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Quick Start Guide

Installation, Operation, Commissioning and Maintenance

Guide Installation, Operation, Commissioning and Maintenance Flat p ack2, PS Sy stem DC Power Supply System
Guide Installation, Operation, Commissioning and Maintenance Flat p ack2, PS Sy stem DC Power Supply System

Flatpack2, PS System

DC Power Supply System

 
DC Power Supply System  
DC Power Supply System  

Integrated, Cabinetized and Outdoor Applications

 

Introduction

o

The Smartpack based Product Range

(2 )

 

o

Brief System Description, Flatpack2

(2 )

Installation

Installation
 

o

Installing Smartpack and Rectifier Modules

( 3)

 
o Installation steps; mechanical, electrical (4-5)
o Installation steps; mechanical, electrical (4-5)

o

Installation steps; mechanical, electrical

(4-5)

Commissioning

 
Commissioning  

o

Pre-start check

(6 )

o

Commissioning steps, Startup

(6-7)

Operation

Operation
Operation

o

Front keys and display

( 8)

o

Software Menus

( 8)

Miscellaneous

 

Communication

o

CAN Bus Addressing and Termination

( 9)

Installing PowerSuite – PC software AC Mains

o

( 9)

o

External AC Fuses, Recommended Rating

(10 )

 

o

Identifying Power Shelves, 4AC or 2AC

( 11)

o

I.

Mains Reconfiguration, Integrated Systems, 1U DC Distribution

( 11)

 

o

II. Mains Reconfiguration, AC Terminal Block

(12)

 

o

III. Mains Reconfiguration, AC Terminal Block with OVP

(13)

o

IV. Mains Reconfiguration, AC Connection Box

(14-15)

o

About AC, DC Earthing Systems

( 15)

Mains Phases vs. Rectifier ID – Phase Balancing & Monitoring Battery Monitoring

o

(16-17)

o

Battery Symmetry Connections ~ 48V Systems (18 )

 

o

Battery Symmetry Connections ~ 24V Systems ( 19)

Terminals & Pin-out Location, Battery Interface Card Alarms & Monitoring

o

( 20)

o

Standard Alarm Relays & Digital Inputs – Connections

( 21)

o

Terminals & Pin-out Location, Alarm Interface Card

( 21)

 
 

Internal Connections

 
o Terminals & Pin-out Location, Sy stem Interface Card (22 )

o

Terminals & Pin-out Location, System Interface Card

(22 )

LVD Latching Contactors – Connections Flatpack2 Integrated System, 2U

o

(22 )

o

Location of Major Components

( 23)

Check Lists

pullout forms

Check Lists pullout forms
Check Lists pullout forms

o

Installation Check List

 
 

o

Circuit Distribution List

 

356804.103

o

Commissioning Procedure

o

Maintenance Procedure

 
Introduction The Smartpack based Product Range Eltek Valere's Smartpack based product range utilizes the

Introduction

The Smartpack based Product Range

Eltek Valere's Smartpack based product range utilizes the Smartpack controller, and Flatpack2 rectifiers, Powerpack rectifiers and Minipack rectifiers as building blocks for implementing effective DC power systems, suitable for a wide range of applications and power ratings.

Powerpack System Flatpack2 System, Cabinetized Indoor and Outdoor Cabinets Flatpack2 System, Integrated 4U and 1U
Powerpack System
Flatpack2 System, Cabinetized
Indoor and Outdoor Cabinets
Flatpack2 System, Integrated
4U and 1U Distributions
Flatpack2 System, Integrated 4U and 1U Distributions Minipack System, Integrated Cabinetized systems are

Minipack System, Integrated

Cabinetized systems are suitable for indoor or outdoor applications. In addition to the power system and the distribution unit, the cabinet may also contain battery banks, additional distribution and other dedicated equipment. Integrated systems consist of the power system, which includes rectifiers and controller(s), and the distribution unit (1U or 4U high). Integrated systems are sold primarily for mounting in existing cabinets.

Powerpack systems are suitable for large Central Office power plants, and use three-phase rectifier modules. Minipack systems are suitable as small, stand-alone battery chargers and DC power supplies.

Brief System Description — Flatpack2

The Flatpack2 PS system is a compact, powerful and cost-effective DC power supply system, specifically developed for the telecom industry.

Alarm Outputs NC-C-NO Digital Inputs

the telecom industry. A larm Outputs NC-C-NO Digital Inputs PowerSuite Remote Application Monitoring Flatpack2

PowerSuite

industry. A larm Outputs NC-C-NO Digital Inputs PowerSuite Remote Application Monitoring Flatpack2 Cabinetized

Remote

Application

Monitoring Flatpack2 Cabinetized Smartpack USB cable ctrl. unit Fuse Alarm Flatpack2 CAN Bus rectifiers LVLD
Monitoring
Flatpack2
Cabinetized
Smartpack
USB cable
ctrl. unit
Fuse Alarm
Flatpack2
CAN Bus
rectifiers
LVLD
AC mains
supply
AC Fuses,
selector
external
Load Fuses
(230VAC or
& MCBs
400VAC
Symmetry
LVBD
Alarm &
DC
Temp. Sensor
distribution
AC Supply
(Single- or
three-phase)
Battery string #1
Battery
Fuses
Telecom equipment
Telecom
equipment

DC Supply

(24V, 48V

or 60V*)

*Available from 2007

Example of a typical Flatpack2 PS system for DC power supply of telecom equipment. The system is fed from an external AC mains supply, and consists of rectifiers in power shelves, a control unit and DC distribution unit. Battery banks, LVD contactors, etc. are typically also a part of the system.

2

Quick Start Guide

Flatpack2 PS System

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Electric

shock

Installation

Installing Smartpack and Rectifier Modules

Installation Installing Smartpack and Rectifier Modules Device hazard CAUTION : - The modules may be warm,

Device

hazard

CAUTION:

- The modules may be warm, but do not hand-carry them by their handles

- Open the handles before inserting them into the power shelves (hot-pluggable) The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing

a Mains fuse in each line. Double Pole / Neutral Fusing Mounting or Removing Smartpack and

Mounting or Removing Smartpack and Flatpack2 Modules

Note that cables are plugged to the Smartpack’s rear panel. When mounting the controller, you must plug the cables before step 2. When removing it, unplug the cables during step 2.

1. Unlock the handles by inserting a screwdriver into the holes to release the spring mechanism

2. Insert or remove the module by sliding it fully into the power shelf, so that the module makes

it fully into the power shelf, so that the module makes proper contact (for Smartpack, plug

proper contact (for Smartpack, plug cables first)

or using both handles to pull the module loose. Support from underneath before the unit is using both handles to pull the module loose. Support from underneath before the unit is completely free. Unplug the cables, when removing the Smartpack module

3. Lock the handles by pushing the handles up into their housings (locked position). Then, the module will be securely locked in the shelf, or ready for transport

4. Mount blind panels in unused module locations

Smartpack controller Hole to release the handle’s spring mechanism Handle in locked position
Smartpack
controller
Hole to release the
handle’s spring
mechanism
Handle in locked position
the handle’s spring mechanism Handle in locked position Flatpack 2 rectifier Handle in unlocked p osition

Flatpack2

rectifier

Handle in
Handle in
Handle in locked position Flatpack 2 rectifier Handle in unlocked p osition Removing Blind Panels 1.

unlocked position

Removing Blind Panels

1.

