Gabinete Rectificador ELTEK FLATPACK 15KW Outdoor

I nstal nstallati lation on G uide

P RSB RS B 15kW , 48VDC

3 3 0 . 5 0 4 1 5 3

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek of Eltek Energy AS. AS. No part of this document may be reproduced or transmitted in any form or by any means — electronic or mechanical, including photocopying and recording — for any purpose without the explicit written permission of ELTEK Energy.

Copyright ©: Eltek Energy AS, AS, Norway 2004 NS-EN ISO 9001:1994 Certificate no: 900005Q NS-EN ISO 14001:1996 Certificate no: 900005E. This product holds a CE mark and satisfies all requirements covering relevant standards and directives.

EM C ▫

▫

▫

LVD

EN61000-6-2 EN61000-6-2 Industrial Environ ment EN61000-6-3 EN61000-6-3 Residential, Com mercial and Light Industry ETS 300386 v1.3.1 Telecommunication Equipment

▫

▫

LVD73/23/EEC Low Voltage Directive EN60950 Safety of Technology Equipment

Certificate Certificate no: 900005

Head Office:

Certificate Certificate no: 900005E

Eltek Energy AS P.O. Box 2340 Strømsø N-3003 Drammen NORWAY Phone: (+47) 32 20 32 00 Fax: (+47) 32 20 32 10 E-Mail [email protected] Internet: http://www.eltekenergy.com

Art. No. 351405.033 351405.033

Issu e 3,

2004 November

Published 2004-11-18 Mfm

Flatpack PRSB 15kW, 48VDC (Outdoor Site Power Cabinet, Fan Cooled) has part no. CF1032.001

2

Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Fan Cooled — Art. No. 351405.03 3, v3—2004-11

Table of Contents 1

2

DESCRIPTION OF FLATPACK PRSB 15KW, 48VDC

4

OVERVIEW – GENERAL ARRANGEMENT

4

INPUT AND DISTRIBUTION ARRANGEMENT

5

AC INPUT TERMINALS

6

DC DISTRIBUTION AND LVBD DEVICE

7

MONITORING, CONTROL

7

AND

SIGNAL INTERFACE

SYSTEM MONITORING

7

INSTALLATION PROCEDURES

8

SAFETY PRECAUTIONS

8

UNPACKING

8

AND

MECHANICAL INSTALLATION

ELECTRICAL INSTALLATION

3

4

5

9

RECTIFIER INSTALLATION — MAINS SUPPLY EFFECT BALANCING

11

RECTIFIER INSTALLATION — HANDLES

11

AND

LOCKING MECHANISM

COMMISSIONING

11

ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS

12

CONNECTIONS FOR INTERNAL SYSTEM WIRING

13

CONNECTIONS GMT FUSES

14

SPECIFICATIONS FLATPACK PRSB 15KW, 48VDC, FAN COOLED

15

SPECIFICATION

15

FAN OPERATION

15

APPENDIX: SCHEMATICS, DRAWINGS, FIGURES, ETC.

16

GENERAL ARRANGEMENT DRAWING

16

SYSTEM SCHEMATIC — PRSB 15KW, 48VDC, OUTDOOR CABINET, FAN COOLED

17

ON SITE DOOR REMOVAL — OUTDOOR CABINET, FAN COOLED

18

DRILLING TEMPLATE

18


3

1

Description of Flatpack PRSB 15kW, 48VDC

This Installation Guide contains information about how to install the Flatpack PRSB 15kW, 48VDC system 1 , for the outdoor site power cabinet, fan cooled. Please, refer to the system’s Documentation Set (art. 351405.003) for an overview of related user documentation.

Overview – General Arrangement The Flatpack PRSB 15kW, 48VDC is a DC power supply system based on the Flatpack 1500 48V rectifier. The system contains AC termination blocks, DC distribution, Flatpack Power Rack, Flatpack 1500 rectifier modules and the Flatpack Monitoring and Control Unit (MCU). The system is designed for cable entry from top and the cabinet size is 770x820x2000mm, (30.3 x 32.3 x 78.7”) (WxDxH).

