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7/26/2019 PRSB 15kW Outdoor Instalation Guide
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351405.
033
Installation Guide
PRSB 15kW, 48VDC
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2 Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Fan Cooled Art. No. 351405.033, v32004-11
Information in this document is subject to change without notice and does not represent acommitment on the part of Eltek Energy AS.
No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical, including photocopying and recording for any purpose withoutthe explicit written permission of ELTEK Energy.
Copyright : Eltek Energy AS, Norway 2004NS-EN ISO 9001:1994 Certificate no: 900005QNS-EN ISO 14001:1996 Certificate no: 900005E.This product holds a CE mark and satisfies all requirements covering relevant standards anddirectives.
EMCEN61000-6-2 Industrial Environment
EN61000-6-3 Residential, Commercial and Light IndustryETS 300386 v1.3.1 Telecommunication Equipment
LVDLVD73/23/EEC Low Voltage Directive
EN60950 Safety of Technology Equipment
Head Office:
Eltek Energy ASP.O. Box 2340 StrmsN-3003 DrammenNORWAYPhone: (+47) 32 20 32 00Fax: (+47) 32 20 32 10E-Mail [email protected]
Internet: http://www.eltekenergy.com
Art. No. 351405.033 Issue 3, 2004 November
Published 2004-11-18
Mfm
Flatpack PRSB 15kW, 48VDC(Outdoor Site Power Cabinet, Fan Cooled)has part no. CF1032.001
Certificate no: 900005ECertificate no: 900005
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Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Fan Cooled Art. No. 351405.033, v32004-11 3
Table of Contents
1 DESCRIPTION OF FLATPACK PRSB 15KW, 48VDC 4
OVERVIEW GENERAL ARRANGEMENT 4
INPUT AND DISTRIBUTION ARRANGEMENT 5
ACINPUT TERMINALS 6
DCDISTRIBUTION AND LVBDDEVICE 7
MONITORING,CONTROL AND SIGNAL INTERFACE 7
SYSTEM MONITORING 7
2 INSTALLATION PROCEDURES 8
SAFETY PRECAUTIONS 8
UNPACKING AND MECHANICAL INSTALLATION 8
ELECTRICAL INSTALLATION 9RECTIFIER INSTALLATION MAINS SUPPLY EFFECT BALANCING 11
RECTIFIER INSTALLATION HANDLES AND LOCKING MECHANISM 11
COMMISSIONING 11
3 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS 12
CONNECTIONS FOR INTERNAL SYSTEM WIRING 13
CONNECTIONS GMTFUSES 14
4 SPECIFICATIONS FLATPACK PRSB 15KW, 48VDC, FAN COOLED 15
SPECIFICATION 15
FAN OPERATION 15
5 APPENDIX: SCHEMATICS, DRAWINGS, FIGURES, ETC. 16
GENERAL ARRANGEMENT DRAWING 16
SYSTEM SCHEMATIC PRSB15KW,48VDC,OUTDOOR CABINET,FAN COOLED 17
ON SITE DOOR REMOVAL OUTDOOR CABINET,FAN COOLED 18
DRILLING TEMPLATE 18
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1 Description of Flatpack PRSB 15kW, 48VDC
This Installation Guide contains information about how to install the Flatpack PRSB 15kW,
48VDCsystem1, for the outdoor site power cabinet, fan cooled. Please, refer to the systems
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 150048V rectifier. The system contains AC termination blocks, DC distribution, Flatpack PowerRack, 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).
Figure 1
FlatpackPower Rack SystemGeneral Arrangement
1PRSB = Power Rack System with Batteries
DC Load Distribution:MCBs, Mains, Alarm and
Signal Terminals
Battery strings. The topthree shelves are optionalkits
LTE Distribution, MCBs
Optional kit.
Heater MCB (AC).
Air filter
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Input and Distribution Arrangement
Figure 2 Location of components in
the Power core. ContainsDistribution and Power Racks
+ve DC Load TerminalsCommon positive bus bar, 70 mm
2
+ve Battery TerminalsCommon positive bus bar, 70 mm
2
Terminals for GMT 15A LoadFuses, 1.5 mm
2
AC Mains Terminals
CON 5, Alarm Terminals1.5 mm
2(Front access)
ve DC Load Terminals (BTS MCBs)On top of each load breaker, 25 mm2(70 mm2)
ve Battery TerminalsBus bar, 35 mm
2
MCU Ctrl. Unit, andCON 4, Monitoring Terminals(Back MCU)
DC Earth (TE) terminal, M6
AC Earth PE terminal M6
Cabinet main Protective Earth (PE). Connectedto powercore PE. Positioned in the ceiling
Flatpack 1500 rectifiermodules
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AC Input Terminals
The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase and N.
