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INSTALLATION, COMMISSIONING
AND OPERATIONS MANUAL FOR
FLATPACK2 OPTUS SYSTEM
REVISION CONTROL
Rev Date Revision Description Orig Check App
A 28/08/09 Modified from TG6340H SW
B 27/11/09 Add New Model A111223.001 SW
C 11/01/10 Update images SW
D 24/01/10 Insert New Optus Part Number Table SW
E 25/05/10 Temperature probe position RB
F 20/11/10 Change of MCB line up and position RB/RZ
and minor edit
G 07/02/11 Included: AG12V100F battery, RZ
manual battery test.
Updated: packing list, scope.
TABLE OF CONTENTS
1. SCOPE .......................................................................................................................................... 5
2. SYSTEM OVERVIEW ................................................................................................................ 6
3. REQUIREMENTS ..................................................................................................................... 11
3.1 INSTALLATION REQUIREMENTS.....................................................................................................................11
3.2 FOR COMMUNICATION WITH THE CONTROLLER: ...........................................................................................11
3.3 WARNINGS ...................................................................................................................................................12
4. PACKING LIST ......................................................................................................................... 14
5. SYSTEM CONFIGURATION.................................................................................................. 14
6. UNPACKING ............................................................................................................................. 15
7. CABINET ASSEMBLY ............................................................................................................. 16
8. FLOOR FIXING ........................................................................................................................ 17
9. EARTH CABLING .................................................................................................................... 17
10. CONNECTING THE BATTERIES ...................................................................................... 18
10.1 SYMMETRY CONNECTIONS ..........................................................................................................................19
10.2 CONTROLLER SETUP ...................................................................................................................................20
11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS. ............... 25
12. EXPANSION RACK ALARM CONFIGURATION .......................................................... 25
13. BATTERY VOLTAGES ........................................................................................................ 26
13.1 REFRESHING OF BATTERIES ........................................................................................................................26
13.2 LOW VOLTAGE BATTERY DISCONNECT (LVBD)........................................................................................26
13.3 TEMPERATURE COMPENSATION ..................................................................................................................26
14. EXPANSION RACK INSTALLATION CHECK LIST ..................................................... 28
15. INSTALLATION AND OPERATION OF RECTIFIER MODULES .............................. 29
15.1 VISUAL INDICATIONS..................................................................................................................................30
15.2 PLUGGING IN RECTIFIERS ...........................................................................................................................31
15.3 REPLACING AND INSTALLING RECTIFIER MODULES .....................................................................................31
15.4 RECTIFIER EFFICIENCY MANAGEMENT / LOAD SHEDDING ..........................................................................32
16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER....................... 33
17. OPERATION OF THE SMARTPACK CONTROLLER .................................................. 35
17.1 FRONT PANEL OPERATION..........................................................................................................................35
17.2 OPERATING MENUS, (MENU MODE) ...........................................................................................................37
17.3 FRONT KEYPAD MENU TREE FOR SMARTPACK CONTROLLER: .....................................................................38
18. ALARM MONITORING ....................................................................................................... 39
18.1 ALARM PCBS .............................................................................................................................................39
18.2 ALARM OUTPUTS........................................................................................................................................40
18.3 ALARM CONNECTIONS ................................................................................................................................40
18.4 ALARM LEVELS SETUP ................................................................................................................................41
18.5 DIGITAL INPUT POSITIONS. ..........................................................................................................................42
19. AC MAIN SUPPLY INSTALLATION................................................................................. 43
20. DC DISTRIBUTION INSTALLATION ............................................................................... 46
21. INSTALLATION CHECKLIST ........................................................................................... 47
22. COMMISSIONING CHECKLIST ....................................................................................... 47
22.1 PRE-START / INITIAL CHECKS .....................................................................................................................47
22.1 SYSTEM START-UP .....................................................................................................................................47
22.3 CHECKING THE ALARMS .............................................................................................................................48
22.4 OTHER COMMISSIONING CHECKS................................................................................................................53
22.6 DEFAULT -48V SYSTEM SETTINGS .............................................................................................................54
23. ON-GOING MAINTENANCE PROCEDURES ................................................................. 55
23.1 GENERAL CHECKS.......................................................................................................................................55
23.2 MODULE MAINTENANCE .............................................................................................................................55
23.3 GENERAL ONGOING MAINTENANCE PROCEDURES ......................................................................................55
23.4 SYSTEM COMPONENTS MINIMUM OPERATING LIFE ....................................................................................56
24. USING POWER SUITE SOFTWARE ................................................................................. 57
24.1 INSTALLATION OF POWER SUITE SOFTWARE...............................................................................................57
24.2 USING POWERSUITE V3.X: A START UP GUIDE. ..........................................................................................58
24.3 USING POWERSUITE V3.X: OPERATION. .....................................................................................................58
24.4 EFFICIENCY MANAGEMENT ........................................................................................................................67
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 3 of 70
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
1. SCOPE
Table 1.1
System Part numbers
Table 1.2
Component Part numbers
2. SYSTEM OVERVIEW
If required, the main system cabinet can be supplemented with a battery expansion cabinet for
increased battery capacity. Details of the expansion battery cabinets are given later in this
manual.
