Installation Guide Flatpack2 PS System DC Power Supply System, 16kW, 48VDC Outdoor 2.0m Fan Cooled Cabinet 951476.0331 Welcome Table of Contents 1, Welcome ‘About this Guide Location of Components ~ General Arrangement. External AC Fuses ~ Recommended Ratings Mains Reconfiguration ~ AC Terminal Block .. Terminals & Pin-out Location, GMT Fuses. Alarm Relays & Digital Inputs Terminals & Pin-out Location, Alarm Interface Card Terminals & Pin-out Location, System Interface Card. LVD Latching Contactors... Monitoring, Control and Signal nterfac ‘System Monitoring . Fan and Heater Operatior 10 System Specification 3.__Installation Safety Precautions. General Safety Precautions Electrical Safety Mechanical Safety... Battery Safety Installing the Modules. Mounting or Removing Smartpack and Flatpack2 Modul Mounting and Removing Blind Panels Correct Rectifier Position in Power Sheives .. ‘System Installation. Site Preparation Mechanical installation... Electrical installation 4. Commissioning Pre-Start Check Commissioning Steps, Startup ‘Startup and No-Load Adjustment Load Adjustments 5.__Maintenance Replacement of Door Filter Replacement of Fan Filter... 6. Forms, Schematics & Drawings Installation Check List Commissioning Procedure... Maintenance Procedure General Arrangement Seariooul> ala Cabinets Neoprene Mat Table, Dring Template, Plinth’ fastening hoes 28 Cabinet Clearance Drawing. 28 System Schematic Drawing... 28 Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m ...28 Load Distribution List.. Insatation Guide Fatpeck2 PS System, 16K, 48VDC, Oukioor20m Fan Cooled Cabinet imanuare ~2 System Description Location of Components ~ General Arrangement Battery DC (+) terminals ‘Bus bar, 35mm2, AWG 2 DE (+) Load Terminals Somme ANG 20 DC () Load Terminals (erSvcee) Senn, AWG 4, 70mm’, AWG 20 {omtep'of each ioad breakon Battery DC (-) terminals Bus bar, Somm2, AWG 2 Terminals for GMT 19A Load Fuses, Se AWG 16 . Smanpeckconroter aterm terminate ie Bese oS ui rear AC Earth Mains Protectve Earth (PE) ‘Connection (Cabinet main ground bar) AC Mains Terminals Ac 5S AUXAC MCB (heater, AC socket, air-conditioner) ™ Figure 1 General Door Filter Outlet ——- Arrangement Flatpack2 PS System, 16kW, Fan Filter Inlet 48V0C, OCab, Fanc 2.0m Battery strings and fuses in the lower part of the cabinet Instatation Guide Fietpack? PS System, 16K, 48VDC, Outdoor 2.0m Fen Gooled Cabinet sstraoss v4z00782 System Description Terminals & Pin-out Location, GMT Fuses GMT fuses Max. 10A each — FS Figure 2. GMT fuse board (max. cable size 1.5mm’, AWG 16) ‘The table below shows the pin-out location for the GMT load fuse card: Pin Assignment for GMT Fuse rae Signal Function inal Function, + GRIT fuse 1 (FS) + “GAT fuse 5 (FB) = GRIT fase 2 (FS) + GHT fase 6 (FIO) + GMT fuse 3 (F7) + GMT fase 7 (Fi) + “Gri fase 4 (FB) + GMT fase 8 (Fi2) = = (fan fuse) Alarm Relays & Digital Inputs ‘The alarm outputs in Flatpack2 systems use the Fail-Safe Operation Mode (relay colls energized in the system’s normal operation mode). When the system Is in alarm mode, the alarm relay coils are de-energized, The figure shows the position of the relay contacts when the relay coils are de-energized (PS system in alarm mode) ‘Alarm Relays & Digital Inputs apis n a BOW (resistive load) _ Maximum switching power 220v0C | Madam swiching vonage | 2ADC Maximum switching curent "oman | ‘rmgaes co) In order to implement monitored fail-safe 75 am tote digital inputs circuits, the external relay coil weep must be energized and the contacts closed in the system’s normal mode of operation. frapct2 8 ya C Us Digital Inputs (example) Instaation Guide Flatpack2 PS System, 16K, 48VDC, Outdoor 20m Fan Cooled Cable astro v.05 72 System Description Terminals & Pin-out Location, System Interface Card Flatpack2 systems are shipped from factory with the CONS signals