Figure 3 AC input terminals, L1, L2, L3 & N, with internal terminal connection bars
You may reconfigure the AC terminal block for connection of 230VAC, 3 phase supply. To doso, rewire the internal (blue) wires as described in the table below, and connect the ACmains supply cable to terminals L1, L2 and L3.
AC Terminal Block400VAC, 3ph+N
Internal Wire ConnectionsInternal Wire
(Labeled)Wire Color Connected to
Terminal Bar
L1,1 Black L1-barN1(L2) Blue N-barL2,1 Black L2-barN1(L3) Blue N-barL3,1 Black L3-barN1(L1) Blue N-barL1,2 Black L1-barN2(L2) Blue N-barL2,2 Black L2-bar
N2(L3) Blue N-barFactory configuration
AC Terminal Block230VAC, 3ph
Internal Wire ConnectionsInternal Wire
(Labeled)Wire Color Connected to
Terminal Bar
L1,1 Black L1-barN1(L2) Blue L2-barL2,1 Black L2-barN1(L3) Blue L3-barL3,1 Black L3-barN1(L1) Blue L1-barL1,2 Black L1-barN2(L2) Blue L2-barL2,2 Black L2-bar
N2(L3) Blue L3-barCustomized configuration
L1(Terminal for
incoming wire)
L3(Terminal forincoming wire)
N(neutral)(Terminal forincoming wire)
L2(Terminal forincoming wire)
Labels on internal wires(Wires may be reconnected tomatch the sites type of ACmains supply)
L3-bar
L2-bar
N-bar
L1-bar
AC Input Feed Sizing(Recommended AC Breaker Rating and Min. Wire Size)
VAC Input 18kW
400VAC +N, 3 ph 40A C4x6 mm2Cu max. 30m
230VAC, 3 ph 63A C3x10 mm2Cu max. 45m
An external breaker isrequired on all sights. Thisshould be turned OFFunder all installation.
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To connect your system to1 phase from a 230 VAC-system or a 400 VAC + N-system connect the inputcables as illustrated in thetable to the right. Withone phase the maximum
amount of rectifiers is 4.These have to be placed inposition 1,4,7 and 9 inFigure 4, page 11. Theother positions will not beusable.
DC Distribution and LVBD device
The system is configured for negative distribution. The common positive bus bar is locatedinside the distribution section; see, page 5. The system is equipped with a Low VoltageBattery Disconnect (LVBD) device.
Monitoring, Control and Signal Interface
The Flatpack PRSB 15kW, 48VDC is available with basic functionality for monitoring andcontrol 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 theterminals), while the other board (104648) is mounted on top of the MCU (with front accessto the terminals).Ses Figure 7 Customer connections interface, page 12.
System Monitoring
The Flatpack MCU Monitoring & Control Unit monitors and controls the entire rectifiersystem including distribution and batteries, as well as other equipment on site. The unit alsoincorporates a communication port for connecting computers via the RS232C interface.
The Flatpack system can be operated and configured locally via the keypad on the MCUunit, by selecting commands from set-upmenusin a hierarchical menu system.
Please refer to the Flatpack MCU Operation Guide for detailed information about systemmonitoring.
Remote system monitoring and configuration may also be performed using WinPower Silvera 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
AC Input Connection1-phase
External Wire ConnectionsAC configuration in
Terminal Block400 VAC + N 230 VAC
L1 L1-terminal L1-terminal400VAC +
N N N-terminal L2-terminalL1 L1-terminal L1-terminal
Input
(230 VAC, 3ph or400 VAC, 3ph +
N)230VAC
L2 N-terminal L2-terminal1 phase configurations
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2 Installation Procedures
This section describes how to install the Flatpack PRSB 15kW, 48VDC. Step-by-stepprocedures will guide you through the installation.
For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and controlunit, please refer to the Operation Guides for the respective modules.
Safety Precautions
The equipment described in this manual must only beinstalled by authorized personnel, and only operated bypersons who have attended a suitable Eltek Energytraining course.
The equipment represents an energy hazard and failureto observe this could cause terminal injury and invalidateour warranty.
There are hazardous voltages inside the rectifier system.As the rectifier units incorporate large chargedcapacitors, it is dangerous to work inside the systemeven if the mains supply is disconnected.
Products into which our components are incorporatedhave to comply with a number of requirements.Installation is to be in accordance with therecommendations herein.
Please read the manual carefully before using theequipment.