Output cable
management Anderson
rail connector
for battery
expansion
rack
0V DC bar 95mm
(SPC) earth
cable
Monitor AC
fail PCB mains
input
Serial
Number
lable
Load
CBs System
connection
board
Battery
expansion Symmetry
rack alarm PCB
(hidden)
Alarm PCBs
Figure 2.1
Top view with cover removed.
Figure 2.2
Front and side views of a A111223.xxx
2200mm(H) x 600mm(W) x 400mm(D)
Figure 2.3
Front and side views of a A111223.xxx
2067mm(H) x 600mm(W) x 400mm(D)
Figure 2.4
Front and side views of a A111223.001
2067mm(H) x 600mm(W) x 400mm(D)
Figure 2.5
Front and side views of battery expansion cabinet with A461033.001, with 12NDF100/AG12V100F
2200mm(H) x 600mm(W) x 400mm(D)
3. REQUIREMENTS
The system should only be installed into locations that have restricted access to personnel.
3.3 Warnings
IMPORTANT: DO NOT mix the standard VRLA (12NDF100) and Polymer Gel
(AG12V100F) Batteries, despite having the same system settings, as batteries they
have different electrochemical properties (for example different internal resistance)
these characteristics can cause dissimilar performance during charging and
discharging process (example: particular string can be discharge faster than the others
but will be slow to recharge) which can affect the service life of the battery bank.
Communications Grade valve regulated gas recombination lead acid cells and
monoblocs are electrically live at all times and must be treated with care. The products
are generally capable of supplying high short circuit currents even if the case or lid is
damaged. Remember that the battery is electrically live at all times and cannot be
isolated in the conventional sense, although the voltage at any point can be reduced by
removal of appropriate inter battery links. Take care that short circuits are not caused
by accidentally dropping or touching metal objects onto the cell or monoblocs
terminals.
Before connecting batteries and cables remove all metallic objects such as rings,
watches etc from your hands and wrists to avoid causing a short circuit.
Do not smoke or permit open flames near batteries. Avoid any activity near the
batteries that may cause sparks.
If the rectifier module is damaged in any way or develops a fault it should be replaced
immediately. This should only be done by appropriately qualified personnel. Refer to
the operations manual for instructions.
The equipment contains voltages that may be lethal. The AC distribution front cover
plate should not be removed without first isolating the AC supplies. AC supply
connection should only be done by appropriately qualified personnel.
Allow for adequate ventilation around the units. A 5 10 mm clearance should be kept
between the batteries as they may expand in high temperatures.
Be aware that the rectifier is rated for high temperature operations. Therefore care
must be taken when handling the modules as they can reach temperatures of 60oC
The system must not be located in an explosive atmosphere, i.e. in the presence of
flammable gases and fumes. Suitable ventilation for the battery must be provided.
Narada 12NDF100 batteries are heavy, 33kg, & may require two people to lift.
4. PACKING LIST
A fully equipped Flatpack2 system is dispatched from Eltek Pacific in a number of packages.
Each package is clearly marked indicating its content. The packages include the following:
Note: The cabinet may contain 1 Smartpack controller and can have up to 9 x 2kW FlatPack2
rectifiers or up to 8 x 2kW FlatPack2 HE rectifiers already fitted.
Battery crates OK
Batteries as required (Monoblocs)
Solid links (Attached to the inside of the cardboard battery box)
5. SYSTEM CONFIGURATION
The different configurations of the Flatpack2 system and expansion battery cabinets are listed
below:
All systems except A111223.001 are 2200MM (H) x 600MM (W) x 400MM (D), and all
use Narada 12NDF100 batteries.
A112007.001 and A111223.001 system are 2067MM (H) x 600MM (W) x 400MM (D), and
they use either Narada 12NDF100 or AG12V100F batteries.
A112007.001 has maximum of 9 rectifier slots.
6. UNPACKING
All equipment is suitable for being moved with a normal pallet truck whilst packed. When
unpacked, cabinets may weigh 145kg and are heavier at the top end of the cabinet.
IMPORTANT: These units are top heavy, and can tip over unexpectedly if not handled
with care.
Appropriate lifting equipment should be used, and suitable care must be taken while handling
these units. The most appropriate method of moving the racks is with the use of a hand
trolley. Some packaging material should be placed between the trolley and the rack to avoid
damage to the rack. It is however recommended that the complete boxes be positioned as
close as possible to the actual location where the system is to be installed.