already connected. Some of the Smartpack controller's Internal system signals are accessible on D-Sub connector CONS, on the controller’s rear panel. Using the System Interface Card (Art. 200625) and a standard 15 pins D-Sub cable, the signals on CONS may be accessible at any suitable location inside your system. For detailed information about the card's pin-out location and terminal block connections, refer to the figures in this section. For Internal Use Only! ioral Canetti) JP1 and JP2 are used to configure the system for Negative DC distribution (48 and GOV systems) or Positive DC distribution (24V systems) LVD Latching Contactors Flatpack2 systems’ LVBD and LVLD' functionality is implemented by the Smartpack controlling magnetically latching contactors. Latching Contactors, LVD1 & LVD2 Taiching contador changes late ony when toversed pulse vatage lapped ffs sor 1 Oe we + Puse Puise The bidretonal ce “run aways, be ‘mounted fo avoo” dane sarge cone Bidirectional diode x Latching Contactor L _filtpeck2 PS System (i Correct Use of Latching Contactors (example) | The coll of latching contactors Is not energized in any state. They change state from open to close, or vice versa, when a reversed pulse is applied to the coll. §LvBb, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect Insalaion Guide Faipack2 PS System, 16K, 48VDC, Outdoor 2.0m Fan Cooled Cabinet ssurecs oan03 92 System Description Technical Specification ae Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m. 9 nner Te eae piste 5 (2 eres re a poe Beene eaten aga oad aa ean connections ‘cable, 70mm? cable clamps 3 phase 208VAC ( 4) ‘Common positive bus bar, 70mm? 3 phase 230VAC (4) cable clamps. — pesos ce ese Lr pase eget ‘Maximum ‘See Flatpack2 48VDC datasheet INo. of DC Load Up to 4 x 3pole 150A Current. (241115.001.0S3) breakers oe SE Ree ey —|Up wo 4x 150K MOBs moun TORTS (Optional Neutral - spark gap. breakers. ‘each battery shelf Sear att rea hses— [Stok eT pe =< type Re ao eee eS ia SO eee SN mS rar ee ‘local operation | Menu driven software via Keypads 1.5 KVAC - input earth and LCD, USB or PC (PowerSuite) 1,0 KVDC - output earth. Remote operation | PowerSuite via modem or Web ‘Operating temp 40 to +50°C (-40 to +122°F) *** oats Sot cae Sees — [ape saee Gane naan sama —— ana Ser ae Ae eae rn DA GOS aan aon [Crean teo Sysen OF ee [eee eer Weight Gablaeks 180 kg 6xC. optional BIAEh, See we sem) reine atau 1p eer ot rasan oy [BaRaTapIE —| Star Sane eal meen ene soustes es” 250 ke wees ae caren measurements Rectifier current ES ees ecuieces Sa ae oes a 1 oes Senate sen ei PS ea 300 36 TacommaTToR Low Battery Voltage network) eae ae mee, 3 (ematon, tit ‘Temperature alarm industry) ee Ce 2 cmmunty, industry) Pesaro cavrsamen Test en sao ates Sen Bret anaop on Te eae as complant ‘5% Note that the cabinet’s operating temperature range does not apply to batteries. Refer to the manual for used batteries. om CCT Nominal 230 275 | Full ouput power ange: Tas — 275 | Full output power 275 =300 | Full power, reduced poner BEOe ow volage- i [0-85 | Shutdown. "300 = 350-| shutdown ow voltage 2 | @5 — 165 | Lear between SSOW and 7O00W. '350-- 420-| Shutdown™ (gee note below) + Note: If te input voltage > 300VaC the recifir wil go into self protective mode. AE no load, the recter wil survive 350vec. With Toad cor battery connected, ell survive 420VaC Specifications are subject to change without notice Inston Guide Flatpeck2 PS System, 16k, 48VDC, Outdoor 2.0m Fan Cooled Cabinet stra. w0rc0 11eagoeaa 3 Installation General Safety Precautions Please read and follow all safety instructions or warnings before installing or maintaining the power system. Review any supporting documentation regarding the power system and its components prior to installation. “The enclosure must be installed, serviced, maintained, and operated