Unpacking and Mechanical Installation
Installation Step Comments OK
1 TAKE THE FLATPACK POWERSYSTEM OUT OF THE PACKAGING
Inspect the unit for any physical or transitdamage, and tighten the screws that connectconductors. Report any transit damage to EltekEnergy immediately
2 DRILL HOLES IN THE GROUNDACCORDING TO DRILLING
TEMPLATE
The Drilling Template with instructions is locatedin section 5, page 18.
3 POSITION THE CABINET IN THEREQUIRED LOCATION
The floor construction must be capable ofsupporting the equipment.
4 BOLT THE CABINET TO THEGROUND/PLINTH
Bolts are not included in the cabinet. If a plinthis used, refer to Installation Guide, Kit forPlinth, Doc. No. 351416.033.
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Electrical Installation
For location of components, see
Figure 2 - page 5, Figure 3 - page 6, and Figure 9.- page 16.
Installation Step Comments OK
1.EARTH CONNECTIONS
The AC Earth (PE) and DC Earth (TE) terminals aremechanically connected tothe cabinet chassis.
The Common Positive Bus baris internally cabled to DCEarth (TE); thus the positiveoutput of the rectifiers isconnected to ground (TE),and the negative outputrepresents the 48Vdc supplyvoltage.
If required, you can remove the internal cable that connectsthe positive bus bar to local PE.
2.ACCONNECTIONS
Switch OFF the AC input power (external MCBs), beforeconnecting the cable.
Open the clamps that fasten the cable entry rubber gland.
Shape the cable entry rubber gland with a knife to fit themains cables, and draw the cables into the top of thecabinet. It is recommended to do the same with the loadcables at this time. Fasten the cables with strips to thebrackets inside the cabinet. Do not make the cable slot toowide! Use silicon to make the input hole watertight.
Connect the AC cables, max. 35sq mm(AWG 2), to theterminal block in the top of the cabinet as the labelsindicate. Replace the cable entry clamps. Do not power upthe system until the whole installation is complete.
Connect the external AC ground wire to the cabinets mainProtective Earth (PE) terminal. See
Figure 2.- page 5.
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3.LOAD CONNECTIONS Turn OFF the Load/BTS MCBs.
Turn OFF the PRS battery MCBs on the left side of thecabinet.
Loosen the screws and pull the black cable gland back todraw the load cables down to the powercore.
The kit includes two copper bridges. One for 100 A (twopins) and one for 150 A. If the load current is larger than50 A use the two pin copper bridge. Then the 3rdhole in thebreaker cannot be used. If the load current is larger than100 A, use the three pin copper bridge. Insert the chosencopper bridge on to the top of the MCB.
Connect the orange alarm wire to the copper bridges with ascrew 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.
4.GMTFUSECONNECTION
Connect the adequate cables,1,5 mm sq (AWG 15), to the GMTfuse card according to the table in section 3 page 14
5.BATTERY CONNECTIONS
The positive and negative (-48V) battery cables are connectedfrom factory to the common positive bus bar and to thebattery MCBs. (Excluding additional battery string kits) Thebattery temperature sense cable is also pre-wired to CON4,and temporally fixed to the cabinets wall.
Connect the loose end of the battery cables to the batteryterminals; blue cable to the negative terminal and blackcable to the positive terminal.
Connect all battery intercell links
Place the temperature sensor, located at the end of thebattery temperature sense cable, on top of the topmostbattery string.
6.POWER UP
Please follow chapters Pre-Start Check and Start-UpProcedure in manual Commissioning Guide Flatpack 1500 DCRectifier Plant, Doc. No. 360006.163.
2The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted
at delivery.
100A 150A
Alarm
connection
Cable gland
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Rectifier Installation Mains Supply Balancing Effect
The Flatpack PRSBsystem 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 themains supply it is advisable to mount the required number of rectifiers in the followingorder:
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 1500rectifier module is equipped with handles that serve two purposes:
Locking the module into position
Open both handles, insert and plug the module into powershelf. Then lock it into position by rotating the handles upwardsand pushing them firmly home; failure to do so will prevent themodule from making proper contact.
Figure 5 Module with released handles
Pulling the module out
Unlock and release the handles by insertinga small screwdriver into the upper holes,
thus releasing the spring mechanisms. Donot use excessive force. The handles willrelease and pop out. When both handles arereleased, use them to pull the module out.
Do not hold or carry the rectifier by itshandles.
Figure 6 Releasing the modules handles
Commissioning
For information regarding system commissioning, please read manual CommissioningGuide Flatpack 1500 DC Rectifier Plant, art. No. 360006.163.
