

Alarm Input 3 Input 3 Input 4 Input 4 Input 5 Input 5 Input 6 Input 6

State TB Pin + 1 2 2 + 3 2 4 + 5 2 6 + 7 2 8

Pin 10 TB1

Pin 1 TB2

Pin 20

Input 1: Generator input. When operating on AC mains, the digital input is left open, (its normal state.) If this input is closed (shorted), the controller will assume that it is now operating from a generator. The controller will then limit the battery charge current down to a small value in order to limit the strain introduced on the generator. In this way, the generator can be used to supply only the load, and not be burdened by also trying to recharge discharged batteries at the same time. Input 2: Off normal input. When in a normal state the digital input is left open. If this input is closed (shorted), the controller will extend an off normal alarm on the alarm relay output (relay 6.)


Page 46 of 64


19. +24 V DC/DC CONVERTER The Flatpack DC/DC 48/24, a modular hot plug-in DC/DC converter.

Fig 19.1 A DC/DC converter module The converter is specially designed to provide a high quality and highly reliable DC output voltage. The module has a soft start power-up and an internal blocking diode allows hot plug-in and isolates any faults in the converter output from the DC bus. Several internal protection circuits ensure safe operation, even outside specified limits for normal operation.. A module failure alarm is given if the module shuts down due to high output voltage, or in case of an internal failure. Converters connected in parallel will exhibit active load sharing via CAN bus. Front LEDs show power ON/OFF and alarm status in addition to a LED bar graph for output current indication. The Flatpack DC/DC 48/24 will operate in ambient temperatures up to +75°C (+167°F). At temperatures above +65°C the output power may be derated. This unit has the part number: 241114.503, and is only included in SEF29-X-156 systems . The output of the 24V DC/DC converter is found on top if the cabinet, via a 175A red Anderson connection. The 24V output of the SEF29-X-156 systems are floating. That is, to achieve a non floating +24V output with respect to the -48V output, the negative of the DC/DC converter will need to be brought back to the common positive bar inside the distribution at the top of the cabinet. The alarms extended from the DC/DC converter are to be found on a labeled terminal block inside the -48V distribution area.

See the attachments for more data regarding the DC/DC Converter.


Page 47 of 64


DCDC converter rack with 4 modules in place

Do not use this top battery shelf if the DCDC converter rack is being used.

Fig 19.2 Do not use the top battery shelf if the DCDC converter rack is being used. If additional battery strings are needed, please use a battery extension rack. Note: This is relevant only for systems with a DCDC converter rack fitted.


Page 48 of 64


20.

AC MAIN SUPPLY INSTALLATION

AC mains connection terminals are provided for the AC mains connection. The terminals are pre-connected to the rectifier modules. Cables of up to 10mm2 size can be connected to these terminals. Termination or configuration of the AC Mains connection is only to be performed by a licensed electrical installer. When connecting power to this system, a nearby AC mains disconnect device should be integrated into the circuit to facilitate servicing. This could be an isolating switch, circuit breaker or equivalent device. Phase distribution on rectifiers The system is pre-wired to suit a 3-phase +N and Earth AC supply. Other configurations are possible, see above. The phase distribution for the rectifiers is shown below. While installing the rectifiers please ensure that they are distributed evenly between phases to ensure a balanced load on each phase where possible.

Figure 20.1 Cabinet Front view.

Distribution controller L1 L1 L1 (Blank) L2 L2 L2 (Blank) L3 L3 L3 DC/DC Converter DC/DC Converter DC/DC Converter DC/DC Converter Figure 20.2 AC Phase arrangement 9 Way Rectifier Rack – showing AC Phase positions and (optional) DC/DC converters


Page 49 of 64


Termination or configuration of the AC Mains connection is only to be performed by a licensed electrical installer. Three-Phase Input Remove the top panel to access the AC mains terminals. 1) Bring the mains cable into the cabinet through the top of the cabinet. The cable entry is through the punch out holes on top of the cabinet. Cable grommets (gland) need to be installed around the hole for cable protection.

L1 L2 L3 N N N PE

2) Ensure that the neutral bridges are in place. 3) Connect Earth conductor to terminal PE, Phase conductors to terminals L1, L2 and L3, and Neutral conductor to terminal N. 4) Tie the incoming AC cables securely with cable ties for support. Ensure that cables do not pass through any sharp edges. N Bridges in place 3 x Single-Phase Input(s) Remove the top panel to access the AC mains terminals. 1) Bring the mains cable into the cabinet through the top of the cabinet. The cable entry is through the punch out holes on top of the cabinet. Cable grommets (gland) need to be installed around the hole for cable protection.

Figure 20.3 Three-Phase

L1 L2 L3 N1 N2 N3 PE

2) Ensure that any neutral bridges are removed. 3) Connect Earth conductor to terminal PE, Phase conductors to terminals L1, L2 and L3, and Neutral conductors to terminals N1,N2,N3. 4) Tie the incoming AC cables securely with cable ties for support. Ensure that cables do not pass through any sharp edges.

Remove bridges

1 x Single-Phase Input Include bridges across the active terminals to activate all 9 rectifier positions, as well as bridges across the neutral terminals.

Figure 20.4 3xSingle-Phases

L1 L2 L3 N N N PE

Alternatively, if no active bridges are on hand and the system has need for only three rectifiers, it is possible to only use the three rectifier positions that are powered by the single connected phase.

In all these cases the system must be labeled accordingly.

Active bridges


Figure 20.5 1xSingle-Phase

Page 50 of 64


21.

DC DISTRIBUTION INSTALLATION

The FlatPack2 System is equipped with a 24-way distribution module fitted at the top of the cabinet. The circuit breakers that can be fitted on the standard comb bus are 6x 80-125A (27mm pitch) + up to 18x 1-63A standard width (18mm pitch) type. The common terminal bar is located behind the load circuit breakers and is accessible by removing the top cover. Note: -48V will be present on the output terminals of the MCB’s even when in the off position and no load is connected, due to MCB monitoring. There is no risk to personnel from this voltage. The current available from the source for the fuse fail diode matrix (through the reverse biased diode) at short circuit using a 20MOhm multimeter= 0.0052A when direct connection is made to the cathode of the sensing diodes. This can be considered a safe level.

When installing DC load cables, be aware of the position of the AC input terminal block, behind the positive common bar. The circuit breakers are arranged from left to right as: Position # from left 1 2 3

Accommodate CB size 80 to 125A 80 to 125A 80 to 125A

4

80 to 125A

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

80 to 125A 80 to 125A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A

CB Factory fitted 100A 100A 125A (125A for DCDC converter if fitted)

32A 32A 32A 32A 32A 32A 32A 32A

10A 4A 4A 4A

Fig 21.1 DC distribution


Page 51 of 64


Load Cable Installation Considerations Consideration should be given to the entry arrangement of load cables to ensure easy installation of additional load cables when the system is operating.  Ensure protective edging is fitted to any sharp edges over which cables pass.  Ensure cables are suitably supported by a cross beam, making sure not to over stress the common positive bar and circuit breakers. 22.

TEMPERATURE COMPENSATION

The system is supplied with a temperature-sensing probe for temperature compensation charging. The temperature compensation cable is temporarily cabled tied to the system. The cable should be carefully untied and the transistor probe should be placed in the middle of the battery string(s) for measurement of air temperature as close as possible to the batteries. Do not rest the probe directly against any of the batteries as this will give a false reading in the event of that individual battery having a fault.

Fig 22.1 Temperature probe deployment should be near, but not touching, the middle string of batteries.


Page 52 of 64


Installation Checklist Check these points

OK

Check that the incoming AC connections are correct.

      

Check that the terminal boots and battery link caps are fitted on all the batteries. Check that the load connections are of correct polarity Check that battery string voltage is between -48 and -55 Vdc Check that the external alarm cabling is installed and terminated Check that the temperature probe is extended to the batteries. Check that the temperature compensation is on (activated by default).


Page 53 of 64


23.

COMMISSIONING

Pre-Start / Initial Checks Check the following:

OK

System installation is completed Check that the system installation has been correctly performed (ref. Installation sections of this manual).



Battery and load are disconnected Verify that the battery circuit breakers and load circuit breakers are in the OFF position.



Rectifier modules are connected Verify that all rectifier modules are plugged in properly & the front pull out levers are pushed in. NOTE: Rectifiers are allocated with a ID that is relevant to its position in shelves.



Rectifier system connected to mains supply and Protective Earth Check that the system’s mains cable is connected to the mains supply.



System Start-Up Check the following:

OK



Turn the system ON from the AC input supply Read output voltage* (approx. 54- 55V) Wait for about 1 min. and check there is DC output voltage* on the alarm module’s display Measure output voltage Use a Digital Voltmeter* to verify that the output voltage is in accordance with VDC the system’s Default Settings (end of this section) and note in the section immediately to the right. Rectifier modules are ON and without fault alarms Verify that the Flatpack2 modules are in normal operating mode (not reporting alarms) Check and calibrate voltage reading in the alarm display If the measured voltage deviates more than  0.2V from the display reading, re-calibrate the alarm module.

