PRSB 15kW Outdoor Instalation Guide

Installation Guide
351405.033
PRSB 15kW, 48VDC
Information in this document is subject to change without notice and does not represent a
commitment on the part of Eltek Energy AS.
No part of this document may be reproduced or transmitted in any form or by any means
electronic or mechanical, including photocopying and recording for any purpose without
the explicit written permission of ELTEK Energy.
Copyright : Eltek Energy AS, Norway 2004

NS-EN ISO 9001:1994 Certificate no: 900005Q
NS-EN ISO 14001:1996 Certificate no: 900005E.
This product holds a CE mark and satisfies all requirements covering relevant standards and
directives.
EMC
LVD
EN61000-6-2 Industrial Environment

EN61000-6-3 Residential, Commercial and Light Industry
ETS 300386 v1.3.1 Telecommunication Equipment
LVD73/23/EEC Low Voltage Directive

EN60950 Safety of Technology Equipment
Certificate no: 900005Q
Head Office:
Certificate no: 900005E
Eltek Energy AS
P.O. Box 2340 Strms
N-3003 Drammen
NORWAY
Phone:
(+47) 32 20 32 00
Fax:
(+47) 32 20 32 10
E-Mail
eltek@eltekenergy.com
Internet: http://www.eltekenergy.com
Art. No. 351405.033
Issue 3, 2004 November
Published 2004-11-18
Mfm
Flatpack PRSB 15kW, 48VDC

(Outdoor Site Power Cabinet, Fan Cooled) has part no. CF1032.001
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Fan Cooled Art. No. 351405.033, v32004-11
Table of Contents
1 DESCRIPTION OF FLATPACK PRSB 15KW, 48VDC
OVERVIEW GENERAL ARRANGEMENT
INPUT AND DISTRIBUTION ARRANGEMENT
AC INPUT TERMINALS
DC DISTRIBUTION AND LVBD DEVICE
MONITORING, CONTROL AND SIGNAL INTERFACE
SYSTEM MONITORING
2 INSTALLATION PROCEDURES
SAFETY PRECAUTIONS
UNPACKING AND MECHANICAL INSTALLATION
ELECTRICAL INSTALLATION
RECTIFIER INSTALLATION MAINS SUPPLY EFFECT BALANCING
11
RECTIFIER INSTALLATION HANDLES AND LOCKING MECHANISM
11
COMMISSIONING
11
3 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS
12
CONNECTIONS FOR INTERNAL SYSTEM WIRING
13
CONNECTIONS GMT FUSES
14
4 SPECIFICATIONS FLATPACK PRSB 15KW, 48VDC, FAN COOLED
15
SPECIFICATION
15
FAN OPERATION
15
5 APPENDIX: SCHEMATICS, DRAWINGS, FIGURES, ETC.
16
GENERAL ARRANGEMENT DRAWING
16
SYSTEM SCHEMATIC PRSB 15KW, 48VDC, OUTDOOR CABINET, FAN COOLED
17
ON SITE DOOR REMOVAL OUTDOOR CABINET, FAN COOLED
18
DRILLING TEMPLATE
18
Description of Flatpack PRSB 15kW, 48VDC
This Installation Guide contains information about how to install the Flatpack PRSB 15kW,
48VDC system1 , for the outdoor site power cabinet, fan cooled. Please, refer to the systems
Documentation Set (art. 351405.003) for an overview of related user documentation.
Overview General Arrangement

The Flatpack PRSB 15kW, 48VDC is a DC power supply system based on the Flatpack 1500
48V rectifier. The system contains AC termination blocks, DC distribution, Flatpack Power
Rack, Flatpack 1500 rectifier modules and the Flatpack Monitoring and Control Unit (MCU).
The system is designed for cable entry from top and the cabinet size is 770x820x2000mm,
(30.3 x 32.3 x 78.7) (WxDxH).
Heater MCB (AC).
DC Load Distribution:
MCBs, Mains, Alarm and
Signal Terminals
LTE Distribution, MCBs

Optional kit.
Battery strings. The top

three shelves are optional
kits
Air filter
Figure 1
Flatpack
Power Rack System
General Arrangement
PRSB = Power Rack System with Batteries
Input and Distribution Arrangement

Cabinet main Protective Earth (PE). Connected
to powercore PE. Positioned in the ceiling
ve DC Load Terminals (BTS MCBs) 2
On top of each load breaker, 25 mm (70 mm2)
ve Battery Terminals
Bus bar, 35 mm2
+ve DC Load Terminals

Common positive bus bar, 70 mm2
+ve Battery Terminals
Common positive bus bar, 70 mm2
DC Earth (TE) terminal, M6
AC Earth (PE) terminal, M6
AC Mains Terminals
Terminals for GMT 15A Load
Fuses, 1.5 mm2
CON 5,2Alarm Terminals
1.5 mm (Front access)
Flatpack 1500 rectifier

modules
MCU Ctrl. Unit, and

CON 4, Monitoring Terminals
(Back MCU)
Figure 2 Location of components in

the Power core. Contains
Distribution and Power Racks
AC Input Terminals
The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase and N.
L1-bar
N-bar
L2-bar
L3-bar
N (neutral)
(Terminal for
incoming wire)
L1
(Terminal for
incoming wire)
L2
(Terminal for
incoming wire)
L3
(Terminal for
incoming wire)
Labels on internal wires