Heater MCB (AC).

DC Load Distribution: MCBs, Mains, Alarm and Signal Terminals

LTE Distribution, MCBs Optional kit.

Battery strings. The top three shelves are optional kits

Air filter

Figure 1 Flatpack Power Rack System General Arrangement

1

PRSB = Power Rack System with Batteries

4


Input and Distribution Arrangement Cabinet main Protective Earth (PE). Connected to powercore PE. Positioned in the ceiling –ve DC Load Terminals (BTS MCBs) 2 2 On top of each load breaker, 25 mm (70 mm ) –ve Battery Terminals 2 Bus bar, 35 mm

+ve DC Load Terminals 2 Common positive bus bar, 70 mm +ve Battery Terminals 2 Common positive bus bar, 70 mm DC Earth (TE) terminal, M6 AC Earth PE terminal, M6 AC Mains Terminals Terminals for GMT 15A Load 2 Fuses, 1.5 mm CON 5, Alarm Terminals 2 1.5 mm (Front access)

Flatpack 1500 rectifier modules

MCU Ctrl. Unit, and CON 4, Monitoring Terminals (Back MCU)

Figure 2 Location of components in the Power core. Contains Distribution and Power Racks


5

AC Input Terminals The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase and N. L1-bar N-bar

L2-bar L3-bar N (neutral) (Terminal for incoming wire)

L1 (Terminal for incoming wire)

L2 (Terminal for incoming wire) L3 (Terminal for incoming wire)

Labels on internal wires (Wires may be reconnected to match the site’s type of AC mains supply)

Figure 3

AC input terminals, L1, L2, L3 & N, with internal terminal connection bars

AC Input Feed Sizing

An external breaker is required on all sights. This should be turned OFF under all installation.

(Recommended AC Breaker Rating and Min. Wire Size) 18kW VAC Input

400VAC +N, 3 ph

40A – C 4x6 mm Cu – max. 30m 63A – C 3x10 mm2 Cu – max. 45m 2

230VAC, 3 ph

You may reconfigure the AC terminal block for connection of 230VAC, 3 phase supply. To do so, rewire the internal (blue) wires as described in the table below, and connect the AC mains supply cable to terminals L1, L2 and L3. AC Terminal Block 400VAC, 3ph+N

AC Terminal Block 230VAC, 3ph

Internal Wire Connections Internal Wire Wire Color Connected to (Labeled) Terminal Bar

Internal Wire Connections Internal Wire Wire Color Connected to (Labeled) Terminal Bar

L1,1 N1(L2) L2,1 N1(L3) L3,1 N1(L1) L1,2 N2(L2) L2,2 N2(L3)

Black Blue Black Blue Black Blue Black Blue Black Blue

L1-bar N-bar L2-bar N-bar L3-bar N-bar L1-bar N-bar L2-bar N-bar Factory configuration

6

L1,1 N1(L2) L2,1 N1(L3) L3,1 N1(L1) L1,2 N2(L2) L2,2 N2(L3)

Black Blue Black Blue Black Blue Black Blue Black Blue

L1-bar L2-bar L2-bar L3-bar L3-bar L1-bar L1-bar L2-bar L2-bar L3-bar Customized configuration


To connect your system to 1 phase from a 230 VACsystem or a 400 VAC + Nsystem connect the input cables as illustrated in the table to the right. With one phase the maximum amount of rectifiers is 4. These have to be placed in position 1,4,7 and 9 in Figure 4, page 11. The other positions will not be usable.

AC Input Connection 1-phase External W ire Connections

AC configuration in Terminal Block 400 VAC + N

Input (230 VAC, 3ph or 400 VAC, 3ph + N)

400VAC + N 230VAC

L1 N L1 L2

L1-terminal N-terminal L1-terminal N-terminal

230 VAC

L1-terminal L2-terminal L1-terminal L2-terminal

1 phase configurations

DC Distribution and LVBD device The system is configured for negative distribution. The common positive bus bar is located inside the distribution section; see, page 5. The system is equipped with a Low Voltage Battery Disconnect (LVBD) device.