Lifting Cables
M8 Eyebolt, placed
in the wall mounting brackets bolt
position
Cabinet
Figure 6.1
Lifting arrangement for the cabinet, using eyebolts and spreader bar
7. CABINET ASSEMBLY
The Cabinets will arrive packed in a box. The following are instructions for assembling this
cabinet.
1. Inspect the installation site and determine where the system will be located. Position the
packages close to the final systems destination.
2. Each package will have affixed to it, a complete packing list, listing the contents of each
package and the quantity. Check to ensure that you have all items marked on the packing
list.
3. Unpack the cabinet from its box.
4. Follow the floor fixing instructions in the next section to fix the cabinet in position.
5. Attach the cabinet to the wall using wall mounting brackets insulation kit.
Figure 7.1
Top wall mounting bracket and insulation kits
8. FLOOR FIXING
All cabinets include a fixing kit. One fixing kit consists of 4 round washers and 4 dynabolts.
Bolt through the 4 holes in the bottom using dynabolts.
Nut
Washer
Cabinet
Dyna-bolt
Concrete Floor
Figure 8.1
Dynabolts Fixing
9. EARTH CABLING
Each cabinet should be bound to earth using links. There is one 95mm earth cable shipped
with each cabinet. Ensure this converter cubicle bond is bonding the cabinet M8 bolt to the
positive common bar (SPC) inside the cabinet, creating a bonded -48V DC supply. External
earthing should be done to relevant company standards, to the common positive bar.
Also connect the battery extension cabinet, if being used, to the SPC inside the rectifier
cabinet with the 95mm earth cable supplied with the extension cabinet.
IMPORTANT: DO NOT mix the standard VRLA (12NDF100) and Polymer Gel
(AG12V100F) Batteries
The FlatPack2 system is supplied with a 100A battery circuit breaker with auxiliary for each
string. The string CBs are located on the left-hand side of each battery shelf. The system is
supplied with cables from the battery CBs to the battery trays already fitted. Ensure that the
battery CBs are turned OFF before connecting the batteries. See the attachments section at
the end of the manual for the battery MSDS. All unused battery CBs should be switch on
to prevent a battery CB alarm. For battery shelves not being used, ensure cable ends
remain insulated with heat shrink provided.
Installation Steps
1. Before commencing the installation, ensure that each battery is in good condition and
has not been damaged during transport. When installing, be careful that the case of the
battery is not permitted to be cracked by resting or dropping on anything pointed.
2. Monoblocs are heavy; and accordingly the recommended lifting equipment should be
used.
3. Remove rack battery retaining strap. Position the batteries on shelves as per Figure
10.1. We suggest that one monobloc be lifted into place at a time. Leave a clearance
space of between 5 10 mm between the batteries. Slide the batteries gently back to
the rear of the system to avoid any risk of damaging them on the rear of the shelf.
4. Particular care should be taken when placing on the shelves to ensure the correct
positioning of the positive (red) and negative (blue) terminals.
5. Connect inter battery flexible cables and inter tier links. To ensure a low resistance
joint, clean the flat contact making surfaces of the terminal posts and connectors with
a soft clean cloth. The links do not normally require cleaning and can be fitted without
any operation. However in some cases the links could show encrustation and this
should be removed using Scotchbrite or fine grade abrasive paper. Do not use a wire
brush and be especially careful not to break through the lead plating. Apply a light
coating of grease to the contact making surfaces and place a solid connector strap or
flexible link in position.
6. Connect the symmetry loom (if used) to the battery terminals. See section 10.1 for
more information on symmetry connections.
7. Tighten the nuts firmly: 7-8 Nm using an insulated torque wrench. Lightly smear
grease on the washer and bolt.
8. Place battery link covers on all battery links.
9. Place the battery numbering labels in place starting at the first battery (on the bottom
shelf) and working to the last.
10. Update the Smartpack controller information for # of symmetry strings.
11. Wait 24 Hours and re-torque the battery terminals.
IMPORTANT: Particular care should be taken to ensure the batteries are not short-
circuited during this procedure. Short circuit current is approximately 2000A
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 18 of 70
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
symmetry connection
Negative
battery cable - + - + - + - + Positive
battery
cable
Battery 4 Battery 1
Figure 10.1
Symmetry connection point, to either side of the middle hard link
Controller
CON 3
CON 4
Symmetry Symmetry
PCB PCB
Battery Battery
symmetry symmetry
connections Temperature connections
probe
Figure 10.2
Symmetry PCB connection points
Temperature
probe
Battery Battery
symmetry symmetry
connections connections
M6 Ring terminals
for battery
Figure 10.3
Symmetry Monitor Box connection points
This value is needed for correct battery testing as this value is multiplied by the Ah of the
battery to give the total system capacity.