(Wires may be reconnected to
match the sites type of AC
mains supply)
Figure 3
AC input terminals, L1, L2, L3 & N, with internal terminal connection bars
AC Input Feed Sizing
An external breaker is
required on all sights. This
should be turned OFF
under all installation.
(Recommended AC Breaker Rating and Min. Wire Size)

18kW
VAC Input
400VAC +N, 3 ph
230VAC, 3 ph
40A C
4x6 mm2 Cu max. 30m
63A C
3x10 mm2 Cu max. 45m
You may reconfigure the AC terminal block for connection of 230VAC, 3 phase supply. To do
so, rewire the internal (blue) wires as described in the table below, and connect the AC
mains supply cable to terminals L1, L2 and L3.
AC Terminal Block
400VAC, 3ph+N
AC Terminal Block
230VAC, 3ph
Internal Wire Connections

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

Internal Wire
Wire Color
Connected to
(Labeled)
Terminal Bar
L1,1
N1(L2)
L2,1
N1(L3)
L3,1
N1(L1)
L1,2
N2(L2)
L2,2
N2(L3)
Black
Blue
Black
Blue
Black
Blue
Black
Blue
Black
Blue
L1-bar
N-bar
L2-bar
N-bar
L3-bar
N-bar
L1-bar
N-bar
L2-bar
N-bar
Factory configuration
L1,1
N1(L2)
L2,1
N1(L3)
L3,1
N1(L1)
L1,2
N2(L2)
L2,2
N2(L3)
Black
Blue
Black
Blue
Black
Blue
Black
Blue
Black
Blue
L1-bar
L2-bar
L2-bar
L3-bar
L3-bar
L1-bar
L1-bar
L2-bar
L2-bar
L3-bar
Customized configuration
To connect your system to

1 phase from a 230 VACsystem or a 400 VAC + Nsystem connect the input
cables as illustrated in the
table to the right. With
one phase the maximum
amount of rectifiers is 4.
These have to be placed in
position 1,4,7 and 9 in
Figure 4, page 11. The
other positions will not be
usable.
AC Input Connection
1-phase
External Wire Connections
AC configuration in
Terminal Block
400 VAC + N
Input
(230 VAC, 3ph or
400 VAC, 3ph +
N)
400VAC +
N
230VAC
L1
N
L1
L2
L1-terminal
N-terminal
L1-terminal
N-terminal
230 VAC
L1-terminal
L2-terminal
L1-terminal
L2-terminal
1 phase configurations
DC Distribution and LVBD device

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

The Flatpack PRSB 15kW, 48VDC is available with basic functionality for monitoring and
control of the system, and is equipped with:
Relay outputs, 6 pcs

Digital inputs, 4 pcs
Symmetry input signals, 2 pcs
(battery string midpoint measurements)
Digital input for external symmetry circuitry
One of the interface boards (104649) is located behind the MCU (with rear access to the
terminals), while the other board (104648) is mounted on top of the MCU (with front access
to the terminals).
Ses Figure 7 Customer connections interface, page 12.
System Monitoring
The Flatpack MCU Monitoring & Control Unit monitors and controls the entire rectifier
system including distribution and batteries, as well as other equipment on site. The unit also
incorporates a communication port for connecting computers via the RS232C interface.
The Flatpack system can be operated and configured locally via the keypad on the MCU
unit, by selecting commands from set-up menus in a hierarchical menu system.
Please refer to the Flatpack MCU Operation Guide for detailed information about system
monitoring.
Remote system monitoring and configuration may also be performed using WinPower Silver
a Windows-based program that runs on a connected PC.
The following configuration tasks require the use of a PC:
Installation settings
System calibration
Battery configuration
Alarm setup
Alarm log retrieval
Site information
Site specific configuration
Installation Procedures
This section describes how to install the Flatpack PRSB 15kW, 48VDC. Step-by-step
procedures will guide you through the installation.
For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and control
unit, please refer to the Operation Guides for the respective modules.
Safety Precautions
The equipment described in this manual must only be

installed by authorized personnel, and only operated by
persons who have attended a suitable Eltek Energy
training course.
The equipment represents an energy hazard and failure

to observe this could cause terminal injury and invalidate
our warranty.
There are hazardous voltages inside the rectifier system.

As the rectifier units incorporate large charged
capacitors, it is dangerous to work inside the system
even if the mains supply is disconnected.
Products into which our components are incorporated

have to comply with a number of requirements.
Installation is to be in accordance with the
recommendations herein.
Please read the manual carefully before using the

equipment.
Unpacking and Mechanical Installation

Installation Step
Comments
1 TAKE THE FLATPACK POWER

SYSTEM OUT OF THE PACKAGING
Inspect the unit for any physical or transit

damage, and tighten the screws that connect
conductors. Report any transit damage to Eltek
Energy immediately
2 DRILL HOLES
IN THE GROUND
ACCORDING TO DRILLING
TEMPLATE
3 POSITION THE CABINET
IN THE
REQUIRED LOCATION
4 BOLT THE CABINET