Monitoring, Control and Signal Interface The Flatpack PRSB 15kW, 48VDC is available with basic functionality for monitoring and control of the system, and is equipped with: • • • •

Relay outputs, 6 pcs Digital inputs, 4 pcs Symmetry input signals, 2 pcs (battery string midpoint measurements) Digital input for external symmetry circuitry

One of the interface boards (104649) is located behind the MCU (with rear access to the terminals), while the other board (104648) is mounted on top of the MCU (with front access to the terminals). Ses “Figure 7 Customer connections interface”, page 12.

System Monitoring The Flatpack MCU Monitoring & Control Unit monitors and controls the entire rectifier system including distribution and batteries, as well as other equipment on site. The unit also incorporates a communication port for connecting computers via the RS232C interface. The Flatpack system can be operated and configured locally via the keypad on the MCU unit, by selecting commands from set-up menus in a hierarchical menu system. Please refer to the Flatpack MCU Operation Guide for detailed information about system monitoring. Remote system monitoring and configuration may also be performed using WinPower Silver — a Windows-based program that runs on a connected PC. The following configuration tasks require the use of a PC: § § § § § § §

Installation settings System calibration Battery configuration Alarm setup Alarm log retrieval Site information Site specific configuration


7

2

Installation Procedures

This section describes how to install the Flatpack PRSB 15kW, 48VDC. Step-by-step procedures will guide you through the installation. For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and control unit, please refer to the Operation Guides for the respective modules.

Safety Precautions

þ

The equipment described in this manual must only be installed by authorized personnel, and only operated by persons who have attended a suitable Eltek Energy training course.

þ

The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty.

þ

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

þ

Products into which our components are incorporated have to comply with a number of requirements. Installation is to be in accordance with the recommendations herein.

þ

Please read the manual carefully before using the equipment.

Unpacking and Mechanical Installation In stallation Step

Comments

1 TAKE THE FLATPACK POWER SYSTEM OUT OF THE PACKAGING

Inspect the unit for any physical or transit damage, and tighten the screws that connect conductors. Report any transit damage to Eltek Energy immediately

2 DRILL HOLES IN THE GROUND ACCORDING TO DRILLING TEMPLATE

3 POSITION THE CABINET IN THE REQUIRED LOCATION

4 BOLT THE CABINET TO THE GROUND /PLINTH

8

OK

The Drilling Template with instructions is located in section 5, page 18. The floor construction must be capable of supporting the equipment. Bolts are not included in the cabinet. If a plinth is used, refer to ‘Installation Guide, Kit for Plinth’, Doc. No. 351416.033.


Electrical Installation For location of components, see Figure 2 - page 5, Figure 3 - page 6, and Figure 9.- page 16.

In stallation Step

1. EARTH CONNECTIONS

Comments

OK

The AC Earth (PE) and DC Earth (TE) terminals are mechanically connected to the cabinet chassis. The Common Positive Bus bar is internally cabled to DC Earth (TE); thus the positive output of the rectifiers is connected to ground (TE), and the negative output represents the –48Vdc supply voltage. • If required, you can remove the internal cable that connects the positive bus bar to local PE. • Switch OFF the AC input power (external MCBs), before connecting the cable. • Open the clamps that fasten the cable entry rubber gland. • Shape the cable entry rubber gland with a knife to fit the mains cables, and draw the cables into the top of the cabinet. It is recommended to do the same with the load cables at this time. Fasten the cables with strips to the brackets inside the cabinet. Do not make the cable slot too wide! Use silicon to make the input hole watertight.

2. AC CONNECTIONS

•

•

Connect the AC cables, max. 35sq mm(AWG 2), to the terminal block in the top of the cabinet as the labels indicate. Replace the cable entry clamps. Do not power up the system until the whole installation is complete. Connect the external AC ground wire to the cabinets main Protective Earth (PE) terminal. See

• •

Figure 2.- page 5.