DO NOT change
this value
Figure 10.4
String number screen (using Power Suite 3.x)
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 21 of 70
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
Important!
Make sure BOTH
major and minor
alarms are set to the
new value
Figure 10.5
Rectifier over-current alarm setting screen (using Power Suite 3.x)
Figure 10.6
Battery charge current limit setting (using Power Suite 3.x)
Click on the battery strings that have symmetry loom connected & press the tick box to
activate the monitoring on that string. Note: the top battery string will not have a symmetry
loom connection, so with 5 strings connected, only the bottom 4 will be monitored & only
these should be activated. Also be aware that the symmetry alarm is a latching alarm that
will be present even when the initial cause has been removed. This will need to be manually
reset by the controller front panel, or by right clicking in the explorer tree to the left of the
screen & selecting reset alarms. A Blue colour indicates that an alarm is actively monitoring
that string, grey indicates there is no monitoring, click to change.
Figure 10.7
Symmetry activation setting screen (using PowerSuite 3.x)
Figure 10.8
Install probe within the rack above batteries
Each expansion battery cabinet is fitted with a flying lead with an Anderson connector on one
end to connect, a 95mm earth cable (to be attached to the SPC) & a battery alarm / symmetry
cable, all to be taken to the system cabinet:
1. Position expansion cabinet and fix it to the floor in the same manner as the rectifier
cabinet.
2. Ensure that all the individual string MCBs are turned OFF
3. Install the batteries and symmetry connections in the controller as detailed in section 10.
4. Double check all the string MCBs are OFF and connect the flying lead with the
Anderson connector to the existing rectifier cabinet as in Figure.11.1 below.
5. Once the battery strings are in place turn on the strings of batteries one by one. Pause
between turning each string on to let the system equalize with the string.
6. Check the string voltage and the battery current on the Smartpack display. There should
be a small positive current flowing to the batteries.
Earth cable
Figure 11.1
Expansion rack connections
The battery alarms provide signals to the Smartpack control module via auxiliary switchs on
each battery circuit breaker. The purpose of this signal is to initiate an alarm condition if the
battery CB has tripped. This is a normally-closed loop which if broken, will create an alarm.
Each system cabinet is supplied with an alarm interconnection cable that connects the system
cabinet to the expansion battery cabinet. The alarm interconnection cable contains both
battery symmetry information, as well as the battery fuse fail alarm. This cable should be
brought back to the back of the Smartpack controller.
The LVBD will only disconnect if BOTH the DC voltage is low, and an AC fail is active. In
this way, the LVBD will never activate during a requested battery test. The LVBD will also
disconnect any battery expansion rack connected to the system.
The LVBD mechanism uses a latching contactor that sends a momentary pulse of current to
the coil to activate / deactivate the contactor. In this way, a service switch is not needed to
keep the contactor closed during servicing of the system.
13.3 Temperature compensation
The system is supplied with a temperature-sensing probe for temperature compensation
charging. The temperature compensation cable is temporarily cable tied to the system. The
cable should be carefully untied and the transistor probe should be placed in the space
above the uppermost string of installed batteries for measurement of air temperature as
close as possible to the batteries. Do not rest the probe directly against any of the batteries
as this will give a false reading in the event of that individual battery having a fault.
Important Note: Redeploy temperature compensation probe to the top of the uppermost
installed battery string when installing extra battery strings. (Use cable ties to fix it into
place.)
Install
probe in
this area
Figure 13.1
Temperature probe deployment should be near, but not touching, above the uppermost string of batteries.
Table 13.1
Battery temperature compensation values.
Important Note: All power settings are the same for both AG12V100F and 12NDF100
Batteries.
Battery
CBs
Retaining
bracket
Figure 13.2
Front view of batteries, showing spacing & battery circuit breaker position.
(Cables / links are not shown)
Table 14.1
Expansion Rack Installation Check List
If for any reason any of the rectifiers have to be removed, or additional rectifiers are being
fitted, please refer to the following procedure. Each rectifier is automatically logged with the
controller & starts operation immediately upon insertion. However, additional rectifiers
require changes to relevant alarm settings, see section 10. For important information
regarding rectifier operation and positioning also see section 25. Noted that the Flatpack2
rectifier module is a Hot plug rectifier allowing expandability and serviceability without
power shutdown. The current share functionality of the modules ensures all modules deliver
the same amount of current. The FlatPack2 rectifier cabinet accommodates up to 9 FP2
rectifier modules or up to 8 FP2 HE rectifiers. The HE rectifier use the same install and
uninstall procedures as the FP2 2kW modules
Installing rectifiers
1. Unpack the rectifier modules from their packaging.
2. Refer to section 15.3: for information regarding the correct rectifier positioning.
3. With the system on, slide each module into place, but do not push the rectifier all the way
home at this point. Make sure the pull out handles have been released as shown in Figures
15.1 and 15.2 below, then push the unit into place and lock the rectifier into position by
pushing the handles firmly into their housing.