GROUND/PLINTH
TO THE
OK
The Drilling Template with instructions is located

in section 5, page 18.
The floor construction must be capable of
supporting the equipment.
Bolts are not included in the cabinet. If a plinth
is used, refer to Installation Guide, Kit for
Plinth, Doc. No. 351416.033.
Electrical Installation
For location of components, see
Figure 2 - page 5, Figure 3 - page 6, and Figure 9.- page 16.
Installation Step
1. EARTH CONNECTIONS
Comments
OK
The AC Earth (PE) and DC Earth (TE) terminals are

mechanically connected to
the cabinet chassis.
The Common Positive Bus bar
is internally cabled to DC
Earth (TE); thus the positive
output of the rectifiers is
connected to ground (TE),
and the negative output
represents the 48Vdc supply
voltage.
If required, you can remove the internal cable that connects
the positive bus bar to local PE.
Switch OFF the AC input power (external MCBs), before
connecting the cable.
Open the clamps that fasten the cable entry rubber gland.
Shape the cable entry rubber gland with a knife to fit the
mains cables, and draw the cables into the top of the
cabinet. It is recommended to do the same with the load
cables at this time. Fasten the cables with strips to the
brackets inside the cabinet. Do not make the cable slot too
wide! Use silicon to make the input hole watertight.
2. AC CONNECTIONS
Connect the AC cables, max. 35sq mm(AWG 2), to the

terminal block in the top of the cabinet as the labels
indicate. Replace the cable entry clamps. Do not power up
the system until the whole installation is complete.
Connect the external AC ground wire to the cabinets main
Protective Earth (PE) terminal. See
Figure 2.- page 5.
3. LOAD CONNECTIONS
Alarm
connection
100A
150A
Cable gland
4. GMT FUSE
CONNECTION
5. BATTERY CONNECTIONS
6. POWER UP
Turn OFF the Load/BTS MCBs.

Turn OFF the PRS battery MCBs on the left side of the
cabinet.
Loosen the screws and pull the black cable gland back to
draw the load cables down to the powercore.
The kit includes two copper bridges. One for 100 A (two
pins) and one for 150 A. If the load current is larger than
50 A use the two pin copper bridge. Then the 3rd hole in the
breaker cannot be used. If the load current is larger than
100 A, use the three pin copper bridge. Insert the chosen
copper bridge on to the top of the MCB.
Connect the orange alarm wire to the copper bridges with a
screw if the bridges are used.
Connect the positive cable(s), max 70 mm sq (AWG 2/0), to
the common positive bus bar on the top of the powercore. 2
Connect the negative (-48V) cables, max 25 mm sq each
(AWG 3), to the top of the MCBs or the copper bridges.
Connect the negative (-48V) cables to the MCBs.
Connect the adequate cables, 1,5 mm sq (AWG 15), to the GMT
fuse card according to the table in section 3 page 14
The positive and negative (-48V) battery cables are connected
from factory to the common positive bus bar and to the
battery MCBs. (Excluding additional battery string kits) The
battery temperature sense cable is also pre-wired to CON4,
and temporally fixed to the cabinets wall.
Connect the loose end of the battery cables to the battery
terminals; blue cable to the negative terminal and black
cable to the positive terminal.
Connect all battery intercell links
Place the temperature sensor, located at the end of the
battery temperature sense cable, on top of the topmost
battery string.
Please follow chapters Pre-Start Check and Start-Up
Procedure in manual Commissioning Guide Flatpack 1500 DC
Rectifier Plant, Doc. No. 360006.163.
The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted
at delivery.
10 Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Fan Cooled
Art. No. 351405.033, v32004-11
Rectifier Installation Mains Supply Balancing Effect

The Flatpack PRSB system may be expanded to a maximum of 10 Flatpack 1500 rectifiers.
In order to load the AC supply net evenly similar current load from the 3 phases of the
mains supply it is advisable to mount the required number of rectifiers in the following
order:
MCU
Rectifiers
1st Pos
(on L1)
4th Pos
(on L1)
2nd Pos
(on L2)
5th Pos
(on L2)
3rd Pos
(on L3)
6th Pos
(on L3)
9th Pos
(on L1)
7th Pos
(on L1)
10th Pos
(on L2)
8th Pos
(on L2)
Figure 4
Rectifier mounting order to load the mains supply evenly.
When possible, mount an equal number of rectifiers on each phase, L1, L2 and L3.
Rectifier Installation Handles and Locking Mechanism

The Flatpack 1500 rectifier module is equipped with handles that serve two purposes:
Locking the module into position

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

Unlock and release the handles by inserting
a small screwdriver into the upper holes,
thus releasing the spring mechanisms. Do
not use excessive force. The handles will
release and pop out. When both handles are
released, use them to pull the module out.
Do not hold or carry the rectifier by its
handles.
Figure 6
Upper hole to
release the spring
mechanism
Handle in locked position
Releasing the modules handles
Commissioning
For information regarding system commissioning, please read manual Commissioning
Guide Flatpack 1500 DC Rectifier Plant, art. No. 360006.163.
11
Alarm Relay Outputs and Signal Connections
The digital inputs are configured as fail-safe, i.e. if the input is

enabled, it will trigger an alarm if the input is open. If several
external devices are going to the same digital input, they
must be connected in series.
The alarm relays are also operated in fail-safe, i.e. the relays
are energized when there is no alarm. The description below
describes the pin out in normal state, i.e. the NO output is
open in normal operation and shorts to the COM output in the
alarm-state.
Input 1
AGND
CON4
External device
alarm state
Alarm relay specification