  

Measure Display in DVM* Alarm Mod.



Switch the system OFF at the Input supply



Connect the load MCB Battery circuit breakers are NOT connected Switch the system ON at the input supply.



Measure the Battery Voltage* Using a DVM measure the battery voltage

 Measured with DVM*




Page 54 of 64


Adjust output voltage to equal the measured battery voltage from the alarm module’s keypad adjust the rectifier output voltage to equal ( 1 V) the measured battery voltage. Temperature-compensated charging must be deactivated when adjusting the output voltage. Close the battery circuit breakers It is important that the system is switched ON before connecting the batteries. Otherwise, the battery terminals could be damaged by high currents trying to charge the rectifiers’ internal capacitors. Measured Adjust output voltage (float voltage) from the alarm module’s with DVM* keypad to the voltage recommended by the battery manufacturer (54.0Vdc at 25°C) Verify that the Low Battery Alarm is not activated. Record the voltage*

  

* DVM must be a Calibrated True RMS meter

Checking the Alarms The Alarms are factory preset and should not require any re-setting on site. To verify the operation of the Alarms use the following procedure. Check the following: 1. Mains Fail Turn off the mains power at the input MCB’s and let the batteries supply the load. Verify if the Alarm LED is illuminated on the Alarm Module. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. Refer to table 18.1. Please ensure batteries are connected prior to starting this test. Turn on the mains again and verify that the Active alarm is automatically reset.


OK



Page 55 of 64


2. The voltage alarms can be tested using any method in which the system voltage can be varied, or the alarm setting can be adjusted. Two methods are listed here. Refer to table 18.1 for relay outputs: 

External Power Supply Method

ISOLATE THE BATTERIES FROM THE SYSTEM AND CONNECT A 0-60VDC EXTERNAL POWER SUPPLY TO THE OUTPUT BARS. ENSURE THE CORRECT POLARITY WHEN CONNECTING!

Once the mains to the system is turned off, the controller will display the output voltage of the external power supply. The power supply can then be adjusted to activate the various high and low voltage alarms. This method will have a constant mains alarm as well as the alarms being tested.  Adjusting Alarm Activation Level Method  Connect a PC/laptop to the Smartpack controller and run the latest version of Powersuite. Note: Once each of the alarms (below) have been tested, ensure you change their alarm levels back to their original values. Each alarm is to be tested, one at a time.



 To test High Battery Alarm 1 (High Float), change its value to at least 0.5V below the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.  To test High Battery Alarm 2 (High Load), change its value to at least 0.5V below the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.  To test Low Battery Alarm 1 (Low Float), change its value to at least 0.5V above the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.  To test Low Battery Alarm 2 (Low Load), change its value to at least 0.5V above the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. 3. Off Normal This alarm indicates that a battery test initiated by a PC is in progress, and can be tested using a PC and the Powersuite software.



Alternatively, short pins 3 & 4 on TB1 to create an off normal ( see section 18.2 Digital inputs) 4. Rectifier Fail Ensure the rectifier is off then insert a plastic object into the fan of the rectifier. Turn ON rectifier; this should give a rectifier fail alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. The fan should never be stopped by inserting an object into it while running, as this could damage the fan. TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems



Page 56 of 64


5. Load Fuse Turn off one of the load circuit breakers. (Note: The CB must be connected to a load). This will activate an Alarm on the Display and at the alarm PCB. Using a Continuity Tester check the operation of the N/O N/C relays at the alarm PCB.



6. Battery Fuse NOTE: All battery CB’s have to be ON for there to be NO Battery fuse alarm. Ensure all vacant battery shelves have heatshrink on their loose cables When the Battery is connected, simply switch off one Battery circuit breaker. This will activate an Alarm on the Display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.



7. Monitor Fail: Unlock and release the handles of the SmartPack alarm module by inserting a small screw driver into the holes in the upper corners of the front panel and carefully push it downwards. The handle will release and pop out. Remove CON5 from the rear on the Smartpack controller. This will activate the Monitor Fail Alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the Monitor Fail PCB.



8. DCDC Converter Fail. Ensure the Converter is off then insert a plastic object into the fan of the rectifier. Turn ON converter; this should give a converter fail alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the converter alarm PCB. The fan should never be stopped by inserting an object into it while running, as this could damage the fan. The DCDC converter alarm terminal block is located to the left of the cabinet below the monitor fail alarm, and is mounted with the battery expansion alarm extension. See section 18.


Page 57 of 64


Default -48V System Settings Alarm & Boost Settings

Factory set Default 54.00

System Voltage High Load Voltage (High Batt 2)

57.60

High Float Voltage (High Batt 1)

55.70

Low Load Voltage (Low Batt 2)

48.00

Low Float Voltage (Low Batt 1)

52.80

Boost Voltage

52.00 -56.00

Checked

     Disabled

24. GENERAL MAINTENANCE CHECKS The following general maintenance checks should be performed on all equipment. Detailed maintenance procedures for specific equipment is included later in this document. Step

Comments

Documentation available

Ensure that all relevant site-specific drawings are available i.e. Layouts, cabling schedule, signal connections. Allowing access to system components.

Remove front Panels Carefully vacuum inside underneath and on top using an insulated hose Ensure that all connections are correct Ensure that all equipment is free from damage Check the alarm voltage settings using the “User” menu via the front keypad Check alarm relay operation to remote monitoring by toggling individual relays using the “Service” menu via the front keypad.

Ensuring the system is free from dust and dirt. Look for any possible defective or loose connections, and excessive temperatures. Verify that damage has not occurred since installation and commissioning Verify that all alarm voltage settings are set as the system default settings. Call remote monitoring station and confirm operation as required.


Page 58 of 64


25.

MODULE MAINTENANCE

The Flatpack2 rectifier has no customer serviceable components

The DC/DC converter has no customer serviceable components.

Should a rectifier exhibit a fault, simply pop the handles out, and pull out using these same handles on the front of the module (Contact Eltek Pacific for repairs/ replacement) Should a converter exhibit a fault, simply pop the handles out, and pull out using these same handles on the front of the module (Contact Eltek Pacific for repairs/ replacement)

26. GENERAL PROCEDURES As a general requirement we would recommend the following checks be made to the system at six monthly intervals. Check Frequency Purpose Visual inspection Monthly To identify any obvious problems. Such as corrosion to terminal posts, leaking batteries, not excessively dirty or dusty, not mechanically damaged in any way Battery Discharge 6 monthly To determine battery performance Test via control module Check and adjust 6 Monthly To ensure rectifier is charging at correct DC output voltage voltage level. Torque battery 6 Monthly To ensure correct level of torque as per battery terminals manufacturers install instructions. General clean 6 Monthly Wipe down systems remove any dust build up

27.

SYSTEM COMPONENTS MINIMUM OPERATING LIFE

Description

Minimum Operating Life (years) >15

FlatPack2 Rectifier Smartpack >15 Control Module DC/DC Converter >15

Potential Failure

Indication

Action

Fault LED lit Monitor Failure Failure

Red LED lit

Replace Module Replace Module Replace Module

Monitor fail relay Red LED lit


Page 59 of 64


28. POWERSUITE AND WEB POWER Installation and Using of PowerSuite Software. The PowerSuite system communication software must be installed on your personal computer. PowerSuite is available on CD-ROM. By inserting the CD-ROM in the CDROM drive. The installation program will guide you through a complete installation. Setting up Communication between PC and Smartpack. There are two methods to build the connection between a computer and a SMARTPACK. Firstly, a connection can be set from a computer, via an A-B USB cable, to the USB port in the front panel of a SMARTPACK. The following steps show how to login to PowerSuite. 1. Via USB connection open PowerSuite 3.3, go to “Connect”  “Serial (Virtual USB) 1”  “Find COM Port #”  enter Password “3” and click “Connect”.

Figure 28.1 Connect to the Smartpack 2. If you have an Ethernet connection plugged into the back of the Smartpack, then you can communicate with the Smartpack. You will need to setup the IP address of the Smartpack following the Webpower system manual (which is on the accompanying CD). To open an Ethernet connection, open PowerSuite 3.3, go to “Network”  “New Connection”, fill in the IP address, enter password “3” and click “Connect”. On the CD you will find “Webpower install” folder and the EVIPsetup file in the Eltek Network Utility folder that can be used to set up the IP address of the Smartpack. Following the manual (also in this folder) will show how to setup the IP and log into the PowerSuite via local network.