Release the panel’s upper left and right corners by inserting a small screwdriver into the panel’s upper left gap and carefully press down and out to release the locking tabs. Repeat on the upper right gap.

2.

Remove the blind panel by using you hand to pull the panel loose

Screwdriver to release the locking tabs

the panel loose Screwdriver to release the locking tabs Blind panel’s upper locking tabs Mounting Blind
the panel loose Screwdriver to release the locking tabs Blind panel’s upper locking tabs Mounting Blind
Blind panel’s upper locking tabs
Blind panel’s upper
locking tabs

Mounting Blind Panels

1. Insert the panel’s upper edge by pressing gently so that its upper locking tabs engage

2. Lock the panel’s lower edge by pressing with your hand so that the blind panel’s lower tabs lock into position.

Quick Start Guide

Flatpack2 PS System

356804.103, v5-2006-11

3

Installation Installation Steps Check off in the Installation Check List, that you find in the

Installation

Installation Steps

Check off in the Installation Check List, that you find in the pullout section of this folder. Also, refer to the system’s specific drawings.

200 mm 600 mm
200 mm
600 mm
refer to the system’s specific drawings. 200 mm 600 mm Preparing the Installation Site Begin preparing

Preparing the Installation Site

Begin preparing the following:

1 Organize the installation site

o

Min. clearances for cabinet access: 60 cm in front, 20 cm on top

o

Levelled surface able to support 600 kg (cabinetized systems)

o

Explosive atmospheres are to be avoided. Ensure suitable ventilation

o

60V systems are only to be installed in Restricted Access Locations (RAL)

2 Prepare the installation tools

Access Locations (RAL) 2 Prepare the installation tools EMC regard o Use insulated tools suitable for

EMC

regard

o Use insulated tools suitable for telecom installations

3 Prepare AC Supply: AC input cable(s) and fuses

o

Correct type AC supply is available

o

External AC fuses have correct rating

o

AC input cable(s) are sized correctly

For external AC fuses and AC input cable ratings, refer to your site’s AC supply specification. Read also our external AC fuse recommendations in section “Miscellaneous”. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.

Mechanical Installation

Power is OFF!

smaller breakers. Mechanical Installation Power is OFF! Flatpack 2 PSS, batteries, Doc. Chart, Spec. Drawings,

Flatpack2 PSS, batteries, Doc. Chart, Spec. Drawings, CD-ROM

Carry out the following:

4 Remove packaging and check equipment

o

Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc.

o

Inspect the equipment for physical damage (report any damages)

o

Leave rectifier modules in their packaging or in the selves, if factory installed. To be installed under commissioning

if factory installed. To be installed under commissioning Device hazard 5 Remove top cover and dummy

Device

hazard

5 Remove top cover and dummy front panels

o

Cable entry from the top. Connection terminals are located behind the upper dummy panels

o

Battery shelves (if any) are placed behind the lower panels

6 Position and fasten the cabinet or subassembly

o

Cabinets are floor-mounted on levelled surface. Adjust the legs if necessary. If the cabinet must be fastened, unscrew the legs and use suitable bolts to fasten it to the floor

o

Subassemblies are fastened in existing 19” or in ETSI cabinets, using brackets. Mount the support & heat deflecting plate under the lower power shelf

4

7 Mount the batteries on the shelves

o

Start (if applicable) placing the batteries on the lower shelf first, and continue upwards

o

Do not terminate the battery cables yet!

Quick Start Guide

Flatpack2 PS System

356804.103, v5-2006-11

o Do not terminate the battery cables yet! Quick Start Guide Flatpack2 PS System 356804.103, v5-2006-11

Electric

shock

Installation

Installation Electrical Installation Power is OFF!   General Torque   Recommended Ratings, FP2 Systems

Electrical Installation

Power is OFF!

 

General Torque

 

Recommended Ratings, FP2 Systems

Application, Type & Size

 

Torque

(Nm)

Circuit Breakers

   

SIEMENS 18 mm, 5SX2, 5SX5

 

3.5

SIEMENS 27 mm, 5SX6, 5SX7, 5SP4

 

5.0

MG, C60 <=25A

 

3.5

MG, C60 >25A

 

3.5

CBI 13 mm, QY, QF, QA

 

3.0

Hex Nuts & Screws (Knife Fuses, general)

   
 

M8.0

 

10.0

 

M10.0

 

16.0

 

M12.0

 

25.0

AC

Terminal Blocks

   
 

WDU 1.5

 

0.5

 

WDU 2.5

 

0.5

 

WDU 4

 

0.6

 

WDU 10

 

2.0

 

WDU 16

 

3.0

 

WDU 35

 

4.0

 

WDU 70

 

10.0

DC

Rail Terminals

   
 

AKG 16

 

3.0

 

AKG 35

 

3.5

Note: General tolerance: ±10%.

NEC/CEC Requirements

Carry out the following: (Refer to the system’s specific drawings)

8 Make the system completely voltage free

o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and the AC supply fuses, in external fuse boards

9 AC Connections Check AC configuration: the AC terminals are correct configured to the external AC supply, otherwise reconfigure the terminals Connect the AC Earth wire (PE) to the terminals AC Earth (PE) Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond 10 DC Connections Load Circuits Terminate DC Earth (TE), and check that the common DC Output Rail is connected to “Telecom Earth” (TE) at only one place (at the cabinet or at a central distribution point). Se chapter about AC, DC earthing systems For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB or load fuse 11 DC Connections Alarm & Signal Circuits Refer to your system’s connection drawings and configuration, or to the “Miscellaneous, Alarms & Monitoring” section (Factory Settings)

o

o

o

o

o

o

o

Terminate Alarm Circuit cables to the relay output terminals

o

Terminate Signal Circuit cables to the digital input/output terminals

Chassis Link 2 (DC Earth) Common Battery EG DC Rail Fuse Card Art.200576 2-1 15
Chassis
Link 2
(DC Earth)
Common
Battery
EG
DC Rail
Fuse
Card Art.200576
2-1
15 pins D-Sub
(male)
Battery
Cable
-
+
-
+
-
+
-
+
-
+
(-48V) Outer
Terminal
Block1
Block3
Block4
+
Intercell Links
0V Outer
Terminal
Symmetry 1
Temp. Sensor cable 1
Temp. sensor

12 DC Connections Battery Cables Careful! Use correct polarity.

For 48V systems using the battery symmetry mid-point measurement, refer to the figure in this page. For other measurement methods and for 24V systems, refer to the Battery Symmetry Connections chapters in this guide’s Miscellaneous section. For each battery shelf:

(In cabinetized systems, steps b, d and f are usually performed in factory)

a

Mount 3 intercell links to connect in series 4 battery blocks

b-c

Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-)

d-e

Connect battery symmetry cables, if applicable, to the input terminals, and to the center terminal of the battery string (+) and to the -48V outer terminal. Deviation from factory settings requires Symmetry reconfiguration via PowerSuite

f-g

Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the temperature sensor (at the end of the cable) to a suitable place in the middle of the installed battery bank

Quick Start Guide

Flatpack2 PS System

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5

Electric

shock

Commissioning The commissioning of Flatpack2 PS System consists of following stages: I. Perform a pre-start

Commissioning

The commissioning of Flatpack2 PS System consists of following stages:

I. Perform a pre-start check before the PS system is switched ON

II. Switch ON the system with disconnected load; adjust output voltage

III. Adjust the nominal output voltage with connected batteries and load

I

Pre-Start Check

Power is OFF!