Nominal switching capacity
2A/30V DC
Maximum switching power
60W (resistive load)
Maximum switching voltage
220V DC
Maximum switching current
2A DC
Interface Customer Connection Pin Out
Interface Card 104648

Located on top of the
MCU Ctrl. Unit
Interface Card 104649

Located back the MCU
Ctrl. Unit
(plug for MCU)
Pin 11
Pin 20
Pin 12
Pin 1
CON2
CON5
CON3
CON4
Pin 1
Pin 1
Pin 10
Pin 20
Terminal
Description
Terminal
Description
CON 2
CON 3
Internal system connections

Internal communication
CON 4
CON 5
Customer connections (digital inputs, symmetry, etc.)

Customer connections (alarm relay outputs)
Figure 7
Customer connections interface and internal terminals. (Max. 1,5 mm , AWG 15)
Art. No. 351405.033, v32004-11
CON 5 Pin Assignment

for basic PCB version, art. No. 104648
Pin
1
2
3
4
5
6
7
8
9
Signal
NC
NO
Com
NC
NO
Com
NC
NO
Com
Function
Relay 6:
Common Alarm
Pin
10
11
12
13
14
15
16
17
18
19
20
Relay 5:
Module Alarm
Relay 4:
Load / Battery Fuse Alarm
Signal
NC
NO
Com
NC
NO
Com
NC
NO
Com
Function
Relay 3:
Low Battery Alarm
Relay 2:
Heat Management
Alarm
Relay 1:
High temp.
(Fan regulation)
(not used)
(not used)
Factory Settings

Pin
1
2
3
4
5
6
Signal
+
AGND
+
AGND
+
AGND
Function
Digital Input 1
(Heat management)
Digital Input 2
(programmable)
Digital Input 3
(programmable)
7
8
+
AGND
Digital Input 4
(programmable)
9
10
+
AGND
Battery Symmetry 2
(digital input)
Pin
11
12
13
14
15
16
17
18
19
20
Signal
+
screen
Function
Battery Symmetry 1
(analogue input)
Battery Symmetry 3
(analogue input)
+21V Auxiliary Supply
(for modem or ext.equipment)
(not used)
Battery Temperature Sense
Analogue ground (system ref.)
Connections for Internal system wiring

CON3 is used for rectifier and power shelf communication. CON2 is used for internal system
wiring, which has been wired at the factory. These connectors are not involved in the
system installation and commissioning process. The table below shows the pin assignment
for CON2.
Pin
1
2
3
4
5
6
7
8
Signal
+
VDC+
VDC
Function
Shunt 2:
Battery current measurement
Shunt 1:
Battery current measurement
Auxiliary Supply
(for Flatpack MCU)
Voltage Sense
(system signal reference)
Pin
9
Signal
+
10
11
12
Function
Battery Fuse State
(digital input)
Load Fuse State
(digital input)
LVBD control
(Battery Disconnect contactor)
LVLD control
(Load Disconnect contactor)
13
Connections for GMT fuses
Pin 16
Pin 1
GMT fuses
Max. 15 A each
Figure 8
GMT fuse card (Max. cable size 1,5 mm sq)
The table below shows the pin assignment for the GMT load fuse card.
Pin Assignment for GMT Fuse
Pin
1
2
Signal
+
Function
GMT fuse 1 (F4)
Pin
9
10
Signal
+
Function
GMT fuse 5 (F8)
3
4
GMT fuse 2 (F5)
11
12
GMT fuse 6 (F9)
5
6
GMT fuse 3 (F6)
13
14
GMT fuse 7 (F10)
7
8
GMT fuse 4 (F7)
15
16
GMT fuse 8 (F11)
Art. No. 351405.033, v32004-11
Specifications Flatpack PRSB 15kW, 48VDC, Fan Cooled
Site Power Outdoor cabinet

SPECIFICATION
Max. number of rectifiers
AC INPUT
Voltage
1 phase 230
rectifiers)
3 phase 208
3 phase 230
3 phase 400
10
VAC (max 4
VAC ( )
VAC ( )
VAC+N ( Y )
Frequency
45 to 66Hz
Maximum
Current
See Flatpack 1500 48VDC

datasheet (241114.100.DS3)
Protection
Soft start
Surge protection (varistors)
Disconnect above 312 VAC
MONITORING
Monitoring Unit
Local operation
Remote
operation
Alarm relays
Flatpack MCU
Menu driven software via
keypads and LCD or PC
(WinPower)
WinPower via modem or Web
NMS via SNMP-agent
6 relays are standard
Visual indications Green LED System ON

Red LED Active alarm(s)
LCD system status
Digital inputs
5 (for monitoring of external
equipment)
Current
Battery current
measurements
Rectifier current
Alarms
Load fuse alarm
Battery fuse alarm
LVD operated
Low output voltage alarms
(2 individual alarm levels)
High output voltage alarms
(2 individual alarm levels)
Battery capacity
Temperature alarm
Symmetry alarm
DC OUTPUT
Voltage
48 VDC
Current
Up to 15 KW 300 Amps
CONNECTIONS
Battery
connections
Load MCB
connections
Battery cable, M8 bolts