Figure 28.2 Contents of accompanying CD TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems

Page 60 of 64


Configuration of the Smartpack The Smartpack is pre-configured before shipment, and all the pre-configuration is saved in an “xml” file on the CD. To upload the configuration to the Smartpack, simply import the “xml” file to Smartpack via PowerSuite. If it is necessary to re-configure it, please follow the step below. 1. Import the required “.xml” file into Smartpack. Go to “Power Suite”  “Tools”  “Import/Export Configuration”  “Source”  “Read from file” .Click “Open…”

Figure 28.3 Import “xml” file (a) 2. Check the box “Read from file” and click “NEXT”, browse to your xml file on the CD and follow the prompts.

Figure 28.4 Import “xml” file (b)


Page 61 of 64


Using PowerSuite to Monitor the Smartpack The site information should be updated at the beginning of the commissioning (Fig 15.6). Message 1 and 2 will be filled out already with some information.

Figure 28.5 Site Information Window The status of each part of the power system can also be read form PowerSuite. To check the status of any particular part of the system, simply double click the name of the coloured indicator in the “Power Explorer”. Alarm indicators: The “Green” shows working normally. The “Red” means a failure is present or power is disconnected.

Figure 28.6 Power Explorer bar


Page 62 of 64


The other parameters of the power system can be read and set in the function block above the Power Explorer.

Figure 28.7 Other Configuration Tools

The Active alarm group window under “Alarms Overview” will give you a quick snapshot of the alarms that are on the system.

Figure 28.8 Activate Alarm Group Window

For more detailed information on using PowerSuite see the attachment: PowerSuite User Guide (356807.063)


Page 63 of 64


29. ATTACHMENTS 29.1 29.2 29.3 29.4 29.5 29.6 29.7 29.8 29.9 29.10 29.11 29.12 29.13 29.14 29.15 29.16 29.17 29.18 29.19 29.20 29.21 29.22 29.23 29.24 29.25 29.26 29.27

Flatpack2 2kW rectifier Datasheet Flatpack2 1.8kW rectifier Datasheet Smartpack Datasheet Flatpack DC/DC -48/+24 Datasheet 12FFT100 Battery Datasheet 12FIT100 Battery Datasheet Battery MSDS TG6209 Battery bracket label swatch TG5537 Front panel label swatch TG5536 Black on Yellow self adhesive vinyl labels TG6208 Software setting file FP2 TG6223 Alarm matrix FP2 TG6228 Alarm matrix DC/DC converter TG6217 Alarm pinout FP2 TG6210 General arrangement SEF29-X-149 TG6211 General arrangement SEF29-X-150 TG6215 General arrangement SEB5-12FIT100-002 TG6216 General arrangement SEB6-12FFT100-002 TG6222 General arrangement SEF29-X-156 TG6308 Cabinet to wall support channel TG6224 Wiring diagram (Legacy) TG6682A Schematic for SP18 System TG6683A Schematic for SP18-RRU System TG6678A General arrangement SP18 system TG6667D General arrangement SP18-RRU system TG9280A General arrangement SP18 Battery Extension Rack PowerSuite User Guide (356807.063)


Page 64 of 64

Flatpack2 48/2000 HE

Rectifier Module

The most efficient rectifier in the industry! The combination of innovative design, efficiency and reliability makes the Flatpack2 HE stand out. With an efficiency up to 96.5%, the losses have been reduced by 50% compared to the current industry standard. In a global perspective, considering the high energy consumption in the telecom industry, this technology breakthrough is not only reducing operational cost for the operators, but it can also have a significant environmental impact.

Applications

Product Features and Advantages

Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost effective and compact DC power systems. Flatpack2 HE delivers an industry leading power density and superb reliability at lowest lifetime cost.

Flexibility and reliability Extensive use of digital controllers has enabled advanced functionality to meet most customers’ requirements. It also provides intelligent self-protective features like reduced output power at high temperatures or low mains.

The HE rectifier also has an extremely high efficiency at low load, which historically has been a drawback with most modern soft switching technologies.

Plug and play Plug a new rectifier into the system, and it automatically logs on, gets an assigned ID, downloads the system set parameters from the control system and starts up with a minimum of installation time, and without interrupting the system or attached equipment.

Broadband and network access Increasing network speed demands flexible and expandable DC power solutions. The Flatpack2 HE rectifiers are your key building blocks for future needs. Small and large Due to the high power density, cost competitive design and a highly flexible system communication interface, Flatpack2 HE rectifiers are used in system solutions from 2kW to 192kW.

The HE rectifier is made fully compliant with the standard Flatpack2 rectifier which means it can be used in any FP2 system solutions, whether it is in new installations, site expansions or replacement programs. Global compliance Eltek Valere is among the market leaders in all regions in the world, and designs the core products to be compliant to all relevant standards and customer requirements. All Flatpack2 rectifiers are CE marked, UL recognized and NEBS compliant. Patents pending Flatpack2 HE is a result of intensive research over many years. Several unique technical solutions are introduced, protected by patent applications.

See reverse side for specifications

www.eltekvalere.com

Flatpack2 48/2000 HE Additional Technical Specifications AC Input

Other Specifications

Voltage

85-300 VAC (Nominal 185 – 275 VAC)

Efficiency

>96% at 30-70% load

Frequency

45 to 66Hz

Isolation

Maximum Current

11.6 Arms maximum at nominal input and full load

3.0 KVAC – input and output 1.5 KVAC – input earth 0.5 KVDC – output earth

Power Factor

> 0.99 at 50% load or more

Alarms:

Input Protection

o Varistors for transient protection o Mains fuse in both lines o Disconnect above 300 VAC

o o o o o o o

Warnings:

o o o o

Visual indications

o Green LED: ON, no faults o Red LED: rectifier failure o Yellow LED : rectifier warning

Operating temp

-40 to +75°C (-40 to +167°F)

Low mains shutdown High temperature shutdown Rectifier Failure Overvoltage shutdown on output Fan failure Low voltage alarm at 43.5V CAN bus failure

Low temperature shutdown Rectifier in power derate mode Remote battery current limit activated Input voltage out of range, flashing at overvoltage o Loss of CAN communication with control unit, stand alone mode

DC Output Voltage

53.5 VDC (adj. range: 43.5-57.6 VDC)

Output Power

2000 W at nominal input

Maximum Current

41.7 Amps at 48 VDC and nominal input

Current Sharing

±5% of maximum current from 10 to 100% load

Static voltage regulation

±0.5% from 10% to 100% load

Storage temp

-40 to +85°C (-40 to +185°F)

Dynamic voltage regulation

±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms

Cooling

Fan (front to back airflow)

Fan Speed

Temperature and current regulated

Hold up time

> 20ms; output voltage > 43.5 VDC at 1500W load

MTBF

> 350, 000 hours Telcordia SR-332 Issue I, method III (a) (Tambient : 25°C)

Ripple and Noise

o < 100 mV peak to peak, o 30 MHz bandwidth o < 2 mV rms psophometric

Acoustic Noise

Output Protection

o o o o

< 20dBA at nominal input and full load (Tambient <= 25°C) < 56dBA at nominal input and full load (Tambient > 40°C)

Humidity

Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing

Dimensions

109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)

Weight

1.950 kg (4.3lbs)

Overvoltage shutdown Hot plug-in - Inrush current limiting Short circuit proof High temperature protection

Applicable Standards Electrical safety

IEC 60950-1 UL 60950-1 CSA 22.2

EMC

ETSI EN 300 386 V.1.3.2 EN 61000-6-1 (immunity, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-4 (emission, industry) Telcordia NEBS GR1089 CORE

Mains Harmonics

EN 61000-3-2

Environment

ETSI EN 300 019-2-1 Class 1.2 ETSI EN 300 019-2-2 Class 2.3 ETSI EN 300 019-2-3 Class 3.2 ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant

Efficiency 100%

95%

90%

96%

95%

85% 200

400

600

800

1000

1200

1400

1600

1800

2000

Output Load (W)

241115.105.DS3 – v9

Specifications are subject to change without notice

Ordering Information

Part no.

Description

241115.105 Flatpack2 48/2000 HE www.eltekvalere.com Eltek Valere Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

Flatpack2 48/2000

Rectifier Module

Versatile and powerful solution for any application The combination of cost-effective design, power density and reliability makes the Flatpack2 a product family that truly stands outs and provides unparalleled network availability. The versatility of the Flatpack2 rectifier means that it can be used in a wide variety of 48VDC and 24VDC applications across the globe.

Applications

Key Features

Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost effective and compact DC power systems. Flatpack2 delivers an industry leading power density and superb reliability at lowest lifetime cost

Highest efficiency in minimum space Resonant topology makes the module efficiency industry leading and contributes to the rectifier’s ultra compact dimensions. Digital controllers Primary and secondary controls are digitalized, enabling excellent monitoring and regulation characteristics. Thus, the number of component has been reduced by 40% - for highly reliable, long life, trouble free DC power systems. Heat management Front-to-back air flow with chassis-integrated heat sinks gives the module the most suitable working environment and no limitations in the scalability of the desired system solution. Unique connection A true plug-and-play connection system: time-to-install and cost-reducing solution. Global approvals Flatpack2 is CE marked, UL recognized and NEBS certified for worldwide installation.