9

3. LOAD CONNECTIONS Alarm connection

• • • •

100A

150A

•

Cable gland •

•

4. GMT FUSE CONNECTION

5. BATTERY CONNECTIONS

6. POWER UP

Turn OFF the Load/BTS MCBs. Turn OFF the PRS battery MCBs on the left side of the cabinet. Loosen the screws and pull the black cable gland back to draw the load cables down to the powercore. The kit includes two copper bridges. One for 100 A (two pins) and one for 150 A. If the load current is larger than 50 A use the two pin copper bridge. Then the 3 rd hole in the breaker cannot be used. If the load current is larger than 100 A, use the three pin copper bridge. Insert the chosen copper bridge on to the top of the MCB. Connect the orange alarm wire to the copper bridges with a screw if the bridges are used. Connect the positive cable(s), max 70 mm sq (AWG 2/0), to the common positive bus bar on the top of the powercore. 2 Connect the negative (-48V) cables, max 25 mm sq each (AWG 3), to the top of the MCBs or the copper bridges. Connect the negative (-48V) cables to the MCBs.

Connect the adequate cables, 1,5 mm sq (AWG 15), to the GMT fuse card according to the table in section 3 – page 14 The positive and negative (-48V) battery cables are connected from factory to the common positive bus bar and to the battery MCBs. (Excluding additional battery string kits) The battery temperature sense cable is also pre-wired to CON4, and temporally fixed to the cabinet’s wall. • Connect the loose end of the battery cables to the battery terminals; blue cable to the negative terminal and black cable to the positive terminal. • Connect all battery intercell links • Place the temperature sensor, located at the end of the battery temperature sense cable, on top of the topmost battery string. Please follow chapters “Pre-Start Check” and “Start-Up Procedure” in manual “Commissioning Guide Flatpack 1500 DC Rectifier Plant”, Doc. No. 360006.163.

2

The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.

10


Rectifier Installation — Mains Supply Balancing Effect The Flatpack PRSB system may be expanded to a maximum of 10 Flatpack 1500 rectifiers. In order to load the AC supply net evenly — similar current load from the 3 phases of the mains supply — it is advisable to mount the required number of rectifiers in the following order: MCU

Rectifiers

1 Pos (on L1)

4 Pos (on L1)

2 Pos (on L2)

5 Pos (on L2)

3 Pos (on L3)

6 Pos (on L3) 9 Pos (on L1)

7 Pos (on L1)

10 Pos (on L2)

8 Pos (on L2)

Figure 4

Rectifier mounting order to load the mains supply evenly.

When possible, mount an equal number of rectifiers on each phase, L1, L2 and L3.

Rectifier Installation — Handles and Locking Mechanism The Flatpack 1500 rectifier module is equipped with handles that serve two purposes:

Locking the module into position Open both handles, insert and plug the module into power shelf. Then lock it into position by rotating the handles upwards and pushing them firmly home; failure to do so will prevent the module from making proper contact. Figure 5

Module with released handles

Pulling the module out Unlock and release the handles by inserting a small screwdriver into the upper holes, thus releasing the spring mechanisms. Do not use excessive force. The handles will release and pop out. When both handles are released, use them to pull the module out. Do not hold or carry the rectifier by its handles. Figure 6

Upper hole to release the spring mechanism

Handle in locked position

Releasing the module’s handles

Commissioning For information regarding system commissioning, please read manual “Commissioning Guide Flatpack 1500 DC Rectifier Plant”, art. No. 360006.163.


11

3

Alarm Relay Outpu ts and Signal Connections

The digital inputs are configured as fail-safe, i.e. if the input is enabled, it will trigger an alarm if t he input is open. If several external devices are going to the same digital input, they must be connected in series. The alarm relays are also operated in fail-safe, i.e. the relays are energized when there is no alarm. The description below describes the pin out in normal state, i.e. the NO output is open in normal operation and shorts to the COM output in the alarm-state.