Negative distribution, Load
cable, M8 bolts. Common
positive bus bar, M8 bolts
Front access screw terminals
Alarm
connections
DISTRIBUTION OPTIONS
No. of DC
Load breakers
No. of Battery
fuses
No. of Aux.
fuses
Programmable
LVD
Up to 3 x (3pole 63Amps)
Up to 3 x 125 Amps MCBs mount
next to each battery shelves
8 x 10 Amps GMT type
Standard: 1 LVBD (max. 400 Amps)
OTHER SPECIFICATIONS
Isolation
Operating temp
Storage temp
Dimensions
Weight
3.0 KVAC input and output

1.5 KVAC input earth
1.0 KVDC output earth
-40 to +50C (-40 to +122F)
-40 to +85C (-40 to +185F)
770 x 820 x 2000mm (WxDxH)
(30.3 x 32.3 x 78.7)
Approx. 170kg excl. rectifiers and
batteries
Max. 250kg load per battery shelf
APPLICABLE STANDARDS
Electrical safety
EMC
Environment
EN 60950
UL 60950
ETSI EN 300 386 V.1.3.1
(telecommunication network)
EN 61000-6-3
(emission, light industry)
EN 61000-6-2
(immunity, industry)
ETSI EN 300 019-2
ETSI EN 300 132-2
Fan operation
The fan runs as soon as the temperature in the cabinet passes 25oC and the fan MCB is
switched on. The fan speed adjuster is pre installed and factory set to the right speed,
which is a bit slower than full speed. It shall not be set again.
15
Appendix: Schematics, Drawings, Figures, etc.

General Arrangement drawing
See also
Figure 2, page 5, for more detailed information about DC distribution.
Main Protective Earth (PE)
Heater MCB (AC)

DC Distribution, Alarm,
AC Terminals, etc.
Rectifiers
LTE Fuses
MCBs
Battery MCB
FB4
Battery MCB
FB3
Battery MCB
FB2
Battery MCB
FB1
Figure 9
General Arrangement drawing, PRSB 15kW, 48VDC Outdoor Cabinet, Fan Cooled
Art. No. 351405.033, v32004-11
System Schematic PRSB 15kW, 48VDC, Outdoor Cabinet, Fan Cooled
Figure 10 Schematic
drawing, PRSB 15kW, 48VDC
system
17
On Site Door Removal Outdoor Cabinet, Fan Cooled
Step Description
1
Disconnect the earth

connection cable on
the bottom of the
door
Lift the door off the

hinges.
When the door is to

be mounted back
on, lift the door
back on to its hinges
Reconnect the earth

connection
Ok
Air filter
Earth
connection
Drilling Template
Figure 11 Top
view of the
cabinets bottom
plate.
700x700 mm
external
dimensions
Holes for mounting

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

plinth. Factory
drilled
Holes for the

plinth. Factory
drilled
The cabinet
overhangs by 35
mm outside the
plinth on the rear,
on the left hand
and on the right
hand side
Art. No. 351405.033, v32004-11
19
Main Office:
Eltek Energy AS
P.O. Box 2340 Strms
N-3003 DRAMMEN
Norway
Phone:
Fax:
47 32 20 32 00
47 32 20 32 10
E-Mail:
eltek@eltek.no
Internet:
www.eltekenergy.com
Art. No. 351405.033

Issue 3, 2004 November
Published 2004-11-18
Commissioning Guide
Flatpack 1500 DC
Rectifier Plant
360006.163
Issue 1
January 2003
Information in this document is subject to change without notice and does not represent a commitment
on the part of ELTEK ASA.
No part of this document may be reproduced or transmitted in any form or by any means electronic
or mechanical, including photocopying and recording for any purpose without the explicit written
permission of ELTEK ASA.
Copyright : ELTEK ASA, Norway 2003

NS-ISO 9001 Certificate No.4
This product holds a CE mark and satisfies all requirements covering relevant standards and
directives.
EMC
LVD
Generic Immunity Standard
EN50082-1 Residential, Commercial and Light Industry
EN50082-2 Industrial Environment
LVD73/23/EEC Low Voltage Directive
Generic Emission Standard

EN50081-1 Residential, Commercial and Light Industry
EN50081-2 Industrial Environment
ELTEK Energy (UK) Ltd
ELTEK ASA
Eltek House
Maxted Road
Hemel Hempstead
Herts HP2 7DX
England
P.O. Box 2340 Stms

N-3003 DRAMMEN
NORWAY
Phone: 47 32203200
Fax: +47 32203210
Phone: +44 1442 219355

Fax: +44 1442 245894
E-Mail: sales@eltek.co.uk
Visit our Web site on Internet: http://www.eltekenergy.com
360006.163
Issue 1, January 2003
This document was produced using Microsoft Word.

l.w 01/2003
2 (12)
Commissioning Guide, Flatpack 1500 DC Rectifier Systems

360006.163 , v1, January 2003
Contents
Contents
1. Introduction
Recommended tools
2. Commissioning
5
5
Pre Start Check ...................................................................................... 6

Start Up Procedure ................................................................................ 7
System Set Up ......................................................................................... 8
Commissioning ....................................................................................... 8
Battery Discharge Tests....................................................................... 10