1 Pos(on L1)
2 Pos(on L2)
3 Pos(on L3)
4 Pos(on L1)
5 Pos(on L2)
6 Pos(on L3)
7 Pos(on L1)
8 Pos(on L2)
9 Pos(on L1)
10 Pos(on L2)
MCU Rectifiers
Handle in locked position
Upper hole torelease the spring
mechanism
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3 Alarm Relay Outputs and Signal Connections
The digital inputs are configured as fail-safe, i.e. if the input isenabled, it will trigger an alarm if the input is open. If severalexternal devices are going to the same digital input, theymust be connected in series.
The alarm relays are also operated in fail-safe, i.e. the relaysare energized when there is no alarm. The description belowdescribes the pin out in normal state, i.e. the NO output isopen in normal operation and shorts to the COM output in thealarm-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
Figure 7 Customer connections interface and internal terminals. (Max. 1,5 mm2, AWG 15)
Terminal Description Terminal Description
CON 2 Internal system connections CON 4 Customer connections (digital inputs, symmetry, etc.)CON 3 Internal communication CON 5 Customer connections (alarm relay outputs)
Interface Card 104649Located back the MCU
Ctrl. Unit(plug for MCU)
Interface Card 104648Located on top of theMCU Ctrl. Unit
CON2
CON4
CON5
Pin 1Pin 10
Pin 11Pin 20
Pin 1Pin 20
CON3
Pin 1
Pin 12
CON4External devicealarm state
Input 1AGND
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Connections for Internal system wiring
CON3 is used for rectifier and power shelf communication. CON2 is used for internal systemwiring, which has been wired at the factory. These connectors are not involved in thesystem installation and commissioning process. The table below shows the pin assignmentfor CON2.
CON 5 Pin Assignmentfor basic PCB version, art. No. 104648
P i n Signal Funct ion Pin Signal Funct ion
123
NCNOCom
Relay 6:Common Alarm
101112
NCNOCom
Relay 3:Low Battery Alarm
4
56
NC
NOCom
Relay 5:
Module Alarm
13
1415
NC
NOCom
Relay 2:
Heat ManagementAlarm
789
NCNOCom
Relay 4:Load / Battery Fuse Alarm
161718
NCNOCom
Relay 1:High temp.(Fan regulation)
1920
(not used)(not used)
Factory Settings
CON 4 Pin Assignmentfor basic PCB version, art. No. 104649
P i n Signal Funct ion Pin Signal Funct ion
12
+AGND
Digital Input 1(Heat management)
1112
+
Battery Symmetry 1(analogue input)
34
+AGND
Digital Input 2(programmable)
1314
+
Battery Symmetry 3(analogue input)
56
+AGND
Digital Input 3(programmable)
151617
+
+21V Auxiliary Supply(for modem or ext.equipment)(not used)
78
+AGND
Digital Input 4(programmable)
181920
+screen
Battery Temperature Sense
Analogue ground (system ref.)
910
+AGND
Battery Symmetry 2(digital input)
CON 2 Pin Assignmentfor basic PCB version, art. No. 104649
P i n Signal Funct ion Pin Signal Funct ion
12
+
Shunt 2:Battery current measurement
9 + Battery Fuse State(digital input)
34
+
Shunt 1:Battery current measurement
10 + Load Fuse State
(digital input)
56
+
Auxiliary Supply(for Flatpack MCU)
11 LVBD control(Battery Disconnect contactor)
78
VDC+VDC
Voltage Sense(system signal reference)
12 LVLD control(Load Disconnect contactor)
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Connections for GMT fuses
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 Signal Funct ion Pin Signal Funct ion
12
+
GMT fuse 1 (F4) 910
+
GMT fuse 5 (F8)
34
+
GMT fuse 2 (F5) 1112
+
GMT fuse 6 (F9)
5
6
+
GMT fuse 3 (F6) 13
14
+
GMT fuse 7 (F10)
78
+
GMT fuse 4 (F7) 1516
+
GMT fuse 8 (F11)
GMT fusesMax. 15 A each
Pin 16 Pin 1
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4 Specifications Flatpack PRSB 15kW, 48VDC, Fan Cooled
Site Power Outdoor cabinet
SPECIFICATION
Max. number of rectifiers 10
AC INPUTVoltage 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
MaximumCurrent
See Flatpack 1500 48VDCdatasheet (241114.100.DS3)
Protection Soft startSurge protection (varistors)Disconnect above 312 VAC
MONITORING
Monitoring Unit Flatpack MCU
Local operation Menu driven software viakeypads and LCD or PC(WinPower)
Remoteoperation
WinPower via modem or WebNMS via SNMP-agent
Alarm relays 6 relays are standard
Visual indications Green LED System ONRed LED Active alarm(s)LCD system status
Digital inputs 5 (for monitoring of externalequipment)
Currentmeasurements
Battery currentRectifier current
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
Alarms
Symmetry alarm
DC OUTPUTVoltage 48 VDC
Current Up to 15 KW 300 Amps
CONNECTIONSBatteryconnections
Battery cable, M8 bolts
Load MCBconnections
Negative distribution, Loadcable, M8 bolts. Commonpositive bus bar, M8 bolts