Check off in the Commissioning Procedure, that you find in the pullout section of this folder.

If you have just finished the system installation successfully and filled in the Installation Check List, jump over the Pre-Start Check and continue with stage II.

Before you switch ON the Flatpack2 PS system, verify the following:

switch ON the Flatpack2 PS system, verify the following: Device hazard 1. System installation is completed

Device

hazard

1. System installation is completed

o

Ensure a correctly performed system installation, with correct polarity on all connections, has been carried out (Installation Check List filled in)

o

All cabling and copper bars are securely terminated and supported

o

All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled

2. Battery and load fuses are disconnected

o Verify that all battery and load MCBs/ fuses are switched OFF or removed

3. AC input cable(s) and AC Earth wire (PE) are terminated

o

Make sure that the AC input cable(s) are connected to correctly configured AC terminals

o

Verify that the AC input cable(s) and external AC fuses are sized and rated as specified

o

Check that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)

4. Site specific parameters and settings are known

o Read the system specific drawings and documentation

5. AC supply and all MCBs, fuses are switched OFF

o Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF

Commissioning Steps, Startup

Check off in the Commissioning Procedure, that you find in the pullout section of this folder.

After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you will switch ON the Flatpack2 PSS — while the batteries and load are disconnected then measure the output voltage, and adjust it if required. Carry out the following:

II

Startup and No-Load Adjustments

Power is ON!

1. Disconnect all rectifier modules, without removing them (keep original location)

modules, without rem oving them (keep original location) Device hazard o Read how to install modules,

Device

hazard

rem oving them (keep original location) Device hazard o Read how to install modules, on page

o

Read how to install modules, on page 3 in this guide. Also, read about the correct rectifier position on page 17, and then,

o

If Flatpack2 rectifier modules are installed, unlock the handles and pull the modules partially out (fan housing visible), but do NOT physically remove them from the power shelves

o

If Flatpack2 rectifier modules are not yet mounted, release their handles and insert them partially into the correct position in the shelves

2. Switch ON the system

o Switch ON the AC input supply (external AC fuses) to the PS cabinet

3. Measure and verify that the AC input voltage is correct

o

Measure the AC input voltage at the cabinet’s mains connection box

o

Verify the AC voltage is within range

6

Quick Start Guide

Flatpack2 PS System

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Commissioning

Commissioning 4. Mount all Flatpack2 rectifier modules in the power sh elves (keep original location) o

4. Mount all Flatpack2 rectifier modules in the power shelves (keep original location)

modules in the power sh elves (keep original location) o Push all rectifiers firmly inwards ⎯

o

Push all rectifiers firmly inwards one module at a time, allowing a 2s delay to plug them in the same shelf location. Lock their handles. Refer also to page 17

o

Mount blanking panels over unused positions

5. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON

o Verify correct operation, by monitoring the modules’ LED lamps and display:

No alarms are present on rectifiers; The Smartpack displays fuse alarms

6. Connect a PC to the PS system (to facilitate operation)

o

Plug a standard USB A-B cable between the PC and the Smartpack controller

o

Start PowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite

Refer to chapter “Installing PowerSuite PC Application”, page 9, if required

o

On the toolbar, click the “Connect” button to establish connection

7. Measure and adjust DC output voltage

o

Read the DC output voltage on the controller’s display

o

With a multi-meter, measure the DC output voltage at the most accessible point, e.g. between the common DC rail and the lower connection of one of the priority load MCBs

o

If required, adjust the voltage using the controller’s front keys or via PowerSuite

8. Verify the alarm relays are working correctly (alarm relay test)

o Run the alarm relay test using the controller’s front keys (refer to page 8) or via PowerSuite (select the menu Go > Output Test)

9. Make sure the System Setup is in accordance with configuration

o

Verify system settings using the controller’s front keys or via PowerSuite

o

Use the opportunity to enter site related information, number of used AC phases, type of batteries, etc.

Load Adjustments

Power is ON!

III

Now, you can begin with stage III, where you will adjust again the output voltage to the battery voltage, and connect the batteries and the load. Carry out the following:

10. Adjust DC output voltage to equal measured battery voltage

o

Measure the battery voltage is within range (check connections have correct polarity)

o

Adjust DC output voltage — using the controller’s front keys (refer to page 8) or via PowerSuite— to equal the measured battery voltage. (Important adjustment to avoid arcing when connecting the batteries)

11. Unplug all rectifiers but one, and connect the battery fuses /MCBs (CAUTION: Have only one rectifier connected, when switching ON the battery fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.)

due to possible incorrect polarity connections, etc.) o Disconnect all rectifiers but one, by unloc king

o

Disconnect all rectifiers but one, by unlocking the handles and pulling them partially out (fan housing visible). Do NOT physically remove them from the power shelves

o

Switch ON all battery fuses or MCBs

power shelves o Switch ON all battery fuses or MCBs Device hazard Device hazard 12. Adjust

Device

hazard

o Switch ON all battery fuses or MCBs Device hazard Device hazard 12. Adjust DC output

Device

hazard

12. Adjust DC output voltage again to equal the nominal battery voltage

o Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to equal the nominal battery voltage (or the nominal load voltage, when not using batteries)

13. Plug in again all rectifiers, and verify the rectifiers’ current sharing

all rectifiers, and verify the rectifiers’ current sharing o Connect all rectifiers again by pushing them

o

Connect all rectifiers again by pushing them firmly inwards Repeat step 4, in stage II

o

Wait for about 2 min., and check — using the PowerSuite application —that each of the rectifiers delivers the same output current. A deviation of 1A is acceptable.

14. Connect the load breakers and verify that no alarms are displayed

o

Switch ON all load MCBs/ fuses

o

Verify correct operation: rectifiers and controller display no alarms

Quick Start Guide

Flatpack2 PS System

356804.103, v5-2006-11

7

Smartpack, Distributed

Smartpack, Distributed

Firmware 402073.003 1v00

Firmware 402073.003 1v00

Firmware 402073.003 1v00 Firmware 402073.003 1v00 … … Operation Front Keys and display, menus, etc. Graphical

Operation

Front Keys and display, menus, etc.

Graphical Alarm Display LED Lamp (red) 16 char. x 2 lines LCD display Warning LED
Graphical
Alarm
Display
LED Lamp (red)
16 char. x 2 lines
LCD display
Warning
LED Lamp (yellow)
Power
”Enter” key
LED Lamp (green)
”Up” arrow key
USB
”Down” arrow key
0ype B port

Smartpack control unit

Warning

arrow key 0ype B port Smartpack control uni t Warning LED Lamp (yellow) Alarm LED Lamp

LED Lamp (yellow)

Alarm

LED Lamp (red)

Power

LED Lamp (green)

Lamp (yellow) Alarm LED Lamp (red) Power LED Lamp (green) Flatpack2 rectifier Smartpack Control Unit —

Flatpack2 rectifier

Smartpack Control Unit — front keys, display, etc

Display: is in Status Mode (displays the system’s status) or in Menu Mode (displays the menu structure). Operation: Press on 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. Menus: When you “enter” Menu Mode (Level 1), you access the User Options. You may also scroll down to password protected Service Options. Default password <0003> should be changed.