360006.163 , v1, January 2003
3 (12)
Warning
Warning
;
;
;
;
;
;
;
The equipment described in this manual must only be worked

on by ELTEK Energy Personnel or by persons who have
attended a suitable ELTEK Energy training course.
The equipment represents an energy hazard and failure to
observe This could cause terminal injury and invalidate our
warranty.
There are hazardous voltages inside the rectifier system. The
rectifier units include large charged capacitors therefore it is
dangerous to work inside the system even if the mains supply
is disconnected.
Removal of cover should only be completed by authorized
personnel. Wait for ten minutes after disconnection before
removing cover to ensure that all high voltages have been
discharged to a safe level.
Some of the units within the system may weigh in excess of
25 kg.the appropriate lifting equipment should be used and
care must be taken whilst handling these units.
Products into which our components are incorporated have to
comply with a number of requirements. Installation is to be in
accordance with the recommendations herein.
Please read the manual carefully before using the equipment.
4 (12)

360006.163 , v1, January 2003
1. Introduction
1. Introduction
ELTEK Energys Flatpack Rectifier System is a standby DC system designed for integration
within Customer Equipment areas and telecommunications equipment.
This manual provides the necessary information to commission the system. The system
Description, Specifications and drawings must be use in conjunction with this manual.
There are two sections within this manual:
1: Start Up/Commissioning Procedure.
2: System Configuration Record.
The Commissioning/Site Acceptance Procedure verifies that the system is correctly
installed and operating satisfactorily.
We recommend that the Commissioning Engineer uses a PC during the testing in order to
carry out the tests efficiently.
Necessary software : Winpower Silver (Eltek provided) Software, Windows 95 or above
Password for MCU is 0000 from the keypad in front of the Alarm Module if nothing else is
specified.
Please consult the Operation Guide for the Alarm Module if any of the System parameters
need to be changed.
The System Configuration Record is vital for future reference and efficient service.
Note: Remote batteries.
The MCU provides the option to compensate for voltage drop in long battery cables. Please
consult the Operation Guide for MCU for further details.
Recommended tools
Standard equipment for an authorized electrician
Digital multimeter
PC with terminal software and cable
Note: All tools must be insulated.

360006.163 , v1, January 2003
5 (12)
2. Commissioning
2. Commissioning
The purpose of this phase is to verify the equipment installation and to commission the equipment in
preparation for operation.
Pre Start Check

Before starting the system the following items should be checked:
Check
Comments
Okay
1. THE SYSTEM INSTALLATION IS
Ensure that all equipment is free from damage.
COMPLETED AND UNDAMAGED
Ensure that all cabling is neat and secured,

components are fixed firmly and all labelling is
clear and correct.
All blank panels are replaced including unused
module positions.
2. THE BATTERY AND LOAD ARE
DISCONNECTED
Verify that all battery and load circuit breakers are

in the OFF position
3. RECTIFIER SYSTEM IS CONNECTED TO

AC SUPPLY AND PROTECTIVE EARTH
Check that the AC supply is connected,

configured correctly and suitable rated.
A protective earth connection must be made and
continuity must exist to all metalwork.
4. SITE PARAMETERS/SETUP KNOWN
Refer to service module for site specific details
5. ALL SUPPLIES DISCONNECTED, FUSES

OUT/OFF AND MODULES REMOVED
6 (12)

360006.163 , v1, January 2003
2. Commissioning
Start Up Procedure
Start Up Step
Comments
1. SWITCH ON THE AC TO THE CABINET
The green LED will light.
Okay
AND START THE ALARM MODULE BY

PRESSING THE SYSTEM ON/OFF SWITCH
2. ENSURE THAT THE AC SUPPLY IS

CORRECT
Measure the AC voltage at the input and selected

rectifier module positions to ensure correct
polarity and potential
3. CONNECT RECTIFIER MODULES
Follow procedure within the installation guide.

Verify that all modules are plugged in and the
securing clips closed.
All unused positions must be covered with
blanking panels.
4. INSTALL BATTERIES
Follow procedure within the Installation Guide
5. CONNECT A PC VIA THE FRONT PANEL

9 WAY D TYPE CONNECTOR AND
Refer to external equipment connection in

MCU operation guide.
ESTABLISH COMMUNICATION
6. ENSURE THAT ALL THE RECTIFIER
Monitor the alarm module and recifier modules.
MODULES ARE OPERATING CORRECTLY

AND NO ALARMS ARE PRESENT

360006.163 , v1, January 2003
7 (12)
2. Commissioning
System Set Up
Step
Comments
Okay
1. CALIBRATE THE INPUT VOLTAGE
Use the calibration function in the service menu.