Alarmconnections
Front access screw terminals
DISTRIBUTION OPTIONSNo. of DCLoad breakers
Up to 3 x (3pole 63Amps)
No. of Batteryfuses
Up to 3 x 125 Amps MCBs mountnext to each battery shelves
No. of Aux.fuses
8 x 10 Amps GMT type
ProgrammableLVD
Standard: 1 LVBD (max. 400 Amps)
OTHER SPECIFICATIONSIsolation 3.0 KVAC input and output
1.5 KVAC input earth1.0 KVDC output earth
Operating temp -40 to +50C (-40 to +122F)
Storage temp -40 to +85C (-40 to +185F)
Dimensions 770 x 820 x 2000mm (WxDxH)(30.3 x 32.3 x 78.7)
Weight Approx. 170kg excl. rectifiers and
batteriesMax. 250kg load per battery shelf
APPLICABLE STANDARDSElectrical 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)
Environment ETSI EN 300 019-2ETSI EN 300 132-2
Fan operation
The fan runs as soon as the temperature in the cabinet passes 25 oC and the fan MCB isswitched 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.
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5 Appendix: Schematics, Drawings, Figures, etc.
General Arrangement drawing
See also
Figure 2, page 5, for more detailed information about DC distribution.
Figure 9 General Arrangement drawing, PRSB 15kW, 48VDCOutdoor Cabinet, Fan Cooled
Battery MCBFB1
Battery MCBFB3
Battery MCBFB4
LTE FusesMCBs
DC Distribution, Alarm,AC Terminals, etc.
Heater MCB (AC)
Battery MCBFB2
Rectifiers
Main Protective Earth (PE)
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System Schematic PRSB 15kW, 48VDC,Outdoor Cabinet, Fan Cooled
Figure 10 Schematicdrawing, PRSB 15kW, 48VDCsystem
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Holes for mountingthe cabinet to theground without a
plinth.
Holes for theplinth. Factorydrilled
Holes for theplinth. Factorydrilled
On Site Door Removal Outdoor Cabinet, Fan Cooled
Step Description Ok
1 Disconnect the earthconnection cable onthe bottom of thedoor
2 Lift the door off thehinges.
3 When the door is tobe mounted backon, lift the doorback on to its hinges
4 Reconnect the earthconnection
Drilling Template
Figure 11 Topview of thecabinets bottomplate.700x700 mmexternaldimensions
The cabinetoverhangs by 35mm outside theplinth on the rear,on the left hand
and on the righthand side
Earthconnection
Air filter
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Main Office:
Eltek Energy ASP.O. Box 2340 StrmsN-3003 DRAMMENNorway
Phone: 47 32 20 32 00Fax: 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
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Flatpack 1500 DCRectifier Plant
360006.163
Issue 1January 2003
Commissioning Guide
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Information in this document is subject to change without notice and does not represent a commitment
on the part of ELTEK ASA.
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 ASA.
Copyright : ELTEK ASA, Norway 2003
NS-ISO 9001 Certificate No.4
This product holds a CE mark and satisfies all requirements covering relevant standards and
directives.
ELTEK Energy (UK) Ltd ELTEK ASAEltek House P.O. Box 2340 Stms
Maxted Road N-3003 DRAMMEN
Hemel Hempstead NORWAY
EMC
Generic Immunity Standard
EN50082-1 Residential, Commercial and Light Industry
EN50082-2 Industrial Environment
Generic Emission Standard
EN50081-1 Residential, Commercial and Light Industry
EN50081-2 Industrial Environment
LVD LVD73/23/EEC Low Voltage Directive
Herts HP2 7DX
England Phone: 47 32203200
Fax: +47 32203210
Phone: +44 1442 219355
Fax: +44 1442 245894
E-Mail: [email protected]
Visit our Web site on Internet: http://www.eltekenergy.com
360006.163 Issue 1, January 2003
This document was produced using Microsoft Word.
l.w 01/2003
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Contents
Contents
1. Introduction 5
Recommended tools 5
2. Commissioning 6
Pre Start Check ...................................................................................... 6
Start Up Procedure ................................................................................ 7
System Set Up ......................................................................................... 8
Commissioning ....................................................................................... 8Battery Discharge Tests....................................................................... 10
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Warning
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Warning
The equipment described in this manual must only be workedon by ELTEK Energy Personnel or by persons who haveattended a suitable ELTEK Energy training course.