by a qualified technician who is familar with electrical wiring, electrical equipment, and enclosure deployment techniques and best practices for safety “The enclosure must remain locked at all times, except when authorized service personnel are present Remove all conductive jewelry or personal equipment prior to servicing equipment, parts, connectors, wiring, or batteries Read and follow all instalation, equipment grounding, usage, and service instructions included in this manual Use proper lifting techniques whenever handling the enclosure, equipment, parts, or batteries Do not rol the cabinets on their sides Do not store anything on top of the cabinet Electrical Safety Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical ‘connection or conductor is not energized. Check the circuit with a volt meter with respect to the ‘grounded portion of the enclesure (both AC and DC) prior to any installation or removal procedure ‘An external electrical service disconnect must be used that is properly sized as required by the NEC ‘andor local codes. ‘The supply neutral conductor must be bonded to earth ground at the disconnect panel Do not work alone under hazardous conditions A licensed electrician is required to install permanently wired equipment Ensure that utility power is disabled before beginning instalation or removal Ensure no liquids or wet clothes contact internal components Hazardous electrically live parts inside the enclosure are energized by batteries even when the AC input power Is disconnected. Make sure the power is removed via the battery disconnect breaker before Servicing any of the equipment ‘The internal equipment may be powered by AC circuits. Make sure power is removed via the appropriate breaker before servicing any of the equipment Prior to installation, verify that the AC Input voltage to the enclosure and its equipment with respect to voltage and frequency Prior to installation, verity that the output voltage from the enclosure or its equipment match the voltage requirements of the connected equipment loads Prior to installation, verify that the enclosure’s utlity service panel is equipped with a properly rated Creuit breaker for use with the equipment inside. Refer to the manufacturer's recommendations. Prior to installation, contact local utlites, local building maintenance departments, and cable/piping locating services to ensure that installation does not interfere with existing utlities or building cables/piping Fuses/circult breakers may not be provided with the equipment. Refer to the documentation for the proper hardware. Use only the parts specified in the documentation. Installing fuses or circuit breakers not specified for use inthis equipment may result in injury to service personnel or equipment damage ‘Where required for installations in the United States or Canada, use listed/certified compression ‘connectors to terminate listed/certfied fleld-Intalled conductors. If the proper connector for the country of installation is not provided, obtain the appropriate connectors and follow all manufacturer and local requirements for proper connections ‘Torque the electrical connections to the values specified on labels or in the product documentation “The DC distribution is considered a Safety Extra Low Voltage (SEL V) with the return side connected to the chassis (earth ground) inside the enclosure ‘The supply neutral conductor must be grounded at the external service supply disconnect panel Insiaton Guide Fspeck2 PS System, 16K, 48VDC, Outdoor 2.0m Fan Cooled Cabinet ses wezor Output Test) 10.Make sure the System Setup is in accordance with configuration © Verify system settings using the controller's front keys or via PowerSuite Use the opportunity to enter site related information, number of used AC phases, type of batteries, etc. Load Adjustments power 