Measure the actual value and then enter via PC.
2. CALIBRATE OUTPUT VOLTAGE

3 CALIBRATE BATTERY CURRENT

An external power supply will need to be
connected to the battery input during this check.
The voltage of the external power supply should
be set to +1V of the Rectifier system and then the
battery fuse can be fitted and removed.
NOTE:
Calibration is only necessary if the alarm module

does not match the actual reading
4. SYSTEM SET UP IS IN ACCORDANCE

WITH CONFIGURATION
Make sure that the system is set up in accordance

with the site requirements.
5. ENSURE ALARM CIRCUITS OPERATE
Use test outputs function within the service menu.
Commissioning
Step
Comments
Okay
1. TEST HIGH BATTERY ALARM
Set the output voltage level to 0.5 V above the

high battery alarm level via the PC and verify that
the High Battery Alarm is activated and the
relevant alarm contact is operated.
2. TEST LOW BATTERY ALARM
Set the output voltage level to 0.5 V below the

low battery alarm level (and reset the High
Battery Alarm) via the PC. Verify that the Low
Battery Alarm is activated and the relevant alarm
contact is operated.
Reset the output voltage to nominal and the low
voltage alarm resets.
8 (12)

360006.163 , v1, January 2003
2. Commissioning
3. TEST LOW VOLTAGE DISCONNECT
ALARM
An external power supply will need to be

connected to the battery input. The voltage of the
external power supply should be set to +1V of the
Rectifier system and then the battery fuse can be
fitted and removed.
Switch off the AC supply and reduce the output
voltage to 0.5 V below the disconnect voltage
level via the external power supply.
Verify that the Disconect Alarm is activated and
the relevant alarm contact is operated. The low
voltage disconnect contactor will operate.
Switch off and remove the external power supply
and re-instate the system by turning on the AC
supply
4. TEST BATTERY FUSE ALARM
Operate the battery MCBs and verify that the Batt

Fuse Fail Alarm is activated and the relevant
alarm contact is operated.
5. TEST LOAD FUSE FAILURE
Connect a tempory load to one of the output

circuit breakers. With the relevant MCB in the Off
position verify that the Load Fuse Fail Alarm is
activated and the relavant alarm contact operates.
6. CONNECT THE BATTERIES
Turn ON relevant battery MCBs. Ensure that the

contactor closes.
7. TEST MAINS FAILURE
Switch off the AC input supply to the system and

verify that the Mains Off Alarm is activated and
the relevant alarm contact is operated.
Also verify that the Module Fail Alarm is
activated. The green LED on each module will
extinguish whilst the red LED will light.
Restore the AC supply and ensure that the alarms
reset.
8. CHECK LOAD SHARING
Connect load to the output, and switch on load

MCB.
Allow several minutes for the modules to share
and check that the output currents of the modules
are within +5 % of the mean current.

360006.163 , v1, January 2003
9 (12)
2. Commissioning
Battery Discharge Tests

The battery should have a full discharge test as part of the commissioning procedure. Six days
should be allowed for charging prior to and after the test.
10 (12)

360006.163 , v1, January 2003

360006.163 , v1, January 2003
11 (12)
ELTEK ASA
P-O- BOX 2340 Strms
N-3003 DRAMMEN
NORWAY
Phone:
Telefax:
Internet:
e-mail:
+4732203200
+47 32203210
http://www.eltekenergy.com
eltek@eltek.no
ELTEK Energy UK Ltd

Maxted Road
Hemel Hempstead
Herts HP 2 7DX
England
Phone:
+44 1442 219355
Fax:
+44 1442 245894
Email:
sales@eltek.co.uk
Installation Guide
Kit for 1 Battery string +
Outdoor Shelf
Art. 351412.033
Issue 3, 2004-11
Index
General ..................................................................................................................................2
Consist of...............................................................................................................................2
Recommended tools ...............................................................................................................3
Installation .............................................................................................................................3
Ordering information..............................................................................................................6
General
This kit enables you to expand your system with additional battery strings. There is room for
three battery strings in addition to one in the standard system.
Consist of
The Kit for 1 Battery string + Outdoor Shelf consist of the following components.
Part
Note
MCB CBI D-frame 150A with aux switch
Quantity Unit
With copper bars pre mounted
1 pcs
Cable clamp for rail 70 mm
For positive connection rail
1 pcs
Cable clamp for rail 35 mm
For negative connection
1 pcs
Battery cables
2 pcs
Black
For positive connection
2.4 m
Blue long
2.4 m
Alarm wire
For connection from battery MCB to

common negative rail
For connection from battery to battery
MCB
Grey
Strips
For collecting and fastening the cables
Blue short
Nut 6mm for square hole in rack
1.2 m
1 pcs
8 pcs
4 pcs
Screw PAN M6X16 A4 DIN 85
For fixing the battery shelf
4 pcs
Screw PAN m3X8 DIN 7985 zinc
For fastening the MCB to the bracket
4 pcs
Screw M5x10 TAPTITE TORX pan tx25
For fixing MCB cover
1 pcs
LOCK WASHER M5 DIN 137B zinc
1 pcs
Battery shelf
1 pcs
Cover for Batteryfuse Outdoor cab.
1 pcs
Valid Option Guide, Kit for 1 battery string + Outdoor shelf Art. No 351412.033, v3 11-2004
Battery
cables
Positive
connection
clamp
Negative
connection
clamp
Alarm
wire
Battery
MCB
Outdoor
Battery
shelf
Recommended tools
Standard equipment for use by an authorized electrician. NOTE: All tools have to be insulated.
Installation
Installation must be done by authorized personnel only.
Eltek Energy recommends that the system is powered down before installation of the kit.
Step Description
Comment
OK
1
Position battery shelf in the Make sure that the distance to the next shelf is
cabinet
large enough the fit the batteries.
2
Fasten the shelf with the
screws.
3
Fit the MCB into the MCB The holder is situated on the left side of the
holder.
cabinet.
MCB
holder
Verify that the MCB is in