Default password <0003> should be changed. Software Menus Level 2 Level 3 User menu < UserOption
Default password <0003> should be changed. Software Menus Level 2 Level 3 User menu < UserOption
Default password <0003> should be changed. Software Menus Level 2 Level 3 User menu < UserOption
Default password <0003> should be changed. Software Menus Level 2 Level 3 User menu < UserOption

Software Menus

Level 2

Level 3

User menu <UserOption>

AlarmReset

 

NomVolt

BoostVolt

LoBattMaj

VoltageInfo

VoltageInfo LoBattMin

LoBattMin

 

HiBattMaj

HiBattMin

LVBD

LVLD 1.1

DisplayMessages

Message

SoftwareInfo

 

SerialNumber

 

Rectifier Info

Rectifier Info NoOfRects. nn RectCurrent RectSerialNumber Rect.PrimaryVolt Rectifier Status Rectifier Temp Rect.

NoOfRects. nn RectCurrent RectSerialNumber Rect.PrimaryVolt Rectifier Status Rectifier Temp Rect. OutputVolt Rectifier SW Ver

 

NoOfPhases nn

Mains Info

Mains Info

Mains Status

Mains Voltage

Temp Level Info

Level

 

NoOfString Nn

BattStringCurr ↓↑

Battery Info

Battery Info BattStringTemp ↓↑

BattStringTemp ↓↑

 

BattBlockVolt ↓↑

Flatpack2 Rectifier Module — front panel

Power LED is OFF (mains unavailable), Flashing (controller accessing information) or ON (powered). Warning LED is ON (derating or similar minor warning), Flashing (over-voltage mode) or OFF (OK) Alarm LED is ON (shutdown or similar major alarm) or OFF (OK, no alarm)

Level 2

Level 3

similar major alarm) or OFF (OK, no alarm) Level 2 Level 3 Service menu < ServiceOption

Service menu <ServiceOption>

 

NomVolt

↓↑

BoostVolt

↓↑

LoBattMaj

↓↑

VoltAdjustment

V oltAd justment LoBattMin ↓↑

LoBattMin

↓↑

 

HiBattMaj

↓↑

HiBattMin

↓↑

LVBD

↓↑

LVLD 1.1

↓↑

VoltCalibration

VoltCal

ChangePassword

Password

SetManBoostTime

Start/StopBoost

 

Auto Boost Conf.

Enable/Disable ↓↑ & Threshold

 

Nxt Test DateTime

Date ↓↑ Time

End Volt

↓↑

Batt Test Setup

Batt Test Setup MaxTestDur ↓↑

MaxTestDur

↓↑

 

Test Int

↓↑

Guard Time

↓↑

Start/Stop Test

 

NoOfRects. ; nn

Reset

Charge Curr Lim.

Enable/Disable ↓↑ & Max

 

Battery Setup

Batter y Setup NumOfStrin g ↓↑

NumOfString

↓↑

 

CellCap Ah nn

↓↑

Output Control

VoltageCtrl / TempComp

Change Date/Time

Date Time

 
 

Alarm Output 1 Alarm Output 2 Batt Contactor Load Contactor

RelayTest

Rela yTest

Alarm Output nn

BattLifeTime Rst

 

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Quick Start Guide

Flatpack2 PS System

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Communication

Miscellaneous

Communication Miscellaneous CAN Bus Addressing and Termination Flatpack2 systems are shipped from factory with the CAN

CAN Bus Addressing and Termination

Flatpack2 systems are shipped from factory with the CAN bus already terminated with 120Ω resistors.

To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120Ω resistors, one at each end of the line (60Ω bus impedance). The figure shows a Flatpack2 system communicating via the CAN bus.

The Smartpack dynamically software-assigns ID numbers to rectifiers. The controller registers the rectifiers’ ID numbers, or CAN bus address (01, 02…), together with their Serial Numbers. The Smartpack’s ID numbers (1, 2…) are assigned by DIP switches on the controller’s side.

Eltek Valere’s CAN bus may address a maximum of 60 nodes. Among them, you may connect a maximum of 8 Smartpack controllers and or 50 rectifiers.

maximum of 8 Smartpack controllers and or 50 rectifiers. CAN bus (twisted-pair internal CAT5 cable) USB

CAN bus

(twisted-pair internal

CAT5 cable)

USB A-B cable (standard)

1 120Ω 01 02 n Flatpack2 DC Power System
1
120Ω
01
02
n
Flatpack2
DC Power System
(standard) 1 120Ω 01 02 n Flatpack2 DC Power System 120 Ω End-of-Line Resisto r End-of-Line

120Ω

End-of-Line

Resistor

End-of-Line

Resistor

CAN bus Addressing

Controller

ID

DIP Switch Position

#

1

2 3 4

Master

1

OFFOFFOFFOFF

Slave 1

2

ONOFFOFFOFF

Slave 2

3

OFFONOFFOFF

Slave 3

4

ONONOFFOFF

Note that the controller’s ID # corresponds to the DIP switch’s binary value plus one.

Slave controller

DIP switch

configuration

Master controller

Alarm Outputs

DIP switch configuration

NC-C-NO

r Alarm Outputs DIP switch configuration NC-C-NO ID <1> (All switches OFF) Digital Inputs 1 120Ω

ID <1>

(All switches OFF)

Digital Inputs 1 120Ω
Digital Inputs
1
120Ω
ID <1> (All switches OFF) Digital Inputs 1 120Ω Alarm Outputs NC-C-NO Digital Inputs ID <2>

Alarm Outputs

NC-C-NO

switches OFF) Digital Inputs 1 120Ω Alarm Outputs NC-C-NO Digital Inputs ID <2> (Switch #1 ON,

Digital Inputs

Inputs 1 120Ω Alarm Outputs NC-C-NO Digital Inputs ID <2> (Switch #1 ON, the rest OFF)

ID <2>

(Switch #1 ON, the rest OFF)

Smartpack controller Smartpack controller 2 120Ω Master Slave 1 01 02 3 4 n n+1
Smartpack controller
Smartpack controller
2
120Ω
Master
Slave 1
01
02
3
4
n
n+1
n+2
m
Flatpack2
DC Power System

End-of-Line

End-of-Line

Resistor

Resistor

The figure shows a Flatpack2 DC power system expanded with a slave controller to implement additional digital inputs, relay outputs or similar functionality.

Installing PowerSuite PC Application

The PowerSuite software application enables you to configure and operate the Flatpack2 Power Supply System from a personal computer.