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: 11.Adjust DC output voltage to equal measured battery voltage © Measure the battery voltage is within range (check connections have correct polarity) 0 Adjust DC output voltage — using the controller's front keys or via g PowerSuite— to equal the measured battery voltage. faced (Important adjustment to avoid arcing when connecting the batteries) 12.Unplug all rectifiers but one, and connect the battery fuses /MCBs (CAUTION: Have only one rectifier connected, when switching ON the battery a& fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity Seep. connections, etc.) hazard ‘© 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 © Switch ON all battery fuses or MCBS 13.Adjust DC output voltage again to equal the nominal battery voltage © 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) 14.Plug in again all rectifiers, and verify the rectifiers’ current sharing ‘© Connect all rectifiers again by pushing them firmly inwards — Repeat step 4, in stage II © 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 i acceptable. 15.Connect the load breakers and verify that no al ‘© Switch ON all load MCBs/ fuses ©. Verify correct operation: rectifiers and controller display no alarms ms are displayed Inston Guide Faipack2 PS System, 16K, 48VDC, Outdoor 2.0m Fen Cooled Cabinet sswrsas, zt 255 Maintenance Replacement of Door Filter ‘Stop ‘Ketion OK 1. Remove Refer to “Figure 3 Location of the cabinet’s door filter and fan filter filter”, on page 26. Remove the Air baffle plate(s) that cover the filter grid on the inside of the cabinet door (plates not shown in Figure 3). o Remove the filter grid by loosening the screws around it. Pull the grid towards you when loose 2. ‘© Exchange the old filter with a new. Make sure that the rough side of the filter faces the inside of the cabinet 3. Mount the o Mount the grid to the door again, fastening the screws around frame it © Mount the Air baffle plate(s) back on again and tighten the screws Replacement of Fan Filter ‘Step Comments: OK. 1. Disconnect co Remove the fan fuse, the fan located at the GMT fuse card (fuse 8). Refer to “Terminals & Pin-out Location, GMT Fuses” on page 7 2. Open the Fan | Refer to "Figure 3 Location of the cabinet’s door filter and fan Filter Door filter”, on page 26. © Open the fan filter door by turning the two knobs on the door (upper and lower right side) 3. Remove the co Remove the filter grid filter grid by loosening the screws around it. Pull the grid towards you when loose (4. Exchange the | © Exchange the old filter with a new. Make sure that the filter smooth side of the filter faces the inside of the cabinet 5. Mountthe | o Mount the grid again, fastening the screws around it |" gria 6. Close the Fan © Close the fan filter door, and turn the knobs closed L Filter door 7. Connect the o Replace the fan fuse, and verify that the system is fan operating normally instalation Guide Flatpack2 PS System, 16kW, 48VDC, Outdoor 2.0m Fan Cooled Cabhet ssracs, 200708 27ae rege cevce Racers Blectie shock eleoe ‘shook INSTALLATION CHECK LIST System Data Flatpack2 PS System Flapack2 Powe Sophy Se, WP RN: Sie rae Sean: Sars, varsen Ne Recto, ype aber ‘Cog Vee, asirod | Baa Typa any Copy | aaa aod cub, nae Snaaaenn 4. Organize the installation site Site Preparations Power is OFF! os a 2. Prepare the installation tools a 3. Prepare AC Supply: AC input cable(s) and fuses: a Craiacees ‘4. Remove packaging and check equipment Mechanical Installation Power is OFF! En o 6. Use the Neoprene Mat a 6. Position and fasten the cabinet QO 7. Mount the batteries on the shelves © Donot terminate the battery cables yet! 2 Do not remove the Condensation Stopper! o ‘8. Make the system completely voltage free Electrical Installation Poweris OFF! ‘9. Open the cabinet’s roof 10. insert