IMPORTANT: During continuous operation, the metal case of the rectifier unit can
become hot. There is no danger of contact burns occurring, but care should still be
taken when handling recently unplugged rectifiers.
IMPORTANT: Rectifier efficiency management may be active on this system. This will
cause some under-used rectifiers to periodically power on & off and show no LED
display on the front of the rectifier. This function is detailed in section 15.4 .
Figure 15.3
Front view of Flatpack2 2kW and HE rectifier modules
The Flatpack2 is intended for use as a stand-alone unit or in systems with multiple modules
and an external alarm / control module. The Flatpack2 will operate in a default mode if the
control module fails
The Flatpack2 Rectifier Module has the following LED indications:
Power (green) indicates whether the power supply is OFF, ON, or communicating.
Alarm (red) indicates an alarm situation.
Notice (yellow) indicates an atypical situation.
15.1 Visual Indications
LED Status Description
Table 15.1
Visual alarm indications
Place the new rectifiers into the next highest rectifier position, in order. See table below.
Their existence will be automatically logged by the controller, no further configuration is
required.
1. Fit the new rectifier into the position left by the faulty rectifier.
2. Eliminate any rectifier alarm by performing a rectifier recount that resets the
number of rectifiers using the front keypad, under service menu (see section 17.3)
1. Remove the highest ID rectifier (important) and fit into the vacant faulty rectifier
position, in order to maintain continuity.
2. Eliminate any rectifier alarm by performing a rectifier recount that resets the
number of rectifiers using the front keypad, under service menu (see section 17.3) The
highest ID rectifier is now reassigned to the ID of the faulty rectifier in the system.
3. When a new rectifier is obtained, fit it into the highest vacant ID position. Its
existence will be automatically logged by the controller.
Smartpack
ID1 ID4 ID7
(controller)
Table 15.2
Rectifier ID positions for C801047
Smartpack
(controller)
Table 15.3
HE Rectifier ID positions for A111223.00x
All rectifiers will eventually be cycled into & out of active use by this method over the course
of many hours. The controller will always ensure that there are enough rectifiers active to
supply the load, including an additional active redundant rectifier. If at any time the load were
to increase, additional rectifiers will be taken on-line in a matter of seconds. Also, if any
rectifier error were to occur, then all installed rectifiers will be taken on-line, effectively
disabling efficiency management until the error is cleared.
Turning on Rectifiers
The average load is monitored continuously. If the system load increases above the high
load limit, the number of operating rectifiers is increased by the number needed to get the
average load within limits.
Safety
There are certain system events that may halt the efficiency manager. These events will
immediately turn on all rectifiers and set the efficiency manager to idle mode.
1. One or more rectifiers stops communicating or has an error.
2. The number of rectifiers installed is changed.
3. System Voltages is changed
4. Battery Boost or Test is started
The Smartpack controller is physically held in place using a similar method as the Flatpack2
rectifiers: It incorporates handles that serve both to lock the module into position and to pull it
out of its housing.
If in the event that the Smartpack needs to be removed for any reason the following procedure
should be used:
1. Release the handles (using similar method as the Flatpack2 rectifiers as described
above)
2. Grasp the Smartpack by the handles at either side of the unit and pull the unit out. The
connection cables are attached to the rear of the controller via several D type
connectors. Pull out the controller enough to access the rear of the unit, and unplug the
cables as detailed over page. See Figure 16.3
IMPORTANT: Open the handles before inserting the controller into the power shelf.
1) Open the handles (insert a screwdriver into the 2) Use both handles to pull the module
holes to release the spring mechanism) Remove gently loose; support it from underneath;
the module hidden cables are connected to the rear
panel.
Figure 16.1
Rectifier locking mechanism
Figure 16.2
The rear of the smartpack controller
Plug Function
CAN 1 Data bus 120 terminating resistor
CAN 2 Communication with the FP2 rectifiers
CON 1 Alarm relay 1-2 & inputs 1-2
CON 2 Alarm relay 3-6 & inputs 3-6
CON 3 Battery expansion symmetry
CON 4 Local rectifier cabinet symmetry & temperature
CON 5 Controller power, voltage measurement, CB fail & other system connections
Table 16.1
Controller connection key
Ethernet Port
Figure 16.3
The rear of the Smartpack controller Web/SNMP
Plug Function
CAN 1 Data bus 120 terminating resistor
CAN 2 Communication with the FP2 rectifiers
CON 1 Alarm relay 1-2 & inputs 1-2
CON 2 Alarm relay 3-6 & inputs 3-6
CON 3 Not Available
Ethernet RJ45 Port for web server and SNMP
CON 4 Local rectifier cabinet symmetry & temperature
CON 5 Controller power, voltage measurement, CB fail & other system
connections
Table 16.2
Controller Web/SNMP connection key
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 34 of 70
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
The Smartpack unit controls, monitors and regulates each FlatPack rectifier module and
provides battery & system surveillance in order to protect and optimize the battery lifetime. If
the alarm module is removed, voltage control / regulation will be lost and system voltage will
equal to default rectifier voltage.