The equipment represents an energy hazard and failure to
observe This could cause terminal injury and invalidate ourwarranty.
There are hazardous voltages inside the rectifier system. The
rectifier units include large charged capacitors therefore it isdangerous to work inside the system even if the mains supplyis disconnected.
Removal of cover should only be completed by authorized
personnel. Wait for ten minutes after disconnection before
removing cover to ensure that all high voltages have beendischarged to a safe level.
Some of the units within the system may weigh in excess of
25 kg.the appropriate lifting equipment should be used andcare must be taken whilst handling these units.
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.
Please read the manual carefully before using the equipment.
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1. Introduction
1. Introduction
ELTEK Energys Flatpack Rectifier System is a standby DC system designed for integration
within Customer Equipment areas and telecommunications equipment.
This manual provides the necessary information to commission the system. The system
Description, Specifications and drawings must be use in conjunction with this manual.
There are two sections within this manual:
1: Start Up/Commissioning Procedure.
2: System Configuration Record.
The Commissioning/Site Acceptance Procedure verifies that the system is correctly
installed and operating satisfactorily.
We recommend that the Commissioning Engineer uses a PC during the testing in order to
carry out the tests efficiently.
Necessary software : Winpower Silver (Eltek provided) Software, Windows 95 or above
Password for MCU is 0000 from the keypad in front of the Alarm Module if nothing else is
specified.
Please consult the Operation Guide for the Alarm Module if any of the System parameters
need to be changed.
The SystemConfiguration Record is vital for future reference and efficient service.
Note: Remote batteries.
The MCU provides the option to compensate for voltage drop in long battery cables. Pleaseconsult the Operation Guide for MCU for further details.
Recommended tools
Standard equipment for an authorized electrician
Digital multimeter
PC with terminal software and cable
Note: All tools mustbe insulated.
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2. Commissioning
2. Commissioning
The purpose of this phase is to verify the equipment installation and to commission the equipment in
preparation for operation.
Pre Start Check
Before starting the system the following items should be checked:
Check Comments Okay
1. THE SYSTEM INSTALLATION IS
COMPLETED AND UNDAMAGEDEnsure that all equipment is free from damage.
Ensure that all cabling is neat and secured,
components are fixed firmly and all labelling isclear and correct.
All blank panels are replaced including unused
module positions.
2. THE BATTERY AND LOAD AREDISCONNECTED
Verify that all battery and load circuit breakers are
in the OFF position
3. RECTIFIER SYSTEM IS CONNECTED TOAC SUPPLY AND PROTECTIVE EARTH
Check that the AC supply is connected,
configured correctly and suitable rated.
A protective earth connection must be made and
continuity must exist to all metalwork.
4. SITE PARAMETERS/SETUP KNOWN Refer to service module for site specific details
5. ALL SUPPLIES DISCONNECTED, FUSES
OUT/OFF AND MODULES REMOVED
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2. Commissioning
CommissioningGuide, Flatpack 1500 DC Rectifier Systems 7 (12)360006.163 , v1, January 2003
Start Up Procedure
Start Up Step Comments Okay
1. SWITCH ON THEAC TO THE CABINET
AND START THE ALARM MODULE BY
PRESSING THE SYSTEM ON/OFF SWITCH
The green LED will light.
2. ENSURE THAT THEAC SUPPLY IS
CORRECT
Measure the AC voltage at the input and selected
rectifier module positions to ensure correct
polarity and potential
3. CONNECT RECTIFIER MODULES Follow procedure within the installation guide.
Verify that all modules are plugged in and the
securing clips closed.
All unused positions must be covered with
blanking panels.
4. INSTALL BATTERIES Follow procedure within the Installation Guide
5. CONNECT A PCVIA THE FRONT PANEL9 WAY D TYPE CONNECTOR AND
ESTABLISH COMMUNICATION
Refer to external equipment connection in
MCU operation guide.
6. ENSURE THAT ALL THE RECTIFIER
MODULES ARE OPERATING CORRECTLYAND NO ALARMS ARE PRESENT
Monitor the alarm module and recifier modules.