Broadband and network access Increasing network speed demands flexible and expandable DC power solutions. The Flatpack2 rectifiers are your key building blocks for future needs. Small and large Due to the high power density, cost competitive design and a highly flexible system communication interface, Flatpack2 rectifiers are used in system solutions from 5kW to 96kW.

Product Description The Flatpack2 is a battery charger and rectifier for standalone use or for working in parallel as part of a DC power system controlled and monitored by the Smartpack. Flatpack2 is optimized for a wide range of system sizes. Digital communication over CAN bus with Smartpack simplifies system design and enhances flexibility. Realization of Flatpack2 systems is possible by fitting 4 rectifiers across a 23” or 19” shelf.


www.eltekvalere.com

Flatpack2 48/2000 Additional Technical Specifications Input

Other Specifications

AC Voltage

85-300 VAC (Nominal 185 – 275 VAC)

Efficiency

Typical 92%, min. 91% at 40-90% load

Frequency

45 to 66Hz

Isolation

Maximum Current



Power Factor


Alarms:

DC Voltage

120-275VDC (Rated 140 – 250VDC)

Input Protection

o Varistors for transient protection o Mains fuse in both lines o Disconnect above 300 VAC

o o o o o o o

Warnings:

o o o o

Visual indications

o Green LED: ON, no faults o Red LED: rectifier failure o Yellow LED : rectifier warning

DC Output

Low mains shutdown High temperature shutdown Rectifier Failure Overvoltage shutdown on output Fan failure, one or two fans. Low voltage alarm at 43.5V CAN bus failure

Low temperature shutdown Rectifier in power derate mode Remote battery current limit activated Input voltage out of range, flashing at overvoltage o Loss of CAN communication with control unit, stand alone mode

Voltage

53.5 VDC (adj. range: 43.5-57.6 VDC)

Output Power


Maximum Current


Current Sharing

±5% of maximum current from 10% to 100% load

Operating temp

-40 to +75°C (-40 to +158°F)


±0.5% from 10% to 100% load

Storage temp

-40 to +85°C (-40 to +185°F)

Cooling

2 fans (front to back airflow)



Fan Speed

Temperature and current regulated

MTBF

Hold up time


> 350, 000 hours Telcordia SR-332 Issue I, method III (a) (Tambient : 25°C)

Ripple and Noise

o < 100 mV peak to peak, o 30 MHz bandwidth o < 0.96 mV rms psophometric

Acoustic Noise

< 55dBA at nominal input and full load (Tambient < 30°C)

Humidity


Dimensions

109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)

Weight

1.9 kg (4.19lbs)

Output Protection

o o o o

Overvoltage shutdown Blocking diode Short circuit proof High temperature protection

Applicable Standards Electrical safety

IEC 60950-1 UL 60950-1 CSA 22.2

EMC

ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-1 (immunity, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-4 (emission, industry) Telcordia NEBS GR1089 CORE

Mains Harmonics

EN 61000-3-2

Environment

ETSI EN 300 019-2 (-1, -2, -3) ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant

Specifications are subject to change without notice

241115.100.DS3 – v6


Part no.

Description

241115.100 Flatpack2 48/2000

www.eltekvalere.com Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Eltek Valere Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

Flatpack2 48/1800 Switch Mode Power Supply 48VDC

Product Description

Key Features

The Flatpack2 is a battery charger and rectifier for

ü

stand-alone use or for working in parallel as part of a

Resonant topology makes the module efficiency industry

DC power system controlled and monitored by the

leading and contributes to the rectifier’s ultra compact

Smartpack.

dimensions.

Flatpack2 is optimized for a wide range of system sizes.

ü

Digital communication over CAN bus with Smartpack

Primary and secondary controls are digitalized, enabling

simplifies system design and enhances flexibility.

excellent monitoring and regulation characteristics.

Realization of Flatpack2 systems is possible by fitting 5 rectifiers across a 23” shelf and 4 rectifiers across a 19” shelf.

Digital controllers

Thus, the number of component has been reduced by 40% - for highly reliable, long life, trouble free DC power systems. ü

Applications

Highest efficiency in minimum space

Heat management

Front-to-back air flow with chassis-integrated heat sinks

Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost efficient and compact DC power systems. Flatpack2

gives the module the most suitable working environment and no limitations in the scalability of the desired system solution.

delivers the industry leading power density of 21W/in3

ü

and superb reliability at lowest lifetime cost.

A true plug-and-play connection system: time-to-install

Unique connection

and cost-reducing solution.

Broadband and network access Increasing network speed demands flexible and

ü

expandable DC power solutions. Flatpack2 is your key

Flatpack2 is CE marked, UL recognized and NEBS

building block for future needs.

certified for world wide installation.

Global approvals

109 mm 109.00

41.50

Flatpack2 Switch Mode Power Supply 48VDC (coming up…) www.eltekenergy.com

I www.flatpack2.com

41,5 mm

327 327 .22 mm

Flatpack2

Additional Technical Specifications Other Specifications

AC Input 85-290 VAC (Nominal 185 – 275 VAC)

Efficiency

Typical 92%, min. 91% at 40-90% load

Frequency

45 to 66Hz

Isolation

Maximum Current



Power Factor


Alarms:

Input Protection

Varistors for transient protection Mains fuse in both lines Disconnect above 290 VAC

Low mains shutdown High temperature shutdown Rectifier Failure Overvoltage shutdown on output Fan failure, one or two fans. Low voltage alarm at 43.5V CAN bus failure

Warnings:

Rectifier in power derate mode Remote battery current limit activated Input voltage out of range, flashing at overvoltage Loss of CAN communication with control unit, stand alone mode

Visual indications

Green LED: ON, no faults Red LED: rectifier failure Yellow LED : rectifier warning

Voltage

DC Output Voltage

53.5 VDC (adj. range: 43.5-56.0 VDC)

Output Power


Maximum Current


Current Sharing

±3% from true average current between modules


±0.5% from 10% to 100% load

Operating temp

-40 to +70°C (-40 to +158°F)



Storage temp

-40 to +85°C (-40 to +185°F)

Cooling

2 fans (front to back airflow)

Hold up time


Fan Speed

Temperature and load regulated

MTBF

Ripple and Noise

< 100 mV peak to peak, 30 MHz bandwith < 0.96 mV rms psophometric

> 250, 000 hours Telcordia SR-332 Issue I, method III (a)

Acoustic Noise

< 50dBA at nominal input and 70% load (Tambient < 30°C)

Humidity


Dimensions

109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)

Weight

1.8 kg (3.97 lbs)

Output Protection

Overvoltage shutdown Blocking diode Short circuit proof High temperature protection

Applicable standards Electrical safety

IEC 60950-1 UL 60950-1 CSA 22.2

EMC

ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-4 (emission, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-1 (immunity, light industry) Telcordia NEBS GR1089 CORE

Harmonics

EN 61000-3-2

Environment

ETSI EN 300 019-2 ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant (pending)

Specifications are subject to change without notice.

ORDERING INFORMATION Part no.

Description

241115.001

Flatpack2 48V

Document Rev. No.: 241115.001.DS3 v.05

Location Europe Americas Asia/Pacific China Middle East

Company Eltek Energy AS Eltek Energy, LLC Eltek Energy Pte Ltd. Eltek Energy Ltd. Eltek Middle East

www.eltekenergy.com

Telephone +47 32 20 32 00 +1 815 459 9100 +65 6 7732326 +852 28982689 +971 4 887 1176

I www.flatpack2.com

Fax +47 32 20 32 10 +1 815 459 9118 +65 6 7753602 +852 28983189 +971 4 887 1175

Smartpack Controller Monitoring and Control Unit

Powerful and cost effective control module The Smartpack controller is a monitoring and control unit used as the vital nerve center of the DC power plant. You operate the system from the elegant front panel, using three front keys and the LCD-display. They represent the main interface between you and the system.

Applications

Key Features

CAN bus communication Smartpack utilizes a digital interface architecture (CAN bus communication). It allows the unit to support dedicated communication channel with each rectifier, providing for increased number of functions and greater flexibility.

ü

Front panel LCD and buttons for on-site service without PC. (Not on Basic Slave model)

ü

USB- or RS-232 interface for PC connection locally or remote monitoring and control via modem, Ethernet, web or SNMP.

Modular design The Smartpack is extremely flexible in its expandability. Additional units connected to the CAN bus can be added to provide extended functionality and increased number of measuring points. Accordingly, system components can be set up and upgraded to meet the demand of any tailor-made power solution.