Figure 17.1
Smartpack front panel
LED indicators
LCD display
The graphic display is an important part of the power supply systems user
interface. The display can be shown in Status Mode (displays the systems status)
or in Menu Mode (displays the menu structure). Depending on the displays
mode, the upper line shows the output voltage or menu options, while the lower
line displays battery and load current, alarms, or information about which key to
press.
Front Keys
You can control the many of the Flatpack2 DC power systems via a network of
software menus accessed with the controllers front keys.
Press the key to change from Status Mode to Menu Mode.
Press the or keys to scroll up or down and navigate to find menu
options (function or parameter).
Press then the key to select the function.
Modes of Operation
The controllers display is either in Status Mode or in Menu Mode.
Status Mode
When the front keys are not in operation, the display is in Status Mode. The
following information is then scrolled through the display:
The upper line continuously displays the battery voltage.
The lower line continuously scrolls the following information: Press to fast
forward through the messages.
Battery Current
Load Current
Active alarms
Other messages
Menu Mode
When the front keys are in operation, the controllers display switches to Menu
Mode and the following information is scrolled through the display:
The upper line shows the name of the active menu or sub-menu
The lower line indicates which key to press
IMPORTANT: If no keys are pressed within 30 seconds the display will automatically
switch from Menu Mode to Status Mode.
User Options
When you enter Menu Mode, you access the User Options.
How to browse the display menus:
Service Options
When you enter Menu Mode, you access the User Options. You may then scroll
down to the password protected Service Options.
The Service Options password is factory-programmed to <0003>. If the wrong
password is entered three times, the controller will be locked out for a period of
time.
IMPORTANT: If no keys are pressed within 30 seconds the display will automatically
switch from Menu Mode to Status Mode.
User Service
Password = 0003
Change Language
Alarm Reset Alarm Reset
VoltAdjustment NomVolt
Voltage Info NomVolt
BoostVolt
BoostVolt
LowBatt1
LowBatt1
Threshold
Display messages Display messages
Rect.PrimaryVolt
OutputControl Temp.Comp
Rectifier Status
VoltageControl
Change Date/Time
Rectifier Temp
Batt Contactor
Mains Status
Alarm Output nn
Mains Voltage
BattLifeTime Rst BattLifeTime Rst
Figure 17.2
Rectifier reset is now under the service menu.
Figure 18.1
Relay Output Card 1; inputs 1 & 2, and outputs 1 & 2
Figure 18.2
Relay Output Card 2; inputs 3 to 6 and outputs 3 to 6
Figure 18.3
Monitor Fail PCB
Table 18.1
Alarm relay output positions
Relays 1,2 are on Relay output card 1, relays 3,4,5,6 are on relay output card 2. Monitor fail
is on a separate card. See the attachments section for full alarm matrix.
Table 18.2
Output relay pin connections
Normally closed
Normally open
Common
Figure 18.4
Top view of monitor fail PCB showing connection points for monitor fail alarm.
Table 18.3
Alarm triggers
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 41 of 70
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
Relay
Alarm State Pin
Card
Input 1 + 1
1
Input 1 - 2
Input 2 + 3 Pin 1 Pin 10
1
Input 2 - 4
Relay Card 1
Relay
Alarm State Pin
Card
Input 3 + 1
2
Input 3 - 2
Input 4 + 3
2
Input 4 - 4
Input 5 + 5
2 Pin 1 Pin 20
Input 5 - 6
Input 6 + 7 Relay Card 2
2
Input 6 - 8
Figure 18.5
Digital input locations
AC mains connection terminals are provided for the AC mains connection. The terminals are
pre-connected to the rectifier modules. Cables of up to 10mm2 size can be connected to these
terminals. Termination or configuration of the AC Mains connection is only to be performed
by a licensed electrical installer.
When connecting power to this system, a nearby AC mains disconnect device should be
integrated into the circuit to facilitate servicing. This could be an isolating switch, circuit
breaker or equivalent device.
Phase 1
Phase 2
Phase 3
Figure 19.1
Cabinet Front view.
Distribution
Controller L1 L1 L1
(Blank) L2 L2 L2
(Blank) L3 L3 L3
Table 19.1
AC Phase arrangement.