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2. Commissioning
System Set Up
Step Comments Okay
1. CALIBRATE THE INPUT VOLTAGE Use the calibration function in the service menu.Measure the actual value and then enter via PC.
2. CALIBRATE OUTPUTVOLTAGE Use the calibration function in the service menu.
Measure the actual value and then enter via PC.
3 CALIBRATE BATTERY CURRENT Use the calibration function in the service menu.
Measure the actual value and then enter via PC.
An external power supply will need to be
connected to the battery input during this check.
The voltage of the external power supply should
be set to +1V of the Rectifier system and then thebattery fuse can be fitted and removed.
NOTE: Calibration is only necessary if the alarm module
does not match the actual reading
4. SYSTEM SET UP IS IN ACCORDANCEWITH CONFIGURATION
Make sure that the system is set up in accordance
with the site requirements.
5. ENSURE ALARM CIRCUITS OPERATE Use test outputs function within the service menu.
Commissioning
Step Comments Okay
1. TEST HIGH BATTERYALARM Set the output voltage level to 0.5 V above the
high battery alarm level via the PC and verify that
the High Battery Alarm is activated and the
relevant alarm contact is operated.
2. TEST LOW BATTERYALARM Set the output voltage level to 0.5 V below thelow battery alarm level (and reset the High
Battery Alarm) via the PC. Verify that the Low
Battery Alarm is activated and the relevant alarm
contact is operated.
Reset the output voltage to nominal and the low
voltage alarm resets.
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2. Commissioning
3. TEST LOWVOLTAGE DISCONNECTALARM
An external power supply will need to be
connected to the battery input. The voltage of the
external power supply should be set to +1V of the
Rectifier system and then the battery fuse can be
fitted and removed.
Switch off the AC supply and reduce the output
voltage to 0.5 V below the disconnect voltagelevel via the external power supply.
Verify that the Disconect Alarm is activated and
the relevant alarm contact is operated. The low
voltage disconnect contactor will operate.
Switch off and remove the external power supply
and re-instate the system by turning on the AC
supply
4. TEST BATTERY FUSEALARM Operate the battery MCBs and verify that the Batt
Fuse Fail Alarm is activated and the relevant
alarm contact is operated.
5. TEST LOAD FUSE FAILURE Connect a tempory load to one of the output
circuit breakers. With the relevant MCB in the Off
position verify that the Load Fuse Fail Alarm is
activated and the relavant alarm contact operates.
6. CONNECT THE BATTERIES Turn ON relevant battery MCBs. Ensure that the
contactor closes.
7. TEST MAINS FAILURE Switch off the AC input supply to the system and
verify that the Mains Off Alarm is activated and
the relevant alarm contact is operated.
Also verify that the Module Fail Alarm is
activated. The green LED on each module will
extinguish whilst the red LED will light.
Restore the AC supply and ensure that the alarms
reset.
8. CHECK LOAD SHARING Connect load to the output, and switch on load
MCB.
Allow several minutes for the modules to share
and check that the output currents of the modules
are within +5 % of the mean current.
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2. Commissioning
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Battery Discharge Tests
The battery should have a full discharge test as part of the commissioning procedure. Six days
should be allowed for charging prior to and after the test.
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ELTEK ASAP-O- BOX 2340 StrmsN-3003 DRAMMENNORWAY
Phone: +4732203200Telefax: +47 32203210Internet: http://www.eltekenergy.com
e-mail: [email protected]
ELTEK Energy UK LtdMaxted RoadHemel HempsteadHerts HP 2 7DXEnglandPhone: +44 1442 219355Fax: +44 1442 245894Email: [email protected]
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Installation Guide
Kit for 1 Battery string +
Outdoor Shelf
Art. 351412.033Issue 3, 2004-11
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2 Valid Option Guide, Kit for 1 battery string + Outdoor shelf Art. No 351412.033, v3 11-2004
Index
General ..................................................................................................................................2
Consist of...............................................................................................................................2Recommended tools ...............................................................................................................3
Installation .............................................................................................................................3
Ordering information..............................................................................................................6
General
This kit enables you to expand your system with additional battery strings. There is room forthree battery strings in addition to one in the standard system.
Consist ofThe Kit for 1 Battery string + Outdoor Shelf consist of the following components.