the cables 11. AC Conne ‘2 Cheak AC configuration: The AC terminals are coect contigured tothe extemal AC supply © Connect the AC Earth wire (PE) to the terminals AC Earth (PE) ‘2 Connect the AG input cabl(s) io the terminals. Cable and ternal block labeling are to corespond 12. AC Socket Connection 13. DC Connections — Load Circuits ‘3 ” Terminate DC Earth (TE): Common OC Output Rallis connected to TE at only one place © Fareach DC foad, connect one ofthe cables tothe common DC output ral, andthe oh directly tothe MCB Terminate the GMT load creuts 14. DC Connections — Alarm & Signal Circuits 18. DC Connections — Battery Cables Careful! Use correct polarity. For each battery set, ‘2 Mount 3infercellinks to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks) © Connect battery cables to fuses and common DC ral, and tothe sheits outer ternal; black (¥; blue () ‘2 Connect the temperature sensor cable, apiicable othe D-Sub plug or input terminal, and fix the sensr (atthe tend ofthe cable) toa suitable place Inthe midal ofthe installed battery bank qo ao aqgga ‘Approval esponnbi of raaaion, 39h ae Teproed esi Sp Inetaaton Guide Flatpack2 PS System, 16HW, 48VDC, Outdoor 2.0m Fan Cooled Cabhet ssuraoss 2038 29COMMISSIONING PROCEDURE ‘System Data Flatpack2 PS System Soopers Oe No Fuck Pner Sppy Sten Woe Tie Sie rane Sa Saar en Ne Rosie ype Enbor o TC pd Vane, weasel Tala Tipe =o Canta earnOT OY, TaN Pre-Start Check Powers OFF Cena ‘OK 1. Flatpack2 system installation is completed; The Fistpack? nsiataion Check Lists ed |] \ ‘Ai cabling is securely terminated with corect polarity couse [2 Allbattery and load MCBs/ fuses are disconnected o Razord 3. AC input cable(6) and AC earth wire (PE) are terminated o 4. Site specific parameters and settings are known o 5. AC supply and all MCBs/ fuses are switched OFF Oo paral No-Load & Load Adjustments Power ON! 1. Disconnect all rectifier modules, without removing them (keep original location) Oo Sage [ % Remove the Condensation Stopper oO sazard 3. Switch ON the system (external AC fuses ON) oO 4. AC input voltage is correct, Measure and verty | %. Insert all Flatpack2 rectifiers in their original locations in the power shelves oO 6. The Smaripack and all rectifier modules are working, LEDs are ON; veaty | 7. Connect a PC to the PS system instal the PowerSute sofware, fvequred | [-] &. DC output votage; Measure and agust | [J 9. Alarm relay test, ‘erty al alarm eays are woringcoreety | [] 17 [40. System Setup is in accordance with configuration Enter ste epee intoin PowerSute | [7] Jp | 44. Adjust DC output voltage to equal measured battery voltage ‘Check conect planiy’ |] ber | 12. Unplug all rectifiers but one, and connect all battery fuses/ MCBs oO Racers 13. Adjust DC output voltage to equal nominal battery or load voltage Oo 14, Plug in again all rectifiers, and verify the rectifiers’ current sharing Oo 16. Connect all load MCBs/ fuses, and verify no alarms are displayed Oo Approval Response aaa Da apoyo Inetaaton Guide Fltpeck2 PS System, 16KW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet sox 23 31MAINTENANCE PROCEDURE [Eltek] System Data Flatpack2 PS System Fett? Powe Spey SSW Taio: a name, Sao ‘Sars wea: Recto, ype bar ok Tp Vala, messes | Baio Type Baty Caper, | Martane cared onan 4 ‘equipment is only to be performed by authorized and eerie a Hazardous voltages inside may cause terminal injury. shock me System Inspection Power is ON! Enausaseeict 7 ‘1. Site specific parameters and settings are known. ‘User manuals and site specie connection & arrangement crawings are avaiable. 