ü

6/2 user programmable relay outputs for traditional remote monitoring

ü

6/2 user programmable inputs for monitoring of other equipment on site

ü

Battery monitoring and testing without site attendance

ü

Temperature compensated charging for increased battery lifetime

ü

Battery lifetime indication

ü

Password protected operator access levels

ü

Alarm/event log with time and date

ü

Windows-based PC communication software

Product Description The Smartpack controller is a powerful and cost-effective module, developed for monitoring and controlling a wide range of Eltek Valere’s DC power supply systems, such as Powerpack, Flatpack2 and Minipack DC power systems. You can also operate the system locally via a PC using the PowerSuite PC application, or remotely via modem, Ethernet and the Web. The module then utilizes the USB- or RS-232 ports to interface with a local PC, SNMP or Web adapters.


www.eltekvalere.com

Smartpack Controller Additional Technical Specifications Remote Monitoring and Control

Local Monitoring and Control

ü From a PC running PowerSuite a Windows-based communication program installed on a remote computer, the system can be monitored and controlled via modem or Ethernet network ü From a PC running a WEB Browser the system can be monitored and controlled via Ethernet network ü

ü

From an NMS via Ethernet (SNMP) With an SNMP agent connected to the Smartpack, the system can be monitored and controlled from a Network Management System (NMS) through Ethernet on Simple Network Management Protocol (SNMP)

ü From a PC running PowerSuite a Windows-based communication software, can also communicate with the Smartpack through an USB serial or RS-232 cable ü

LCD and three keypads for local operations If any alarm (major or minor) is activated, a (red or yellow) LED is lit in the front panel, the alarm text appears in the LCD and the corresponding alarm relay is activated In normal operation, the front LCD will display the output voltage, battery current, load current and charge mode. (Not on Basic Slave version)

Using alarm relays (voltage free contacts) 6/2 internal failsafe alarm relays provide voltage free contacts that can be connected to equipment used for traditional alarm monitoring

Available Alarms All alarms can be set up with monitoring of minor, major, average and peak levels.

Features System o Output Voltage Measurement o Total Load Current Measurement o Load/Battery Disconnect o Alarm Level Settings (major / minor) o Alarm Log (up to 1000 events, 10k on HW v2) o Real Time Clock with Battery Backup o Site Text/ID o Test of Relay Outputs o Voltage Level setup o Data logging (up to 7000 data points) Battery o Battery Current Measurement o Battery Temperature Measurement (optional) o Battery Testing (acc. to discharge table or set time limit) o Battery Test Information (10 latest tests) o Setup of Battery Data o Battery shunt setup o Battery quality indication o Battery Boost Charging o Battery Cable Voltage Drop Compensation o Temperature Compensated Charging o Protection against Temperature Probe Failure Rectifier o Available information about each rectifier, e.g. serial o number, version, internal temperature o Individual Rectifier Current Measurement o Individual Rectifier Input Voltage o Efficiency Management

System o Mains Failure (individual phases) o Digital Inputs (programmable names) o Load Disconnect (voltage or timer) o Load Fuse o Load Current Battery o High Battery voltage o Low Battery voltage o High Battery temperature o Low Battery temperature o Battery Capacity o Battery Disconnect o Battery Fuse o Symmetry Failure o Battery quality indication Battery discharge current Rectifier o Rectifier Failure o Critical Rectifier Failure (> 1, programmable) o Rectifier Capacity w. programmable level o Rectifier Current Limit o Rectifier Overvoltage Protection o Rectifier Current

Specifications Input Voltage

24/48/60 VDC nominal system voltages

Dimensions (WxHxD)

109 x 44 (1U) x 140mm 4.3 x 1.7 x 5.5”

Specifications are subject to change without notice 242100.100.DS3– v7


Part no.

Description

242100.110 242100.111 242100.112 242100.113 242100.118 242100.000

Smartpack Extended (6 + 6 I/O, 2 String Battery connection) Smartpack RS-232 front (RS-232, 6 + 6 I/O, 2 String Battery connection) Smartpack RS-232 rear (RS-232, 6 + 6 I/O, 1 String Battery connection) Smartpack WEB/SNMP (Ethernet, 2 + 2 I/O, 2 String Battery connection) Smartpack WEB/SNMP (Ethernet, 6 + 6 I/O, 1 String Battery connection) Smartpack Basic Slave (without display, buttons & internal power for distributed systems)

www.eltekvalere.com Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Eltek Valere Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

Flatpack DC/DC | 48/24 DC/DC Converter

The Flatpack DC/DC 48/24 is a modular hot plug-in DC/DC converter prepared for stand-alone use, or for working in parallel as part of a DC/DC rack system. The converter is specially designed to provide a high

A module failure alarm is given if the module shuts down

quality and highly reliable DC output voltage.

due to high/low input voltage, high output voltage (selective), or in case of an internal failure.

Switch mode technology with soft switching and high switching frequency is used to minimise volume and

Converters connected in parallel will exhibit active load

weight, and to obtain fast output voltage regulation.

sharing, even without a Monitoring and

Control Unit via

CAN bus. The module has a soft start power-up. When working in parallel, the converters provide active current sharing. An internal blocking diode allows hot plug-in and

Front LEDs show power ON/OFF and alarm status in addition to a LED bar graph for output current indication.

isolates any faults in the converter output from the DCbus.

The Flatpack

DC/DC 48/24

will

operate in ambient

temperatures up to +75°C (+167°F). At temperatures Several

internal

protection

circuits

ensure

safe

operation, even outside specified limits for normal operation.

above

+65°C

derated.

(+149°F),

the

output

power may

be

OTHER SPECIFICATIONS

FLATPACK DC/DC 48/24

Isolation Voltages

SPECIFICATIONS INPUT Input Voltage range Maximum Current Protection

40.0-60 VDC 32 Amps at 40.0 VDC input Soft start Internal fuse Automatic shutdown for input voltages < 40 VDC and > 62 VDC

OUTPUT Output Voltage Output Power Output Current Current Share Static Voltage Regulation Dynamic Voltage Regulation Ripple and Noise Protection

24-28 VDC 1100 W at 27.5 VDC 40 Amps at 24 VDC ± 2 Amps ±0.5% from 0 to full load ±4.0% for 10-90% or 90-10% load variation <100 mV peak to peak, 30 MHz bandwidth Blocking diode Non-destructive short circuit operation and selective high output voltage shutdown (30 V)

Input/ Earth: 600 VDC Input/ Output: 600 VDC Output/ Earth: 600 VDC Converter No output voltage alarms Overvoltage shutdown Fan failure 1 or 2 High temperature shutdown Short circuit/ fold back activated Converter DC input voltage out of range warnings Single fan failure High temperature/ derating activated Current limit Visual Green LED: ON, no faults indications Red LED: No output, converter failure Yellow LED bargraph: measuring output current (0-100%) Efficiency 90% typical Operating -40 to +65°C (-40 to +149°F) Temp +65 to +75 °C (+149 to +167°F): Temperature dependent power limiting may occur Storage Temp -40 to +85 °C (-40 to +185°F) Cooling Temperature controlled fans Acoustic Noise 6.3 Bels Dimensions 218 x 43 x 240mm (wxhxd) (8.58 x 1.69 x 9.45”) Weight < 3kg (< 6.6lbs)

APPLICABLE STANDARDS Electrical safety EN 60950, UL 60950 EMC

ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-4 (emission, industry) EN 61000-6-1 (immunity, light industry) Telcordia GR1089 CORE Environment ETSI EN 300 019-2 ETSI EN 300 132-1 ETSI EN 300 132-2 Telcordia GR63 CORE Zone 4 ETSI EN 300 753 class 3.1 (acoustic noise) Specifications are subject to change without notice.