Figure 19.2
Cabinet Front view (A111223.00x)
Figure 19.3
Cabinet Front view (A111223.00x).
Smartpack
(controller)
L1 L2 L3 L1
L2 L3 L1 L2
Table 19.2
AC Phases arrangement (A111223.00x).
May be cable
jumpers
Figure 19.5
1 x Three-Phase input
Figure 19.6
AC input CB size recommendation
Table 20.1
DC load circuit breaker distribution (A111223.00x)
Load Cable Installation Considerations should be given to the entry arrangement of load
cables to ensure correct installation of additional load cables when the system is operating.
Ensure protective edging is fitted to any sharp edges over which cables pass. Ensure cables
are suitably supported by the internal cable management rail, making sure not to over stress
the common positive bar and circuit breakers.
IMPORTANT: Be aware that AC voltages are present within the system when
installing DC load cables.
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MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
Check that the terminal boots and battery link caps are fitted on all the batteries.
Check that the load connections are of correct polarity
Check that battery string voltage is between -48 and -55 Vdc
Check that the external alarm cabling is installed and terminated
Check that the temperature probe is extended to the batteries.
Check that the temperature compensation is on (activated by default).
Table 21.1
Install Checklist
Table 22.1
Pre-Start / Initial Checks
Check and calibrate voltage reading in the alarm display Meas Display in
ure Alarm
If the measured voltage deviates more than 0.2V from the display
Mod.
reading, re-calibrate the alarm module. DVM*
Switch the system OFF at the Input supply
Connect the load MCB
Battery circuit breakers are NOT connected
Switch the system ON at the input supply.
Measure the Battery Voltage* Measured
Using a DVM measure the battery voltage with DVM*
Adjust output voltage to equal the measured battery voltage from the alarm modules keypad
adjust the rectifier output voltage to equal ( 1 V) the measured battery voltage. Temperature-
compensated charging must be deactivated when adjusting the output voltage.
Close the battery circuit breakers
It is important that the system is switched ON before connecting the batteries. Otherwise, the
battery terminals could be damaged by high currents trying to charge the rectifiers internal
capacitors.
Adjust output voltage (float voltage) from the alarm modules keypad to Measured
the voltage recommended by the battery manufacturer (54.0Vdc at 25C) with DVM*
Verify that the Low Battery Alarm is not activated. Record the voltage*
Table 22.2
System Start Up
Connect a PC/laptop to the Smartpack controller and run the latest version of Powersuite.
Once each of the alarms (below) has been tested, ensure you change their alarm levels
back to their original values. Each alarm is to be tested, one at a time.
To test High Battery Alarm 1 (High Float), change its value to at least 0.5V below the system
voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity
Tester, check the operation of the N/O N/C relays at the alarm PCB.
To test High Battery Alarm 2 (High Load), change its value to at least 0.5V below the system
voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity
Tester, check the operation of the N/O N/C relays at the alarm PCB.
To test Low Battery Alarm 1 (Low Float), change its value to at least 0.5V above the system
voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity
Tester, check the operation of the N/O N/C relays at the alarm PCB.
To test Low Battery Alarm 2 (Low Load), change its value to at least 0.5V above the system
voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity
Tester, check the operation of the N/O N/C relays at the alarm PCB.
3) Rectifier Fail
Ensure the rectifier is off then insert a plastic object into the fan of the rectifier. Turn ON
rectifier; this should give a rectifier fail alarm. Using a Continuity Tester, check the operation of
the N/O N/C relays at the alarm PCB. The fan should never be stopped by inserting an object
into it while running, as this could damage the fan.
4) Load Fuse
Turn off one of the load circuit breakers. (Note: The CB must be connected to a load). This
will activate an Alarm on the Display and at the alarm PCB. Using a Continuity Tester check
the operation of the N/O N/C relays at the alarm PCB.
5) Battery Fuse
NOTE: All battery CBs have to be ON for there to be NO Battery fuse alarm. Ensure all
vacant battery shelves have heatshrink on their loose cables
When the Battery is connected, simply switch off one Battery circuit breaker. This will activate
an Alarm on the Display and at the alarm PCB. Using a Continuity Tester, check the operation
of the N/O N/C relays at the alarm PCB.
6) Monitor Fail
Unlock and release the handles of the SmartPack alarm module by inserting a small screw
driver into the holes in the upper corners of the front panel and carefully push it downwards.
The handle will release and pop out. Remove CON5 from the rear on the Smartpack
controller. This will activate the Monitor Fail Alarm. Using a Continuity Tester, check the
operation of the N/O N/C relays at the Monitor Fail PCB.
7) LVBD Active. (Low Voltage Battery Disconnect)
With an external power supply connected, Disconnect the batteries & turn off the AC supply.