Part Note Quantity Unit
MCB CBI D-frame 150A with aux switch With copper bars pre mounted 1 pcs
Cable clamp for rail 70 mm2 For positive connection rail 1 pcs
Cable clamp for rail 35 mm2 For negative connection 1 pcs
Battery cables 2 pcs
Black For positive connection 2.4 m
Blue long For connection from battery MCB tocommon negative rail
2.4 m
Blue short For connection from battery to batteryMCB
1.2 m
Alarm wire Grey 1 pcs
Strips For collecting and fastening the cables 8 pcs
Nut 6mm for square hole in rack 4 pcs
Screw PAN M6X16 A4 DIN 85 For fixing the battery shelf 4 pcs
Screw PAN m3X8 DIN 7985 zinc For fastening the MCB to the bracket 4 pcs
Screw M5x10 TAPTITE TORX pan tx25 For fixing MCB cover 1 pcs
LOCK WASHER M5 DIN 137B zinc 1 pcs
Battery shelf 1 pcs
Cover for Batteryfuse Outdoor cab. 1 pcs
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Valid Option Guide, Kit for 1 battery string + Outdoor shelf Art. No 351412.033, v3 11-2004 3
Recommended tools
Standard equipment for use by an authorized electrician. NOTE: All tools have to be insulated.
Installation
Installation must be done by authorized personnel only.
Eltek Energy recommends that the system is powered down before installation of the kit.
Step Description Comment OK
1 Position battery shelf in the
cabinet
Make sure that the distance to the next shelf is
large enough the fit the batteries.
2 Fasten the shelf with the
screws.3 Fit the MCB into the MCB
holder.The holder is situated on the left side of thecabinet.
4 Verify that the MCB is in
OFF position
MCB
holder
Battery
cables
Battery
MCB
Outdoor
Battery
shelf
Negativeconnection
clamp
Positive
connection
clamp
Alarm
wire
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4 Valid Option Guide, Kit for 1 battery string + Outdoor shelf Art. No 351412.033, v3 11-2004
5 Connect the alarm wires to
the MCB. Use the C
(common) and NO
(normally open) alarm
connection points.
If there is more than one battery string in the
system the MCB alarms must be connected in
series.
6 Connect the negative
battery cables
Connect the single insulated negative battery
cable (blue) to the bottom of the MCB. Draw out
the cable up through the back of the cabinet. Cut
the cable to length if needed. Connect the cable tothe negative bus bar with the 35mm cable clamp.
Connect the double insulated negative cable
(blue) to the top of the MCB
7 Place the batteries on the
shelf
Loosen the screws to the battery fixing
mechanism andpull the battery
stopper as far as
possible to you.
Place the
batteries on the
shelf, push thebattery fixing
mechanism until it holds the batteries tightly andfasten the screws.
Movewire
from 2
to 4
MCU
1 2 (NO)
43
MCU
1 2 (NO)
43
MCU
1 2
43
Connect
wirebetween
3 and 2
Prewired cables
Kit wire
Additional
battery banks
1-4 Connectionpoints
MCB
MCU
1 2
43
Multiple battery
strings
Battery fixingmechanism
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Valid Option Guide, Kit for 1 battery string + Outdoor shelf Art. No 351412.033, v3 11-2004 5
8 Connect the positive
battery cable.
Place the positive battery cable (black) up
through the back of the cabinet and fasten it. Cut
the cable to the right length if needed. Use the
70mm clamp to connect the positive cable to the
positive bus bar.
9 Connect to batteryterminals
Connect the positive cable to the positive batterypole. Then connect the double insulated negative
cable from the MCB to the negative battery pole..
10 Install the MCB cover
10 Power Up the system Repeat installation for all battery strings before
you Power Up the system.
Before turning on the battery MCBs, measure the
battery voltage and adjust the system output
voltage to this level. For details seeFlatpackMCU operation Guidewith Art. No. 351300.013.
Turn on the battery MCBs and increase thesystem output 2 volts every minute until you have
reached the wanted value.
Battery MCB
Double insulatednegative batterycable
Single insulatednegative batterycable
Alarm wire NO
Alarm wire C
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6 Valid Option Guide, Kit for 1 battery string + Outdoor shelf Art. No 351412.033, v3 11-2004
Ordering information
Part Number Description
104672 Kit for 1 Battery bank + shelf outd
The Kit is suited for the Flatpack PRSB 15kW, 48 V, Outdoor Site Power Cabinet system,
both Air Condition and Fan cooled.
Negative bus
bar (Battery)
Negative bus
bar clamp
Positive bus
bar clamp
Positive bus
bar
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ELTEK EnergP-O- BOX 2340 StmsN-3003 DRAMMENNORWAY
Phone: +4732203200Telefax: +47 32203210Internet: http://www.eltekenergy.come-mail: [email protected]
http://www.eltekenergy.com/mailto:[email protected]:[email protected]://www.eltekenergy.com/