   

Flatpack2 system configuration from a PC running MS Windows XP

1
1
 
1   1. Install PowerSuite
1   1. Install PowerSuite

1. Install PowerSuite

Insert the CD in your PC drive, start the PowerSuite installation and follow & accept the wizard default steps

2
2
 

2. Switch Smartpack ON and plug USB cable

(Part 202073)

to Smartpack and to any available USB port in the PC

3
3
 
3   3. Wait for Windows to install USB drivers

3. Wait for Windows to install USB drivers

New hardware is ready to use
New hardware
is ready to use

Follow & accept the wizard default steps to automatically install the USB drivers; the wizard runs twice

4
4
 
4   4. Start PowerSuite and establish connection  

4. Start PowerSuite and establish connection

 

Select “Start > All Programs > Eltek > PowerSuite”. On the toolbar, click “Connect” button. On the Connection dialogue box, click the “Connect” button

   

If PowerSuite fails communicating via the standard COM port, find the COMx assigned to Smartpack (My Computer/ Properties / Hardware/ Device Manager) and configure PowerSuite to communicate via this COMx (read the instructions in the installation CD).

PowerSuite’s newest version is always available on our FTP server. Call your Eltek Valere’s contact person.

Quick Start Guide

Flatpack2 PS System

356804.103, v5-2006-11

9

Only difference between the 205 and the 185VAC recommendation tables

between the 205 and the 185VAC recommendation tables Miscellaneous AC Mains External AC Fuses ⎯ Recommended

Miscellaneous

AC Mains

External AC Fuses Recommended Rating

The site’s AC supply quality is of great impor- tance. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.

205VAC Inputs 2AC Power Shelves 4AC Power Shelves 2 AC inputs per shelf, each feeding
205VAC Inputs
2AC Power Shelves
4AC Power Shelves
2 AC inputs per shelf, each
feeding 2 rectifiers
4 AC inputs per shelf, each
feeding 1 rectifier
AC Mains No of Power Shelves Current Max. (A) 2000W Rect. Ext. Fuse Type Type

AC Mains

No of Power Shelves

Current Max. (A) 2000W Rect.

Ext. Fuse

Type

Type

400VAC +N

1

22.1

25A-D

3

phase

2

33.1

40A-C

230VAC

1

29.2

32A-D

3

phase

2

57.3

63A-C

230VAC

1

44.1

50A-C

1

phase

2

88.2

100A-C

AC Mains

No of Power Shelves

Current Max. (A) 2000W Rect.

Ext. Fuse

Type

Type

 

1

22.1

25A-D

400VAC +N

2

44.1

50A-C

3

phase

3

44.1

50A-C

 

4

66.1

80A-C

230VAC

1

38.2

40A-C

2

58.3

63A-C

3

phase

     

3

76.4

80A-C

230VAC

1

44.1

50A-C

1

phase

2

88.2

100A-C

AC Mains Type No of Power Shelves Current Max. (A) 2000W Rect. Ext. Fuse Type
AC Mains Type No of Power Shelves Current Max. (A) 2000W Rect. Ext. Fuse Type
AC Mains
Type
No of Power
Shelves
Current Max. (A)
2000W Rect.
Ext. Fuse
Type
400VAC +N
1
24.4
25A-D
3
phase
2
36.7
40A-C
230VAC
1
32.3
40A-C
3
phase
2
63.5
80A-C
230VAC
1
48.9
50A-C
1
phase
2
97.7
100A-C
4AC Power Shelves
4 AC inputs per shelf, each
feeding 1 rectifier
AC Mains No of Power Shelves Current Max. (A) 2000W Rect. Ext. Fuse Type Type
AC Mains
No of Power
Shelves
Current Max. (A)
2000W Rect.
Ext. Fuse
Type
Type
1
24.4
25A-D
400VAC +N
2
48.9
50A-C
3
phase
3
48.9
50A-C
4
73.3
80A-C
1
42.3
50A-C
230VAC
2
64.6
80A-C
3
phase
3
84.6
100A-C
230VAC
1
48.9
50A-C
1
phase
2
97.7
100A-C
2AC Power Shelves
2 AC inputs per shelf, each
feeding 2 rectifiers

1AC Feed to 1 Rectifier

External AC Fuses

Recommended Ratings 1AC Feed to 1 Flatpack2 rectifier

AC Mains

Ext. Fuse Type

Type

FS=I

FS=0

185VAC

25A-D

13A-B

205VAC

25A-D

10A-B

Note: Always replace a rectifier with blown internal AC fuse with a new module, and send the mal- functioning module for servicing.

FS=I (Fuse Selectivity:

Internal) which means that the Flatpack2 rectifier’s in- ternal fuse will trip before the external AC fuse.

FS=0 (Fuse Selectivity:

none) these fuse types may be used when it is irrelevant whether the internal or the external fuse trips first.

Use the recommendations in the 205VAC table, if you are sure the available AC mains voltage will not drop below 205VAC.

OR

If you are unsure or know that

the

205VAC use the 185VAC table recommendations.

may

below

voltage

drop

For installations in USA and Canada only • For external fuses above 50A, only the
For installations in
USA and Canada only
• For external fuses above 50A, only the high current
backplane can be used
• External fuse rated 32A is replaced by 40A
• External fuse rated 63A is replaced by 70A
• The installation has to comply with the NEC/CEC
requirements
• Connection to AC Mains shall be in accordance
with the number of power shelves in the tables. If
number of shelves exceeds the numbers in the
table, a combination of several AC Mains must
be used instead
External AC Input Wires
Recommended Ratings
Current
Wire Section
Max. (A)
(mm 2)
(AWG)
6
0.75
18
10
1.00
16
13
1.25
16
16
1.50
14
25
2.50
12
32
4.00
10
40
6.00
8
63
10.00
6
80
16.00
4
100
25.00
2
Note: The external terminal
blocks must be rated to accept
the actual wire section above.
NEC/CEC Requirements

10

Quick Start Guide

Flatpack2 PS System

356804.103, v5-2006-11

the actual wire section above. NEC/CEC Requirements 10 Quick Start Guide Flatpack2 PS System 356804.103, v5-2006-11

AC Mains

Miscellaneous

AC Mains Miscellaneous Identifying Power Shelves, 4AC or 2AC Flatpack2 rectifiers are accommodated in one or

Identifying Power Shelves, 4AC or 2AC

Flatpack2 rectifiers are accommodated in one or several power shelves. Two types of power shelves are available:

power shelves. Two types of power shelves are available: 4AC Power Shelves 2AC Power Shelves Flatpack2

4AC Power Shelves

2AC Power Shelves
2AC Power Shelves

Flatpack2 System, 1U DC Distr.

Power Shelf
Power Shelf

4AC Power Shelves, or single AC feed (4 AC inputs per shelf, each feeding 1 rectifier)

AC feed (4 AC inputs per shelf, each feeding 1 rectifier) AC Mains & PE terminals

AC Mains & PE terminals

2AC Power Shelves, or dual AC feed (2 AC inputs per shelf, each feeding 2 rectifiers) You can identify the type of power shelves used by your system by reading the shelf’s label, or by looking at the shape of the shelf’s AC mains terminals, at its rear. (Also viewable by removing the rectifier in the shelf’s 4 th position)

(rear view)

I

Mains Reconfiguration ~Integrated System 1U Distr.

The AC mains terminals of Flatpack2 integrated systems with 1U DC distribution units are located on the power shelf’s rear.

Find out whether your system is implemented with 4AC or 2AC powers shelves (read the Identifying Power Shelves section, page11) and terminate the AC mains cable according to the type of AC mains to be used, as shown in the actual example below.