OFF position
Connect the alarm wires to

the MCB. Use the C
(common) and NO
(normally open) alarm
connection points.
If there is more than one battery string in the

system the MCB alarms must be connected in
series.
MCU
MCU
MCU
Move
wire
from 2
to 4
2 (NO)
Connect
wire
between
3 and 2
2 (NO)
Multiple battery
strings
1-4
Prewired cables
Kit wire
Additional
battery banks
Connection
points
MCU
MCB
6
Connect the negative

battery cables
Place the batteries on the

shelf
Connect the single insulated negative battery

cable (blue) to the bottom of the MCB. Draw out
the cable up through the back of the cabinet. Cut
the cable to length if needed. Connect the cable to
the negative bus bar with the 35mm cable clamp.
Connect the double insulated negative cable
(blue) to the top of the MCB
Loosen the screws to the battery fixing
mechanism and
Battery fixing
pull the battery
mechanism
stopper as far as
possible to you.
Place the
batteries on the
shelf, push the
battery fixing
mechanism until it holds the batteries tightly and
fasten the screws.
Connect the positive

battery cable.
Connect to battery
terminals
10
10
Install the MCB cover

Power Up the system
Place the positive battery cable (black) up

through the back of the cabinet and fasten it. Cut
the cable to the right length if needed. Use the
70mm clamp to connect the positive cable to the
positive bus bar.
Connect the positive cable to the positive battery
pole. Then connect the double insulated negative
cable from the MCB to the negative battery pole..
Repeat installation for all battery strings before
you Power Up the system.
Before turning on the battery MCBs, measure the
battery voltage and adjust the system output
voltage to this level. For details see Flatpack
MCU operation Guide with Art. No. 351300.013.
Turn on the battery MCBs and increase the
system output 2 volts every minute until you have
reached the wanted value.
Alarm wire C
Battery MCB
Double insulated
negative battery
cable
Single insulated
negative battery
cable
Alarm wire NO
Positive bus
bar clamp
Negative bus
bar clamp
Positive bus
bar
Negative bus
bar (Battery)
Ordering information
Part Number
104672
Description
Kit for 1 Battery bank + shelf outd
The Kit is suited for the Flatpack PRSB 15kW, 48 V, Outdoor Site Power Cabinet system,
both Air Condition and Fan cooled.
ELTEK Energy
P-O- BOX 2340 Stms
N-3003 DRAMMEN
NORWAY
Phone:
Telefax:
Internet:
+4732203200
+47 32203210
http://www.eltekenergy.com
e-mail:
eltek@eltekenergy.com

PRSB 15kW Outdoor Instalation Guide

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Installation Guide

PRSB 15kW, 48VDC

Copyright : Eltek Energy AS, Norway 2004

EN61000-6-2 Industrial Environment

LVD73/23/EEC Low Voltage Directive

Certificate no: 900005Q

Certificate no: 900005E

Art. No. 351405.033

Issue 3, 2004 November

Flatpack PRSB 15kW, 48VDC

OVERVIEW GENERAL ARRANGEMENT

INPUT AND DISTRIBUTION ARRANGEMENT

DC DISTRIBUTION AND LVBD DEVICE

MONITORING, CONTROL AND SIGNAL INTERFACE

UNPACKING AND MECHANICAL INSTALLATION

RECTIFIER INSTALLATION MAINS SUPPLY EFFECT BALANCING

RECTIFIER INSTALLATION HANDLES AND LOCKING MECHANISM

3 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS

CONNECTIONS FOR INTERNAL SYSTEM WIRING

CONNECTIONS GMT FUSES

4 SPECIFICATIONS FLATPACK PRSB 15KW, 48VDC, FAN COOLED

5 APPENDIX: SCHEMATICS, DRAWINGS, FIGURES, ETC.

GENERAL ARRANGEMENT DRAWING

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

ON SITE DOOR REMOVAL OUTDOOR CABINET, FAN COOLED

Description of Flatpack PRSB 15kW, 48VDC

Overview General Arrangement

Heater MCB (AC).

LTE Distribution, MCBs

Battery strings. The top

PRSB = Power Rack System with Batteries

Input and Distribution Arrangement

+ve DC Load Terminals

Flatpack 1500 rectifier

MCU Ctrl. Unit, and

Figure 2 Location of components in

Labels on internal wires

AC Input Feed Sizing

(Recommended AC Breaker Rating and Min. Wire Size)

Internal Wire Connections

Internal Wire Connections

To connect your system to

DC Distribution and LVBD device

Monitoring, Control and Signal Interface

Relay outputs, 6 pcs

The equipment described in this manual must only be

The equipment represents an energy hazard and failure

There are hazardous voltages inside the rectifier system.

Products into which our components are incorporated

Please read the manual carefully before using the

Unpacking and Mechanical Installation

1 TAKE THE FLATPACK POWER

Inspect the unit for any physical or transit

3 POSITION THE CABINET

4 BOLT THE CABINET

The Drilling Template with instructions is located

The AC Earth (PE) and DC Earth (TE) terminals are

Connect the AC cables, max. 35sq mm(AWG 2), to the

Figure 2.- page 5.

Turn OFF the Load/BTS MCBs.

Art. No. 351405.033, v32004-11

Rectifier Installation Mains Supply Balancing Effect

Rectifier mounting order to load the mains supply evenly.