Set the supply to a value below that of the LVBD disconnect. The contactor should open & the
system be turned off. The LVBD alarm should activate. NOTE: As a safety mechanism, the
voltage of the rectifiers cannot be deliberately set below that of the LVBD value.
8) In order to test the Battery Test Fail Alarm, the procedure below must be
followed:
1. With the system running normally, i.e. no alarms, turn off all the batteries.
2. Attach an external DC source to a pair of the spare battery leads (Ensure the
polarity if correct). If there are no spare battery leads connect via a spare
circuit breaker.
3. Turn ON the external DC source and increase to 54 VDC.
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MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
4. Follow steps in Figure 22.1. Select the simplified battery test, click Start Test
button
Figure 22.1
5. Wait until battery test warning MANUAL TEST appears at the bottom of the
screen.
6. Follow the steps in Figure 22.2
a. Click Alarms Overview
b. Click Summary
c. Check that Battery test active alarm is present
d. Check if Relay #5 has changed state.
Relay #5 change
states
Ensure the
Battery test Act
alarm activates
Figure 22.2
Figure 22.3
Click OK to reset
battery test fail
alarm
Figure 22.4
Table 22.3
Checking the alarm
Table 22.4
Other Commissioning Checks
Table 22.5
Default-48V System settings
Step Comments
Carefully vacuum inside underneath and on Ensuring the system is free from dust and dirt.
top using an insulated hose
Ensure that all connections are correct Look for any possible defective or loose
connections, and excessive temperatures.
Ensure that all equipment is free from damage Verify that damage has not occurred since
installation and commissioning
Check the alarm voltage settings using the Verify that all alarm voltage settings are set as the
User menu via the front keypad system default settings.
Check alarm relay operation to remote Call remote monitoring station and confirm
monitoring by toggling individual relays using operation as required.
the Service menu via the front keypad.
Table 23.1
General Checks
Table 23.2
General ongoing maintenance procedures
Table 23.3
System components Minimum Operating life
Install the software supplied on the CD before connecting the computer to the controller. If
the controller is connected before the supplied software is run, the controller driver software
may need to be uninstalled from the computer. To do so, leave the controller connected to the
computer, then use the windows device manager to uninstall the device. Install the software
on the CD. Disconnect and reconnect the USB cable and then the correct connection should
be automatically installed.
The Smart Suite system communication software must be installed on your personal
computer. Smart Suite is available on CD-ROM . By inserting the CD-ROM in the CD-ROM
drive. The installation program will guide you through a complete installation. NOTE, this
program requires Microsoft .NET 2.1 to be installed if not already done. This is included in
the software package supplied. Also required is the windows installer 3.0 program or later
(3.1 included on CD). It is also recommended to install any updates to .NET that may be
available.
Then connect:
Figure 24.1
Correct Software installation
Figure 24.2
Powersuite Startup guide
The COM port may vary on different computers. If no Comms port is displayed, it may be
that the controller was connected before the supplied software was run; the controller driver
software may need to be uninstalled from the computer. To do so, leave the controller
connected to the computer, then use the windows device manager to uninstall the device.
Disconnect and reconnect the USB cable & restart the Powersuite program.
1. Power Explorer: This panel shows an overview of all the (selectable) components of
the system in a collapsible tree structure. (can be hidden / shown with [CTRL] E)
2. Power animation: A real-time pictorial representation of the voltages, currents and
temperature of the system. (can be hidden / shown with [CTRL] A)
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 58 of 70
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
6 8
1
2 3
4
Figure 24.3
The Main Screen
Apply the
changes
Check the box to enable the
temperature compensation
Figure 24.5
Battery Configuration
Choose settings of
the Shunt, and click Apply the changes
Apply
Figure 24.7
Shunt Configuration
Figure 24.9
Event log
Event log download: Use the [Latest XX events] & [Get all] to download the controller alarm
events. It can store up to 1000 events before overwriting the oldest event.
[Export to file] will create an .XML file that can be imported into Excel. When importing use
the option as an XML list
Figure 24.10
Event log downloading
Change setting of
system voltages at
here
Figure 24.11
System Voltages
Contact Open
Contact Close
Click on it
for testing
Testing timeout
Figure 24.12
Output Relays
Choose controller
module, such as
Smartpack or I/O box
Figure 24.13
Alarms Overview
Figure 24.14
Alarms Overview
Figure 24.15
Module number resetting
Figure 24.16
Active alarms & battery test results
Company name
System S/N:
Reference No. for
Location / Site service and warranty
name or No.
Click here to
update to today
Figure 24.18
Efficiency Manager (Load Shedding)
Figure 24.19
Load xml to a Smartpack controller
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 68 of 70
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Installation & Commissioning,
Operation & Maintenance Manual
Figure 24.20
Save xml to a computer
25. ATTACHMENTS