Υ Mains Three-phase & N, 400VAC Δ Mains Three-phase, 230VAC Mains One-phase, 230VAC L1 L2
Υ
Mains
Three-phase & N, 400VAC
Δ Mains
Three-phase, 230VAC
Mains
One-phase, 230VAC
L1
L2
L3
N
PE
L1
L2
L3
PE
L (L1)
N (L2)
PE(CON12)
PE(CON12)
PE(CON12)
L1(CON11)
L1(CON11)
L1(CON11)
L2(CON10)
L2(CON10)
L2(CON10)
PE(CON15)
PE(CON15)
PE(CON15)
L1(CON14)
L1(CON14)
L1(CON14)
L2(CON13)
L2(CON13)
L2(CON13)
PE(CON18)
PE(CON18)
PE(CON18)
L1(CON17)
L1(CON17)
L1(CON17)
L2(CON16)
L2(CON16)
L2(CON16)
PE(CON21)
PE(CON21)
PE(CON21)
L1(CON20)
L1(CON20)
L1(CON20)
L2(CON19)
L2(CON19)
L2(CON19)
4AC Power Shelves
Single AC feed: 4 AC inputs per
shelf, each feeding 1 rectifier
AC feed: 4 AC inputs per shelf, each feeding 1 rectifier Υ Mains Three-phase & N,
Υ Mains Three-phase & N, 400VAC Δ Mains Three-phase, 230VAC Mains One-phase, 230VAC L1 L2
Υ
Mains
Three-phase & N, 400VAC
Δ Mains
Three-phase, 230VAC
Mains
One-phase, 230VAC
L1
L2
L3
N
PE
L1
L2
L3
PE
PE
L (L1)
N (L2)
Power Shelf
Power Shelf
Power Shelf
CON13
CON13
CON13
(PE)
(PE)
(PE)
CON9
CON9
CON9
(L1 1/2)
(L1 1/2)
(L1 1/2)
CON11
CON11
CON11
(L1 3/4)
(L1 3/4)
(L1 3/4)
CON10
CON10
CON10
(L2 1/2)
(L2 1/2)
(L2 1/2)
CON12
CON12
CON12
(L2 3/4)
(L2 3/4)
(L2 3/4)
Quick Start Guide
Flatpack2 PS System
356804.103, v5-2006-11
11
2AC Power Shelves
Dual AC feed: 2 AC inputs per
shelf, each feeding 2 rectifiers
II Miscellaneous AC Mains Mains Reconfiguration ~AC Terminal Block To reconfigure the AC mains feed

II

Miscellaneous

AC Mains

Mains Reconfiguration ~AC Terminal Block

To reconfigure the AC mains feed of Flatpack2 DC power systems that use the AC Mains terminal block, you have to reconnect the AC mains wires and fish plates on the terminal block.

1. Switch OFF the AC supply fuses in external fuse boards

2. Check that your system is implemented with 4AC powers shelves (read the Identifying Power Shelves section, page 11). If your system utilizes 2AC power shelves, you can NOT reconfigure it as described in this section

3. Connect the AC Mains wires to the AC terminal block, and mount the fish plates, according to the type of AC mains to be used, as shown in the actual example in this section

Configurable Mains Input Terminal Block 4AC Power Shelves (single AC feed: 4 AC inputs per
Configurable Mains Input Terminal Block
4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)
Υ Mains, TN
Three-phase & N, 400VAC
Δ Mains, IT
Three-phase, 230VAC
Mains
One-phase, 230VAC
(1 Y Mains input will feed 2 power shelves)
(1 Δ Mains input will feed 2 power shelves)
(3 Mains inputs will feed 2 power shelves)
3 AC Mains
Cables
AC Mains
AC Mains
Cable
Cable
AC Mains
AC Mains
AC Mains
wires
wires
wires
1 fish
3 fish
0 fish
plate
plates
plates
AC Mains
AC
Mains
AC Mains
Terminal
Terminal
Terminal
Block
Block
Block
X:******
X:******
X:******
(To internal connections
for 2 power shelves)
(To internal connections
for 2 power shelves)
(To internal connections
for 2 power shelves)
Flatpack2 DC Power System
Flatpack2 DC Power System
Flatpack2 DC Power System
2009604, v7
Fixed Individual Mains Input Terminal Block
4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)
Mains reconfiguration is
NOT possible when the
system is shipped with
fixed individual Mains
input terminal blocks.
Such systems have to be
configured at the factory
prior to delivery.
Mains
One-phase, 230VAC
8 AC Mains
Cables
AC Mains wires
0 fish plates
AC Mains
Terminal
Block
X:******
To
To
To
To
To
To
To
To
rectifier 1
rectifier 2
rectifier 3
rectifier 4
rectifier 5
rectifier 6
rectifier 7
rectifier 8
(To internal connections for 2 power shelves)
Flatpack2 DC Power System
2009604, v7
Chassis
Chassis
Chassis
Chassis

12

Quick Start Guide

Flatpack2 PS System

356804.103, v5-2006-11

Pull out the pages with the gray outer band, and use them as check lists

Check Lists Pullout

PULLOUT

Form 173-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_5v0ev.doc_mfm_2007-11-01

www.eltekvalere.com Headquarters: ValereEltek ValereEltek USA75081,TX.Richardson,Rd,ArapahoE.1303
www.eltekvalere.com
Headquarters:
ValereEltek
ValereEltek
USA75081,TX.Richardson,Rd,ArapahoE.1303
NorwayDrammen,3003Strømsø,2340PB8,Gråterudv.
330-9101(469)+1Fax:330-9100(469)+1Phone:
10322032+47Fax:00322032+47Phone:

sign.:customer,bypprovedA

Date:

sign.:installation,ofResponsible

Approval

 

bankbatteryinstalledtheofmiddletheinplacesuitableatocable)theofend

the(atsensorthefixandterminal,inputorplugD-Subthetoapplicable,if,cablesensortemperaturetheConnecto

terminalsinputthetoapplicable,if,cablessymmetrybatteryConnecto

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:FOLLOWINGOUTCARRY

OFF!isPowerInstallationMechanical

ratedsuitablyarecable(s)inputACandfusesACternalexthethatandtype,correcttheissupplyACtheChecko

fusesandcable(s)inputACSupply:ACPrepare3.

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systems)(cabinetizedkg600supporttoableissurfacelevelledthethatChecko

20cmaccess,top60cm,access,frontss:accecabinetforclearancesmin.Checko

siteinstallationtheOrganize1.