Input 1 AGND

CON4 External device alarm state

Alarm relay specification Nominal switching capacity

2A/30V DC

Maximum switching power

60W (resistive load)

Maximum switching voltage

220V DC

Maximum switching current

2A DC

Interface Customer Connection Pin Out

Interface Card 104648 Located on top of the MCU Ctrl. Unit

Interface Card 104649 Located back the MCU Ctrl. Unit (plug for MCU)

Pin 11 Pin 20

Pin 12 Pin 1

CON2 CON5 CON3

CON4 Pin 1

Pin 1

Pin 10

Pin 20

Terminal

Description

Terminal

Description

CON 2 CON 3

Internal system connections Internal communication

CON 4 CON 5

Customer connections (digital inputs, symmetry, etc.) Customer connections (alarm relay outputs)

Figure 7

12

2

Customer connections interface and internal terminals. (Max. 1,5 mm , AWG 15)


CON 5 Pin Assignment for basic PCB version, art. No. 104648 Pi n

1 2 3 4 5 6 7 8 9

Signal NC NO Com

Function Relay 6: Common Alarm

Pin 10 11 12

Signal NC NO Com

Function Relay 3: Low Battery Alarm

NC NO Com NC NO Com

Relay 5: Module Alarm

13 14 15 16 17 18 19 20

NC NO Com NC NO Com

Relay 2: Heat Management Alarm Relay 1: High temp. (Fan regulation) (not used) (not used)

Relay 4: Load / Battery Fuse Alarm

Factory Settings

CON 4 Pin Assignment for basic PCB version, art. No. 104649

1 2 3 4 5 6

Signal + AGND + AGND + AGND

Function Digital Input 1 (Heat management) Digital Input 2 (programmable) Digital Input 3 (programmable)

7 8

+ AGND

Digital Input 4 (programmable)

P i n

9 10

+ AGND

Pin 11 12 13 14 15 16 17 18 19 20

Signal + — + — + — + — screen

Function Battery Symmetry 1 (analogue input) Battery Symmetry 3 (analogue input) +21V Auxiliary Supply (for modem or ext.equipment) (not used) Battery Temperature Sense Analogue ground (system ref.)

Battery Symmetry 2 (digital input)

Connections for Internal system wiring CON3 is used for rectifier and power shelf communication. CON2 is used for internal system wiring, which has been wired at the factory. These connectors are not involved in the system installation and commissioning process. The table below shows the pin assignment for CON2. CON 2 Pin Assignment for basic PCB version, art. No. 104649 P i n

1 2 3 4 5 6 7 8

Signal + — + — + — VDC+ VDC—

Function Shunt 2: Battery current measurement Shunt 1: Battery current measurement Auxiliary Supply (for Flatpack MCU ) Voltage Sense (system signal reference)

Pin 9

Signal +

10

+

11

—

12

—

Function Battery Fuse State (digital input) Load Fuse State (digital input) LVBD control (Battery Disconnect contactor) LVLD control (Load Disconnect contactor)


13

Connections for GMT fuses

Pin 16

Pin 1

GMT fuses Max. 15 A each

Figure 8

GMT fuse card (Max. cable size 1,5 mm sq)

The table below shows the pin assignment for the GMT load fuse card. Pin Assignment for GMT Fuse Pin 1 2

14

Signal + —

Function GMT fuse 1 (F4)

Pin 9 10

Signal + —

Function GMT fuse 5 (F8)

3 4

+ —

GMT fuse 2 (F5)

11 12

+ —

GMT fuse 6 (F9)

5 6

+ —

GMT fuse 3 (F6)

13 14

+ —

GMT fuse 7 (F10)

7 8

+ —

GMT fuse 4 (F7)

15 16

+ —

GMT fuse 8 (F11)


4

Specifications Flatpack P RSB 15kW , 48VDC, Fan Cooled

Site Pow er Outdoor cabinet SPECIFICATION Max. number of rectifiers

10

AC INPUT Voltage

1 phase 230 VAC (max 4 rectifiers) 3 phase 208 VAC ( ∆ ) 3 phase 230 VAC ( ∆ ) 3 phase 400 VAC+N ( Y )

Frequency

45 to 66Hz

Maximum Current

See Flatpack 1500 48VDC datasheet (241114.100.DS3)