2. The battery bank has been fully charged in advance. ‘Aleaa! for #2 hours since sta-up of mans fare. Enebles correct measurements & calration ry 3. The equipment and door fiers are free from damage, dust or dit; very Carefully vacuum clean or remove any accumuation of dust, cortosion or dit, Perform iter maintenance. “4. All cabling and copper bars are securely terminated and supported. Correct any loose cannectons, excessive cable temperature, defective insulation, etc. 5. The Smartpack & all rectifier modules are ON, no alarm present: verity (Otherwise, comect and put the PS system in normal mode of operation. 6. All rectifiers functionality & Smartpack’s keys and display work OK; verify Correct possible abnormalities before contruing 7. Connect the PS system fo a PC (install the PowerSuite application if required) “The PowerSuite program in the PC enables systam cariguration from the PC. 8. Rectifiers’ load current sharing, verify. Use the PowerSuite PC application fo check al rectifiers output the Same amount of cuent (21) ‘9. Display the stored log of Alarm Messages. Using the Keypad on the Sarak controller or rom the PC. qogqq ga Qa o System Adjustment eee ee 11. DC Output Voltage Calibration; ensure correct display readings. Hf measured DC output voltage atthe loa terminals deviates more than +1% from the display reading, callbrate the ‘output voltage from the Smertpack’s keypad othe PC. 2. Load & Battery Current Calibration; verify correct display read ‘Measure with a clip-on ammeter the batiery current & avery load cuit current. Calcite the total load & battery current. I the calculated Tol values deviate more than 1% from the display readings, callbrate the current from the PC (calioration value>50% of systems max. capacty) ‘3. DC Output Voltage Adjustment; measure and adjust, ‘Measure and, I required, adjust the cutput vliage tothe nominal voltage recommended bythe battery manufacturer. (Votage messurements io be done at the DC ral, wtn te load current) 4, Alarm Relay Test; verity all alarm relays are working correcth From the Smerfpack’s Keypad 0: PC use the Relay Test function. verify activation of extemal equipment oo og} ga '5. Battery bank control; measure and verify battery specifications. Follow the recommendations ofthe actul battery manufacture. Approval Response ofa canta Sn Dal ROO Co, TO Instatsion Guide Faipack2 PS System, 16K, 48VDC, Oudoor 2.0m Fan Cooled Cabinet ssureas, m.03 33mm. Cabinet’s Neoprene Mat Specifications DIN 53 505 ‘Shore hardness A ‘Tenste strength ss eee nS Elongation at rupture 45% DIN 53 5: ‘Dens UREN a Se RE Mass per unit area 730g/m2/mm ; Operational temperature 40 to +155°C Table 1 Neoprene Mat Specifications Note: The mat is only to be used when the cabinet is placed directly on concrete floor and a cabinet plinth is not mounted. Figure 5 Drilling Template, top Ex view of the cabinet’s bottom plate. For ge cabinet fastening directly to the floor or © toa plinth \ 75 mm 75 mm oeeeeeeeeeeneeeee £ e E EE 8 5 8 08,80. 72.59, z 2m Cabinotte-Plinth Fastening Hote (4x) ‘One hole in each comer 1.3m Cabinetto-Pint Fastening Hole (4x) ‘One ole in each comer (315,00 (575,00 } Figure 6 Cabinet's plinth, top and 3D view. Cabinet's and plinth’s fastening holes 35 Installation Guide Fatpack2 PS System, 1SkW, 48VDC, Outdoor 2.0m Fan Cooled Cabinet s1ersoxs, w.2070037 Boe men 40 Figure 8 System! Schematic Flatpack2 PS System, 16kW, 48VDC, OCab, FanC 2.0m ntalton Gude. Fateeck2 PS System, 1h, 48V0C, Outdoor 20m Fan Cold Cabinet sere 4.8System Data LOAD DISTRIBUTION LIST Fatt? PSS. We Tessa Sia rae ier Carers Pra “Optional fuses/breakers. F3 & F4 are only fitted if optional BTS breaker kit(s) are installed in the cabinet. For Pak MCB a eae ee pe ‘GMT FUSES: ai, gee chapter “eran pe beaten oi Ba oo F13-F20 are only fitted if optional LTE kit is installed in the cabinet Breakers F'1, F2 and GMT fuses F5-F12 are always part of cabinet LTE MCB" (Optional) For detass, see nsaiaion marl Tor LTE wt (351480 033) oe - Eitek Energy AS Tel, +47 3220 32.00 Internet: wn atekeneray.com E-Mail: eek @eltekeneray.com