OK

:FOLLOWINGOUTCARRY

PreparationsSite

EMC

regard

1. OK : FOLLOWINGOUTCARRY PreparationsSite EMC regard name:by,outcarriedInstallation Capacity:Battery

name:by,outcarriedInstallation

Capacity:Battery

Type:Battery

measured:Voltage,InputCA

of:number&typeRectifiers,

 

No.:versionSoftware,

No.:Serial

 

name:Site,

No.:rticleA

 

type:,SystemSupplyPower2Flatpack

SystemPSFlatpack2DataSystem

LISTCHECKINSTALLATION

Form 172-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_5v0ev.doc_mfm_2007-11-01 LOAD BATT. type:,SPS2kFlatpac
Form 172-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_5v0ev.doc_mfm_2007-11-01
LOAD
BATT.
type:,SPS2kFlatpac
No.:rticleA
name:Site,
.CIRC
.NO
FUSE
TYPE
LVLD
DESCRIPTION
FUSE
CABLE
2
KNIFE
MCB
CONTROLLED
AMPERE
mm
Fb1
Fb2
Fb3
Fb4
Fb5
Fb6
F1
F2
F3
F4
F5
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2.
3.
4.
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6.
7.
8.
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11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Continue
www.eltekvalere.com
Headquarters:
ValereEltek
ValereEltek
USA75081,TX.Richardson,Rd,ArapahoE.1303
NorwayDrammen,3003Strømsø,2340PB8,Gråterudv.
330-9101(469)+1Fax:330-9100(469)+1Phone:
10322032+47Fax:00322032+47Phone:

DataSystem

LISTDISTRIBUTIONCIRCUIT

Form 172-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_5v0ev.doc_mfm_2007-11-01

www.eltekvalere.com Headquarters: ValereEltek ValereEltek USA75081,TX.Richardson,Rd,ArapahoE.1303
www.eltekvalere.com
Headquarters:
ValereEltek
ValereEltek
USA75081,TX.Richardson,Rd,ArapahoE.1303
NorwayDrammen,3003Strømsø,2340PB8,Gråterudv.
330-9101(469)+1Fax:330-9100(469)+1Phone:
10322032+47Fax:00322032+47Phone:
LOAD .CIRC .NO FUSE TYPE LVLD DESCRIPTION FUSE CABLE 2 KNIFE MCB CONTROLLED AMPERE mm
LOAD
.CIRC
.NO
FUSE
TYPE
LVLD
DESCRIPTION
FUSE
CABLE
2
KNIFE
MCB
CONTROLLED
AMPERE
mm
1.
2.
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8.
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24.
25.
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27.
28.
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30.
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33.
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35.
36.

LISTDISTRIBUTIONCIRCUIT

Form 171-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_5v0ev.doc_mfm_2007-11-01

www.eltekvalere.com Headquarters: ValereEltek ValereEltek USA75081,TX.Richardson,Rd,ArapahoE.1303
www.eltekvalere.com
Headquarters:
ValereEltek
ValereEltek
USA75081,TX.Richardson,Rd,ArapahoE.1303
NorwayDrammen,3003Strømsø,2340PB8,Gråterudv.
330-9101(469)+1Fax:330-9100(469)+1Phone:
10322032+47Fax:00322032+47Phone:

sign.:customer,bypprovedA

Date:

sign.:control,maintenanceofResponsible

Approval

 

manufacturer.batteryactualtheofrecommendationstheFollow

specifications.batteryverifyandmeasurecontrol;bankBattery5.

 

equipmentexternalofactivationverifyon;functiTestRelaytheusePCorkeypad’sSmartpacktheFrom

correctly.workingarerelaysalarmallverifyTest;RelayAlarm4.

 

current)loadlittlewithrail,DCtheatdonebetomeasurements(Voltage

manufacturer.batterythebyrecommendedvoltagenominalthetovoltageoutputtheadjustrequired,ifand,Measure

adjust.andmeasureAdjustment;VoltageOutputDC3.

 

capacity)max.system’sofvalue>50%(calibrationPC

thefromcurrentthecalibratereadings,displaythefrom1%±thanmoredeviatevaluestotalcalculatedtheIfcurrent.

battery&loadtotaltheCalculatecurrent.circuitloadyever&currentbatterytheammeterclip-onawithMeasure

readings.displaycorrectverifyCalibration;CurrentBattery&Load2.

 

PC.theorkeypad’sSmartpackthefromvoltageoutput

thecalibratereading,displaythefrom1%±thanmoredeviatesterminalsloadtheatvoltageoutputDCmeasuredIf

readings.displaycorrectensureCalibration;VoltageOutputDC1.

OK

:FOLLOWINGOUTCARRY

AdjustmentSystem

 

PC.thefromorcontrollerSmartpacktheonkeypadtheUsing

Messages.AlarmoflogstoredtheDisplay9.

 

1A)±(currentofamountsametheoutputrectifiersallchecktoapplicationPCPowerSuitetheUse

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required)ifapplicationPowerSuitethe(installPCatosystemPStheConnect7.

 

continuing.beforeabnormalitiespossibleCorrect

verifyOK;workdisplayandkeys’sSmartpack&functionalityrectifier’sAll6.

 

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verify.present;alarmnoON,aremodulesrectifierall&SmartpackThe5.

 

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supported.andterminatedsecurelyarebarscopperandcablingAll4.

 

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verify.dirt;ordustdamage,fromfreeisequipmentThe3.

 

calibration&measurementscorrectEnablesfailure.mainsorstart-upsincehours12forleastAt

advance.inchargedfullybeenhasbankbatteryThe2.

 

available.aredrawingsarrangement&connectionspecificsiteandmanualsUser

known.aresettingsandparametersspecificSite1.

OK

:FOLLOWINGOUTCARRY

ON!isPowerInspectionSystem

andauthorizedbyperformedbetoonlyisequipmentliveonworkMaintenanceWARNING:
andauthorizedbyperformedbetoonlyisequipmentliveonworkMaintenanceWARNING:
injury.terminalcausemayinsidevoltagesHazardoustools.insulatedusingpersonsqualified

Electric

shock

Electric shock name:by,outcarriedMaintenance Capacity:Battery

name:by,outcarriedMaintenance

Capacity:Battery

Type:Battery

measured:Voltage,InputCA

of:number&typeRectifiers,

 

No.:versionSoftware,

No.:Serial

 

name:Site,

No.:rticleA

 

type:,SystemSupplyPower2Flatpack

SystemPSFlatpack2DataSystem

PROCEDUREMAINTENANCE

PULLOUT

Form 170-gb-v5-C01_356804-103_qstart_flatpack2-pssyst_5v0ev.doc_mfm_2007-11-01

www.eltekvalere.com Headquarters: ValereEltek ValereEltek USA75081,TX.Richardson,Rd,ArapahoE.1303
www.eltekvalere.com
Headquarters:
ValereEltek
ValereEltek
USA75081,TX.Richardson,Rd,ArapahoE.1303
NorwayDrammen,3003Strømsø,2340PB8,Gråterudv.
330-9101(469)+1Fax:330-9100(469)+1Phone:
10322032+47Fax:00322032+47Phone:

sign.:customer,bypprovedA

Date:

sign.:ssioning,commiofResponsible

Approval

displayedarealarmsnoverifyandfuses,MCBs/loadallConnect14.

sharingcurrentrectifiers’theverifyandrectifiers,allagaininPlug13.

voltageloadorbatterynominalequaltovoltageoutputDCAdjust12.

MCBsfuses/batteryallconnectandone,butrectifiersallUnplug11.

polarity!correctCheckvoltagebatterymeasuredequaltovoltageoutputDCAdjust10.

PowerSuiteininfospec.siteEnterconfigurationwithaccordanceinisSetupSystem9.

correctlyworkingarerelaysalarmallVerifytest;relayAlarm8.

adjustandMeasurevoltage;outputDC7.

requiredifsoftware,PowerSuitetheInstallsystemPSthetoPCaConnect6.

VerifyON;areLEDsworking,aremodulesrectifierallandSmartpackThe5.

shelvespowertheinlocationsoriginaltheirinrectifiersFlatpack2allInsert4.

verifyandMeasurecorrect;isvoltageinputAC3.

