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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

    mailto:[email protected]://www.eltekenergy.com/http://www.eltekenergy.com/mailto:[email protected]
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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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    Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Fan Cooled Art. No. 351405.033, v32004-11 9

    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

    mailto:[email protected]://www.eltekenergy.com/http://www.eltekenergy.com/mailto:[email protected]
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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

    2 (12) CommissioningGuide, Flatpack 1500 DC Rectifier Systems360006.163 , v1, January 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

    4 (12) CommissioningGuide, Flatpack 1500 DC Rectifier Systems360006.163 , v1, January 2003

    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

    10 (12) CommissioningGuide, Flatpack 1500 DC Rectifier Systems360006.163 , v1, January 2003

    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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    CommissioningGuide, Flatpack 1500 DC Rectifier Systems 11 (12)360006.163 , v1, January 2003

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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/