Protection

Soft start Surge protection (varistors) Disconnect above 312 VAC

MONITORING Monitoring Unit Local operation

Remote operation Alarm relays

Flatpack MCU Menu driven software via keypads and LCD or PC (WinPower) WinPower via modem or Web NMS via SNMP-agent 6 relays are standard

Visual indications Green LED – System ON Red LED – Active alarm(s) LCD – system status Digital inputs 5 (for monitoring of external equipment) Current Battery current measurements Rectifier current Alarms Load fuse alarm Battery fuse alarm LVD operated Low output voltage alarms (2 individual alarm levels) High output voltage alarms (2 individual alarm levels) Battery capacity Temperature alarm Symmetry alarm

DC OUTP UT Voltage

48 VDC

Current

Up to 15 KW – 300 Amps

CONNECTIONS Battery connections Load MCB connections

Battery cable, M8 bolts Negative distribution, Load cable, M8 bolts. Common positive bus bar, M8 bolts Front access screw terminals

Alarm connections

DISTRIBUTION OPTIONS No. of DC Load breakers No. of Battery fuses No. of Aux. fuses Programmable LVD

Up to 3 x (3pole 63Amps) Up to 3 x 125 Amps MCBs mount next to each battery shelves 8 x 10 Amps GMT type Standard: 1 LVBD (max. 400 Amps)

OTHER SPECIFI CATIONS Isolation

Operating temp Storage temp Dimensions Weight

3.0 KVAC – input and output 1.5 KVAC – input earth 1.0 KVDC – output earth -40 to +50°C (-40 to +122°F) -40 to +85°C (-40 to +185°F) 770 x 820 x 2000mm (WxDxH) (30.3 x 32.3 x 78.7”) Approx. 170kg excl. rectifiers and batteries Max. 250kg load per battery shelf

APP LI CABLE STANDARDS Electrical safety EMC

Environment

EN 60950 UL 60950 ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) ETSI EN 300 019-2 ETSI EN 300 132-2

Fan operation The fan runs as soon as the temperature in the cabinet passes 25 oC and the fan MCB is switched on. The fan speed adjuster is pre installed and factory set to the right speed, which is a bit slower than full speed. It shall not be set again.


15

5

Appendix: Schematics, Draw ings, Figures, etc. General Arrangement drawing

See also Figure 2, page 5, for more detailed information about DC distribution.

Main Protective Earth (PE)

Heater MCB (AC) DC Distribution, Alarm, AC Terminals, etc. Rectifiers

LTE Fuses MCBs

Battery MCB FB4

Battery MCB FB3 Battery MCB FB2 Battery MCB FB1

Figure 9

16

General Arrangement drawing, PRSB 15kW, 48VDC Outdoor Cabinet, Fan Cooled


System Schematic — PRSB 15kW, 48VDC, Outdoor Cabinet, Fan Cooled

Figure 10 Schematic drawing, PRSB 15kW, 48VDC system


17

On Site Door Removal — Outdoor Cabinet, Fan Cooled

Step Description 1

Disconnect the earth connection cable on the bottom of the door

2

Lift the door off the hinges.

3

When the door is to be mounted back on, lift the door back on to its hinges

4

Reconnect the earth connection

Ok

Air filter

Earth connection

Drilling Template Figure 11 Top view of the cabinet’s bottom plate. 700x700 mm external dimensions

Holes for mounting the cabinet to the ground without a plinth.

Holes for the plinth. Factory drilled

Holes for the plinth. Factory drilled

The cabinet overhangs by 35 mm outside the plinth on the rear, on the left hand and on the right hand side

18



19

Main Office:

Eltek Energy AS P.O. Box 2340 Strømsø N-3003 DRAMMEN Norway Phone: Fax:

47 32 20 32 00 47 32 20 32 10

E-Mail:

[email protected]

Internet:

www.eltekenergy.com

Art. No. 351405.033 Issue 3, 2004 November Published 2004-11-18

Gabinete Rectificador ELTEK FLATPACK 15KW Outdoor

Recommend Documents