ORDERING INFORMATION Part no. Description 241114.503

Flatpack DC/DC 48/24 converter

241114.503. DS3 v.02

Location Europe Americas Asia/Pacific China Middle East

Company Eltek Energy AS Eltek Energy, LLC Eltek Energy Pte Ltd. Eltek Energy Ltd. Eltek Middle East

Telephone +47 32 20 32 00 +1 815 459 9100 +65 6 7732326 +852 28982689 +971 4 887 1176

Fax +47 32 20 32 10 +1 815 459 9118 +65 6 7753602 +852 28983189 +971 4 887 1175

B649=:42; 762BC@6A

Yeb cîfhu fj`hqabo i^ju _^ppbnu n^jdbo bolb`f^hhu abofdjba pk kccbn peb sfabn ob`qnfpu ^ja nbhf^_fhfpu ckn Ybhb`kiiqjf`^pfkj ^llhf`^pfkjo _kpe sfnbhfjb ^ja sfnbhboo : Yeb VVW hfjb `krbno peb n^jdb _bpsbbj =<< Ge ^ja =B< Ge: Yeb LOGRR [^hrb Wbdqh^pba Qbâ G`fa _^ppbnfbo 6[WQG7 ^nb kc G_okn_ba Mhôo R^p pbèjkhkdu 6GMR7: Ktpbjofrb pbopfjd ^ja `qopkibn cfbha btlbnfbj`b ofj`b 5o fj`blpfkj aqnfjd =EDA bjoqnbo qhpfi^pb nbhf^_fhfpu ^ja kccbno peb i^ju _bjbcfpo: Yeb LOGRR VVW n^jdb kccbnfjd ^hh peb âr^jp^dbo kc ^_okn_ba bhb`pnkhupb r^hrb nbdqh^pba hbâ9^`fa _^ppbnfbo8 sfpe peb ^``boof_fhfpu kc cnkjp pbnifj^ho: Yeb cnkjp pbnifj^ho c^`fhfp^pb ^``boo sebj `kjjb`pfkj ql peb ikjk_hkò aqnfjd peb fjop^hh^pfkj8 ^ja ofilhfcu i^fjpbj^j`b:R^fjpbj^j`b `kopo ^nb pebnbcknb nbaq`ba ^ja ouopbi nbhf^_fhfpu filnkrba: Yeb cnkjp ^``boo pbnifj^ho ^nb cqhhu fjoqh^pba _u pbnifj^h `krbno peqo bjoqnfjd bhb`pnf`^h o^cbpu: Yeb pbnifj^h `krbno e^rb ^ olb`f^hhu abofdjba ^``boo ekhb pk bj^_hb rkhp^db nbâfjdo pk _b iâb o^cbhu ^ja bôfhu: Yeb `kil^`p abofdj c^`fhfp^pbo ^ ifjfiqi ckkplnfjp ^hhksfjd ^ _bppbn _^ppbnu ^nn^jdbibjp _kpe fj `^_fjbpo ^ja kj n^`go:Yeb efdebop mq^hfpu hbrbh fo bjoqnba _u peb OXT E<<= ^ja OXT=@<<= Ibnpfcf`^pba Vq^hfpu Xuopbi:

?LESHR ENG 8QKGRF pef`g lôpba lh^pbo ^ja dnfao kc efde mq^hfpu Qbâ9Yfj9I^h`fqi ^hhku AHPEQESOQRF if`nklknkqo dhôo i^po 4ONSEKNHQR ENG ;KGRF iâb cnki pef`g9 s^hhba GHX chîb nbp^na^jp lhôpf` abofdjba ckn qjoqnlôoba ibè^jf`^h opnbjdpe ^ja fj ^``kna^j`b sfpe chîb nbp^na^jù op^ja^na OKI C
2??;:423;6 AB2=52@5A Kqnk_^p Mqfab 9 hkjd hfcb Ybh`knaf^ 6Hbhh`knb7 YW9S\Y9<<E< U^np @ Hnfpfoe Xp^ja^na B??@ ibpeka L[< OKI B=9>> ZQ Wb`kdjfvba

?@>5C4B 762BC@6A

Lfpo fj >?4 n^`g;`^_fjbp Kôu qjl^`gfjd Tlpfkj^h nbikpb rbjpfjd ouopbi Tlpfkj^h ib^jo kc `kjjb`pfkj cnki peb cnkjp8 peb pkl ^ja peb ofab kc peb ikjk_hkò kccbnfjd chbtf_fhfpu pk `kjjb`p peb ikjk_hkò ^``knafjd pk ^r^fh^_hb ol^`b

+yz} y*xy}

6;64BW:42; 492@24B6@+AB:4A

7: 2<< 77B Q ENJ H HGYYKW] Y]UK

STROSGQ [TQYGMK 6[7

STROSGQ OSYKWSGQ IGUGIOY] WKXOXYGSIK 6 Ge ^p >< 7 6ikei7 =< eno pk=:D< [UI

XNTWY IOWIZOY IZWWKSY 6G7

Q

\

\KOMNY

JORKSXO T SX 6ii7 YN

6Pd7

z{ ,,/ zyy

=>

=<<

@:A

2200

AAD

=>B

>?<

?D

z{ ,,/ zy}

=>

=
@:@

>D<<

AAD

=>B

>?<

@=

z{ ,,/ z|y

=>

=?<

@:=

?<<<

AAD

=>B

>C<

A<

?><<

AAD

=>B

?><

B<

z{ ,,/ z~y

=>

=B<

?:E

.

0

/-

222*./,00*-10

fit range TECHNICAL FEATURES

The family includes many battery ranges especially designed to offer the wider security and reliability for Telecommunication applications both wireline and wireless. The fit line covers the range between 30 Ah and 100 Ah. The FIAMM Valve Regulated Lead Acid batteries (VRLA) are of Absorbed Glass Mat technology (AGM). Extensive testing and customer field experience since 's inception during 1985 ensures ultimate reliability and offers the many benefits. The FIAMM fit range offering all the advantages of absorbed electrolyte valve regulated lead-acid batteries, with the accessibility of front terminals. The front terminals facilitate access when connection up the monoblocs during the installation, and simplify maintenance.Maintenance costs are therefore reduced and system reliability improved. The front access terminals are fully insulated by terminal covers thus ensuring electrical safety. The terminal covers have a specially designed access hole to enable voltage readings to be made safely and easily. The compact design facilitates a minimum footprint allowing a better battery arrangement both in cabinets and on racks.The highest quality level is ensured by the ISO 9001 and ISO14001 Certificated Quality System.

APPLICABLE STANDARDS Eurobat Guide - long life Telcordia (Bellcore) TR-NWT-000766 Telcordia (Bellcore) TR-NWT-000909 British Standard BS 6290 Part 4 British Standard 6334 method FV0 IEC 60896 Part 21-22 UL Recognized

PRODUCT FEATURES

Fits in 19" rack/cabinet Easy unpacking Optional remote venting system

Standby Batteries

Plates and Grids: thick pasted plates and grids of high quality Lead-Tin-Calcium alloy Separators: microporous glass mats Containers and Lids: made from thickwalled ABS flame retardant plastic designed for unsurpassed mechanical strength and in accordance with flame retardancy standard IEC 707 FV0 . Terminals: M6 terminals provide for high conductivity, minimum installation time, and maximum torque retention Flame Arrestors: expel excess gas while preventing any errant spark or flame from entering the battery Handles:facilitate ease in handling, installation and removal of the batteries Safety Valves: operate at low internal pressure Connections: the terminals allow for front, top or side connections depending on the space constraints of the installation Remote Venting System: an optional Remote Venting System (RVS) is available for applications which require small amounts of gas (generated during normal operation) to be vented externally

fit range

8014 07.05

FI AMM F I T r ang e

Standby Batteries

(mm) 12 FIT 30

12

30

13.5

700

280

105

190

14

12 FIT 40

12

40

13

800

395

108

199

18

12 FIT 55

12

55

9.4

1200

395

108

199

22

12 FIT 75

12

75

5.8

1980

395

108

287

29

12 FIT100

12

100

4.4

2200

395

108

287

33

www.fiamm.com

Industrial Batteries Department Viale Europa, 63 - 36075 Montecchio Maggiore (VI) ITALY

MATERIAL SAFETY DATA SHEET FIAMM BATTERIES: Monolite

PRODUCT CHARACTERISTICS PRODUCT Valve Regulated Lead Acid Sealed batteries with absorbed electrolyte wet (non spillable). PRODUCT TECHNICAL COMPONENTS Components Lead and Compounds Electrolyte Polymer

Description Pb, PbO2, PbSO4 Sulphuric acid in max concentration of 35% ABS

% 70-80 12-20 6-9

TECHNICAL NAME OF DANGEROUS SUBSTANCE Sealed batteries containing a solution of sulphuric acid and distilled water, completely absorbed in separators. PROPERTIES OF CONTAINER ABS polymer, flame retardant FV0, anti-cracking. PROPERTIES OF DANGEROUS SUBSTANCE Liquid, clear, colourless. BOILING POINT OF DANGEROUS SUBSTANCE 110o C CLASSIFICATION OF DANGEROUS SUBSTANCE Class 8 Code page IMDG IMCO No.8121 UN No 2800 PACKAGING REQUIRED FOR TRANSPORTATION Batteries have to be packed in strong outer packagings after insulating each cell terminals. Packaging Group III IMPORTANT NOTE There is no electrolyte in liquid status inside the battery due to the fact that this electrolyte is completely absorbed by a spungy material. This means that even if you turn upside down (ermetically closed) there will be no leakage of the electrolyte. Conditions will not change below boiling point (110o C).