ON)fusesAC(externalsystemtheONSwitch2.

location)original(keepthemremovingwithoutmodules,rectifierallDisconnect1.

OK

:FOLLOWINGOUTCARRY

ON!isPowerAdjustmentsLoad&No-LoadStart-up,

OFFswitchedarefusesMCBs/allandsupplyAC5.

knownaresettingsandparametersspecificSite4.

terminatedare(PE)wireearthACandcable(s)inputAC3.

disconnectedarefusesMCBs/loadandbatteryAll2.

polaritycorrectwithterminatedsecurelyiscablingAll

in.filledisListCheckInstallationFlatpack2Thecompleted;isinstallationsystemFlatpack21.

OK

:FOLLOWINGCHECK

OFF!isPowerCheckPre-Start

Device

hazard

: FOLLOWINGCHECK OFF!isPower CheckPre-Start Device hazard III Device hazard II Device hazard I

III

Device

hazard

OFF!isPower CheckPre-Start Device hazard III Device hazard II Device hazard I name:by,outcarriedCommissioning

II

Device

hazard

Device hazard III Device hazard II Device hazard I name:by,outcarriedCommissioning Capacity:Battery

I

name:by,outcarriedCommissioning

Capacity:Battery

Type:Battery

 

measured:Voltage,InputCA

of:number&typeRectifiers,

 

No.:versionSoftware,

 

No.:Serial

 

name:Site,

No.:rticleA

 

type:,SystemupplySowerP2kFlatpac

No.:OrderSupplier’s

SystemPSFlatpack2DataSystem

PROCEDURECOMMISSIONING

Pull out the pages with the gray outer band, and use them as check lists

Check Lists Pullout

PULLOUT

AC Mains

Miscellaneous

III

Mains Reconfiguration ~AC Terminal Block with OVP

Mains reconfiguration is NOT possible when Flatpack2 DC power systems are shipped with

AC terminal blocks with OVP factory prior to delivery.

surge arrestors. Such systems have to be configured at the

1
1
arrestors . Such systems have to be configured at the 1 NON Configurable Mains Input Terminal
NON Configurable Mains Input Terminal Block with OVP 4AC Power Shelves (single AC feed: 4
NON Configurable Mains Input Terminal Block with OVP
4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)
Υ Mains, TN
Three-phase & N, 400VAC
(1 Y Mains input will feed 2 power shelves)
AC Mains wires
4
fish plates
AC Mains
Terminal
Block
(To internal
connections for 2
power shelves)
X:******
Flatpack2 DC Power System
2009604, v7
NON Configurable Mains Input Terminal Block with OVP 4AC Power Shelves (single AC feed: 4
NON Configurable Mains Input Terminal Block with OVP
4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)
Δ Mains, IT
Three-phase, 230VAC
(1 Δ Mains input will feed 2 power shelves)
AC Mains wires
4
fish plates
AC Mains
Terminal
Block
(To internal
connections for 2
power shelves)
X:******
Flatpack2 DC Power System
2009604, v7
1
1

Over Voltage Protection, OVP

Quick Start Guide

Flatpack2 PS System

356804.103, v5-2006-11

13

IV Miscellaneous AC Mains Mains Reconfiguration ~AC Connection Box To reconfigure the AC mains feed

IV

Miscellaneous

AC Mains

Mains Reconfiguration ~AC Connection Box

To reconfigure the AC mains feed of Flatpack2 DC power systems that use the Erico AC Mains connection box, you have to reconnect the AC mains wires and rewire the internal cables of the connection box.

AC Mains

Connection Box

cables of the connection box. AC Mains Connection Box For external AC Mains For external AC

For external

AC Mains

For external

AC Mains

PS2:CON10 PS2:CON11 PS2:CON13 PS2:CON14 PS2:CON16 PS2:CON17 PS2:CON19 PS2:CON20 PS1:CON10 PS1:CON11 PS1:CON13
PS2:CON10
PS2:CON11
PS2:CON13
PS2:CON14
PS2:CON16
PS2:CON17
PS2:CON19
PS2:CON20
PS1:CON10
PS1:CON11
PS1:CON13
PS1:CON14
PS1:CON16
PS1:CON17
PS1:CON19
PS1:CON20
PS1:CON14 PS1:CON16 PS1:CON17 PS1:CON19 PS1:CON20 cable cable Rewire the Internal connection point (power

cable

cable

PS1:CON16 PS1:CON17 PS1:CON19 PS1:CON20 cable cable Rewire the Internal connection point (power shelf # and

Rewire the

Internal connection point (power shelf # and connector #) for each cable

internal

cables

1. Switch OFF the AC supply fuses in external fuse boards

2. Find out whether your system is implemented with 4AC or 2AC powers shelves (read the Identifying Power Shelves section, page 11).

3. Connect the AC Mains wires, and rewire then the internal cables of your system’s AC Mains connection box, according to the type of AC mains to be used, as shown in the actual example in this section.

PS2:CON10 PS2:CON11 PS2:CON13 PS2:CON14 PS2:CON16 PS2:CON17 PS2:CON19 PS2:CON20 PS1:CON10 PS1:CON11 PS1:CON13
PS2:CON10
PS2:CON11
PS2:CON13
PS2:CON14
PS2:CON16
PS2:CON17
PS2:CON19
PS2:CON20
PS1:CON10
PS1:CON11
PS1:CON13
PS1:CON14
PS1:CON16
PS1:CON17
PS1:CON19
PS1:CON20
4AC Power Shelves
Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier
PS2:CON10
PS2:CON11
Υ Mains, TN
Three-phase & N, 400VAC
Δ Mains, IT
Three-phase, 230VAC
Mains
One-phase, 230VAC
PS2:CON13
PS2:CON14
PS2:CON16
PS2:CON17
PS2:CON19
PS2:CON20
AC Mains
AC Mains
AC Mains
PS1:CON10
PS1:CON11
Cable
Cable
Cable
PS1:CON13
PS1:CON14
PS1:CON16
L3
L1
PE
N
L2
L3
L1
PE
L2
PE
PS1:CON17
L (L1)
N (L2)
PS1:CON19
PS1:CON20
Chassis
Chassis
Chassis
Rewire
X:******
Rewire
X:******
Rewire
X:******
the box
the box
the box
as shown
as shown
as
shown
PS2:CON10
PS2:CON11
PS2:CON13
PS2:CON14
PS2:CON16
PS2:CON17
PS2:CON19
PS2:CON20
PS1:CON10
PS1:CON11
PS1:CON13
PS1:CON14
PS1:CON16
PS1:CON17
(To internal connections)
(To internal connections)
(To internal connections)
PS1:CON19
PS1:CON20
Flatpack2 DC Power System
Flatpack2 DC Power System
Flatpack2 DC Power System
Quick Start Guide
Flatpack2 PS System
14
356804.103, v5-2006-11
AC Mains box
connection
AC Mains box
connection
AC Mains box
connection

AC Mains Input

(L1,L2,L3,N)

AC Mains

Miscellaneous

i n s I n p u t (L1,L2,L3,N) AC Mains Miscellaneous 2AC Power Shelves Dual
2AC Power Shelves Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
2AC Power Shelves
Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
Υ Mains, TN
Three-phase & N, 400VAC
Δ Mains, IT