SAFETY DATA NATURE OF HAZARD Corrosive liquid electrolyte causes damage to eyes, skin & air passages. Attacks many materials & clothing. Attacks many metals with liberation of hydrogen which is flammable and forms explosive mixture with air. Stored electrical energy.

an

PROTECTIVE MEASURES Goggles giving complete protection to eyes, acid resistant clothing and gloves, and safety footwear. Have available an eyewash bottle with clean water. Store in a cool dry place. Keep all vent plugs in position. Charge in a well ventilated area, avoid breathing mist. Keep away from sources of ignition, do not allow smoking or any naked lights. Keep away from children. For safe operating practices see BS 6287:1982 FIRST AID If substance has got into eyes, immediately wash out with plenty of water. If ingested drink copious amounts of water and seek immediate medical attention. Remove any contaminated clothing and wash skin with water. Seek medical treatment. SPILLAGE Close off or contain leak if without risk, using plastic containers if available. Neutralise with soda ash, sodium carbonate or sodium bicarbonate. If undiluted substance has entered a watercourse or contaminated soil or vegetation, advise local authority. FIRE If circuit still made, and if safe to do so, the emergency services may sever cables with fireman’s axe. Smother with dry powder or foam. If necessary keep containers cool by spraying with water. DISPOSAL This product is defined in SI 232:1994 as being for fitment to an excluded appliance. The cells contain heavy metal and must not be put out for collection in refuse containers. Keep all constituents enclosed and upright. Dispose of only to authorised scrap recoverer. Move only in accordance with local authority requirements. Do not incinerate or throw away.

_____________________________________________________________________________ Fiamm Asia Pacific Pte Ltd 36 Tuas Crescent Singapore Tel 0065 8653278 Fax 0065 8626550

Industrial Batteries Department Viale Europa, 63 - 36075 Montecchio Maggiore (VI) ITALY

MATERIAL SAFETY DATA SHEET FIAMM BATTERIES: SLA/FAT/UMTB

PRODUCT CHARACTERISTICS PRODUCT Valve Regulated Lead Acid Sealed batteries with absorbed electrolyte wet (non spillable). PRODUCT TECHNICAL COMPONENTS Components Lead and Compounds Electrolyte Polymer

Description Pb, PbO2, PbSO4 Sulphuric acid in max concentration of 35% ABS

% 70-80 12-20 6-9

TECHNICAL NAME OF DANGEROUS SUBSTANCE Sealed batteries containing a solution of sulphuric acid and distilled water, completely absorbed in separators. PROPERTIES OF CONTAINER ABS polymer, flame retardant FV0, anti-cracking. PROPERTIES OF DANGEROUS SUBSTANCE Liquid, clear, colourless. BOILING POINT OF DANGEROUS SUBSTANCE 110o C CLASSIFICATION OF DANGEROUS SUBSTANCE Class 8 Code page IMDG IMCO No.8121 UN No 2800 PACKAGING REQUIRED FOR TRANSPORTATION Batteries have to be packed in strong outer packagings after insulating each cell terminals. Packaging Group III IMPORTANT NOTE There is no electrolyte in liquid status inside the battery due to the fact that this electrolyte is completely absorbed by a spungy material. This means that even if you turn upside down (ermetically closed) there will be no leakage of the electrolyte. o Conditions will not change below boiling point (110 C).

SAFETY DATA NATURE OF HAZARD Corrosive liquid electrolyte causes damage to eyes, skin & air passages. Attacks many materials & clothing. Attacks many metals with liberation of hydrogen which is flammable and forms explosive mixture with air. Stored electrical energy.

an

PROTECTIVE MEASURES Goggles giving complete protection to eyes, acid resistant clothing and gloves, and safety footwear. Have available an eyewash bottle with clean water. Store in a cool dry place. Keep all vent plugs in position. Charge in a well ventilated area, avoid breathing mist. Keep away from sources of ignition, do not allow smoking or any naked lights. Keep away from children. For safe operating practices see BS 6287:1982 FIRST AID If substance has got into eyes, immediately wash out with plenty of water. If ingested drink copious amounts of water and seek immediate medical attention. Remove any contaminated clothing and wash skin with water. Seek medical treatment. SPILLAGE Close off or contain leak if without risk, using plastic containers if available. Neutralise with soda ash, sodium carbonate or sodium bicarbonate. If undiluted substance has entered a watercourse or contaminated soil or vegetation, advise local authority. FIRE If circuit still made, and if safe to do so, the emergency services may sever cables with fireman’s axe. Smother with dry powder or foam. If necessary keep containers cool by spraying with water. DISPOSAL This product is defined in SI 232:1994 as being for fitment to an excluded appliance. The cells contain heavy metal and must not be put out for collection in refuse containers. Keep all constituents enclosed and upright. Dispose of only to authorised scrap recoverer. Move only in accordance with local authority requirements. Do not incinerate or throw away.

_____________________________________________________________________________ Fiamm Asia Pacific Pte Ltd 36 Tuas Crescent Singapore Tel 0065 8653278 Fax 0065 8626550

TG6208F Ericsson FP2 System Setting file.xls

Service Setup Nom.Voltage Language Battery Fuse Auto-Boost Auto battery test LVLD1 LVDB Set Levels Battery Voltage Boost Voltage Battery Test Standby Voltage Rectifier Standby Voltage High Float Active (High Battery 1) Low Float Active (Low Battery 1) High Load Active (High Battery 2) Low Load Active (Low Battery 2) Temperature 1.1 High Battery High Battery Low Temp. Low Temp. Alarm Setup/Display High Float Active (High Battery 1) Low Float Active (Low Battery 1) High Load Active (High Battery 2) Low Load Active (Low Battery 2) Battery Fuse Load fuse Rectifier Fail Critical Rectifier Fail (>1) Mains Fail Off normal Battery test fail Monitor Fail Configurable Inputs ProgInput 1 - "Generator input" ProgInput 2 - "Off normal" ProgInput 3 ProgInput 4 ProgInput 5

Setting


H:\eltek\(TG) Controlled Documents\TG6208F Ericsson FP2 System Setting file.xls

Normaly Open Normaly Open Normaly Closed Normaly Closed Normaly Closed

Relay 3 Relay 3 Relay 2 Relay 2 Relay 4 Relay 4 Relay 5 Relay 5 Relay 1 Relay 6 Relay 6 Configured to external relay

45degC 50degC -10degC 0degC

54.0V 55.0V NA 43.0V 55.7V 52.8V 57.6V 48.0V

48V English Enabled Disabled Disabled Disabled Disabled

Smartpack Powersuite

Page 1 off 2

Eltek Pacific

Date:

Signed:

Name:


Normaly Closed

Disabled Disabled Set to 10hrs 0min NA NA NA NA Enabled Set to 25% of installed C10 capacity X no. Strings Temperature Compensation 57.0 V

Enter battery name Enter battery capacity To be entered by the installer on site Enter battery discharge table in Amps to 1.9V 2.25 V/cell 25 deg C 4 mV/C/cell 2.21 V/cell 2.30 V/cell

"Set to customer name" Enter Location FlatPack2 system To be entered by the installer on site Enter serial no To be entered by the installer on site Enter name For service call Eltek Pacific (02) 9479 4200

H:\eltek\(TG) Controlled Documents\TG6208F Ericsson FP2 System Setting file.xls

Please sign and fax this back to Eltek Pacific Engineering department (02) 9450 1661

Approval to proceed

ProgInput 6 Site Info Company Site Info Model Install date Serial # (system serial) Service date Responsible Message 1 Message 2 Battery Setup Battery Description Capacity (Ah) Battery Install date Battery table (only relevant if batt. test enabled)* Reference voltage (V/cell) Reference temperature ( C ) Temperature slope (mV/C/cell) Min compensation voltage (V/cell) Max compensation voltage (V/cell) Battery Test Setup *(These settings will only take effect if the battery test is enabled) Auto Boost Manual Boost Duration Guard Time Interval Boost Interval Start Time Current Limit Cfg Maximum charge current Output Control Rectifier OVP


Page 2 off 2

Eltek Pacific

ALARM MATRIX (Eltek Flatpack2 Ericsson)

Alarm Causes

AC Mains fail

(Relay output)

(1)

Failed AC supply

9

High Load / High Float / Battery CB / Rectifier fail Off-Normal / Monitor fail Low load Low Float Load CB BCM (2)

(3)

(4)

(5)

(External)

9 9

Low mains / High mains supply High Bus Voltage

X

X

Low Bus Voltage

X

X

Large Voltage deviation

9 9

Small Voltage deviation Load CB tripped

9

Battery CB tripped

9 9

Failed Rectifier X

Rectifier Overload

X 9

Rectifier High Voltage

9

BCM has started Alarm module failure *

(6)

X

X

X – may cause

X

X

X

X

9 - will always cause

* On Alarm module failure, all alarms from the controller (relays 1-6) will enter an open state, giving an alarm on the normally closed (failsafe) output terminals.

TG6223A Alarm Matrix FP2 Ericsson.doc

9

ALARM MATRIX (Eltek DC/DC Converter Ericsson)

Alarm Causes

Alarm Output

DC input voltage >60VDC

9

DC input voltage <40VDC

9

Single fan failure

9

High temperature / Derating activated

9

Current limit

9

No output voltage

9

Over voltage shutdown ( 30V )

9

Both fans failed

9

High temperature shutdown

9

Short circuit / fold back activated

9

Warnings: amber LED

Alarms: Red LED

All of the above situations will cause an alarm signal to be output, however, the warnings will produce an amber light to appear on the module, and an alarm will cause a red light to appear.

TG6228A Alarm Matrix Ericsson DCDC converter.doc

TB1

Alarm High Float / Low Float High Float / Low Float High Float / Low Float Load / Battery CB fail Load / Battery CB fail Load / Battery CB fail Rectifier Fail Rectifier Fail Rectifier Fail

Pin 10

Pin 5 6 7 8 9 10

ALARM OUTPUT CONFIGURATION

Pin 1

1

1

1 2

TB

Relay

[NC and NO indicates when system is energized with no alarms]

State NO COM NC NO COM NC

TG6217A Relay pinout label for FP2 Ericsson Systems.xls

Monitor Fail Card (top view)

Normally closed Normally open Common

Alarm Mains Fail Mains Fail Mains Fail High Load / Low Load High Load / Low Load High Load / Low Load

State NO COM NC NO COM NC NO COM NC

2

5

Pin 1

2

2

TB

4

3

Relay

Pin 9 10 11 12 13 14 15 16 17

TB2

Alarm Off Normal / BCM Off Normal / BCM Off Normal / BCM Monitor Fail Monitor Fail Monitor Fail

Pin 20

State NO COM NC NO COM NC

2

TB

Pin 18 19 20

TG6217A

Ext (see diagram Monitor Fail card)

6

Relay

F

E

D

C

B

1

5

4

3

2

1

2

2

460

3

B

Revision note

ADD NOTE DETAILS BATTERY SHELF GAP DIMENSION FROM 38mm TO 50mm

C

R evNo

AMENDED BAT TER Y SHA PE

D

TOP VIEW SCALE 0.14:1

30/01/06

F OL D

Date

18/01/06

19/01/06 Signature C hecked

THIR D ANGLE

FINISH:

MA TERIA L:

SIDE VIEW SCALE 0.14:1

5

FRONT VIEW SCALE 0.14:1

4

400

3

2200

108 600

287

A

1

337 50

F.M. 12/12/05 Drawn

6

Released

Approved

Chec ked

N.E. 01/12/05 Designed

6 Load Circuit Breakers SmartPack Module FlatPack 2 Power Racks 12FIT100 Type Battery Battery CB's with Auxiliaries

1 2 3 4 5

7

TG6210

FL ATPACK 2 400D

GENER AL AR RANGEMENT

SEF 29 -X- 149

R EVISION D

8

SCALE NTS

SHEET 1/1

Eltek Pacific Pty Ltd Unit 1, 22 Narabang W ay Belrose NSW 2085 Australia

P ACI FI C

Eltek

Notes: 1. Batteries Shown are 12FIT100 Type. 2. Each Monobloc Weighs 33 Kg. 3. System Contains 3 FlatPack2 Power Racks with a Total of 9 Rectifier Positions. 4. Weight of Each Rectifier is 1.8 Kg. 5. Weight of System Excluding Batteries and Rectifiers is approx. 120 Kg. 6. System Contains a 24 Way Distribution Panel. 7. Total Weight is 810 Kg. 8. Floor Loading is 33.75 Kpa.

DESCRIPTION

8

ITEM NO.

7

F

E

D

C

B

A

F

E

D

C

B

1

5

4

3

2

1

2

3

Revision note

3

B

R evNo

A DD NOTES BATTERY SHELF GAP DIMENSION FROM 47mm TO 50mm

C

4

CHANGED CONTAINS DISTR IBUTION PANEL FROM 26 TO 24

2200

D


126 600 FRONT VIEW SCALE 0.14:1

2 460 230

A

1

F OL D

Date

18/01/06

19/01/06

03/01/06

Signature C hecked

THIR D ANGLE

FINISH:

MA TERIA L:

600 SIDE VIEW SCALE 0.14:1

5

280

F.M. 12/12/05 Drawn

6

Released

Approved

Chec ked

N.E. 01/12/05

6

Designed

50

Load Circuit Breakers SmartPack Module FlatPack 2 Power Racks 12FFT100 Type Battery Battery CB's with Auxiliaries

1 2 3 4 5

7

TG6211

FL ATPACK 2 600D

GENER AL AR RANGEMENT

SEF 29 -X- 150

R EVISION D

8

SCALE NTS

SHEET 1/1


P ACI FI C

Eltek

Notes: 1. Batteries Shown are 12FFT100 Type. 2. Each Monobloc Weighs 38 Kg. 3. System Contains 3 FlatPack2 Power Racks with a Total of 9 Rectifier Positions. 4. Weight of Each Rectifier is 1.8 Kg. 5. Weight of System Excluding Batteries and Rectifiers is approx. 140 Kg. 6. System Contains a 24 Way Distribution Panel. 7. Total Weight is 1080 Kg. 8. Floor Loading is 30 Kpa.

DESCRIPTION

8

ITEM NO.

7

F

E

D

C

B

A

F

E

D

C

B

A

1

1

2

1

2

2

30/01/06

5

R evNo

B

Revision note


F OL D

Date

Signature C hecked

THIR D ANGLE

FINISH:

MA TERIA L:

400

4

SIDE VIEW SCALE 0.14:1

3

287

FRONT VIEW SCALE 0.14:1

AMENDED BATTER Y SHA PE

2200

600

108

3

337 50

F.M. 12/12/05 Drawn

6

Released

Approved

Chec ked


6

12FIT100 Type Battery

Battery CB's with Auxiliaries

1

2

7

TG6215

OF 12FIT100

BATTERY R ACK WITH 5 STR INGS

SEB5-12FIT100-002

R EVISION B

8

SCALE NTS

SHEET 1/1


P ACI FI C

Eltek

Note: 1. Batteries Shown are 12 FIT100 Type. 2. Each Monobloc Weighs 33Kg. 3. Weight of System Excluding Batteries is approx. 85 Kg. 4. Total Weight is 745 kg. 5. Floor Loading is 31 Kpa.

DESCRIPTION

8

ITEM NO.

7

F

E

D

C

B

A

F

E

D

C

B

A

1

1

2

1

2

R evNo

Revision note



2 3

2200

3

4

F OL D

Date

Signature C hecked

THIR D ANGLE

FINISH:

MA TERIA L:


5

280 50

230

F.M. 12/12/05 Drawn

6

Released

Approved

Chec ked


6

12FFT100 Type Battery

Battery CB's with Auxiliaries

1

2

7

TG 6216

OF 12FFT100

BATTERY R ACK WITH 6 STR INGS

SEB6-12FFT100-002

R EVISION A

8

SCALE NTS

SHEET 1/1


P ACI FI C

Eltek

Notes: 1. Batteries Shown are 12FFT100 Type. 2. Each Monobloc Weighs 38 Kg. 3. Weight of System Excluding Batteries is approx. 105 Kg. 4. Total Weight is 1017 Kg. 5. Floor Loading is 28.25 Kpa.

DESCRIPTION

8

ITEM NO.

7

F

E

D

C

B

A

F

E

D

C

B

1

6

5

4

3

2

1

2

2

RevNo

B

Revision note



460

3

2200

3

REM OVED TOP STRING OF B ATTER IES

230

A

1

4

F OL D

Date

18/04/06

G.T. Signature Chec ked

F.M.

THIR D ANGLE

FINISH:

M ATERIAL:


5

280 50

F.M. 30/01/06 Drawn

6

R eleased

Approved

Checked


6

Load Circuit Breakers SmartPack Module FlatPack 2 Power Racks +24V DC/DC Converter 12FFT100 Type Battery Battery CB's with Auxiliaries

1 2 3 4 5 6

7

TG6222

FLATPACK 2 600D WITH DC/DC CONVERTER

GENERAL ARRANGEMENT

SEF 29 -X- 156

PACIFIC

REVISION B

8

SCALE NTS

SHEET 1/1

Elt ek Pacific Pty Ltd Unit 1, 22 Narabang Way Belrose NSW 2085 Australia

Eltek

Notes: 1. Batteries Shown are 12FFT100 Type. 2. Each Monobloc Weighs 38 Kg. 3. System Contains 3 FlatPack2 Power Racks with a Total of 9 Rectifier Positions. 4. Weight of Each Rectifier is 1.8 Kg. 5. Weight of System Excluding Batteries, Rectifiers and DC/DC Converters is approx. 140 Kg. 6. System Contains a 24 Way Distribution Panel. 7. System Contains up to 4 DC/DC Converters. 8. Weight of Each DC/DC Converter is 3 Kg. 9. Total Weight is 943 Kg. 10. Floor Loading is 26.2 Kpa.

DESCRIPTION

8

ITEM NO.

7

F

E

D

C

B

A

Eltek Flatpack 2 User Manual

Recommend Documents