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Quick Start Guide

Installation, Operation, Commissioning and Maintenance

Flatpack2, PS System
DC Power Supply System
Integrated, Cabinetized and Outdoor Applications

Introduction
o o

The Smartpack based Product Range (2 ) Brief System Description, Flatpack2 (2 )

Installation
o o

Installing Smartpack and Rectifier Modules ( 3) Installation steps; mechanical, electrical (4-5)

Commissioning
o o

Pre-start check (6 ) Commissioning steps, Startup

(6-7)

Operation
o o

Front keys and display Software Menus ( 8)

( 8)

Miscellaneous

Check Lists
356804.103 o o o o

Communication o CAN Bus Addressing and Termination ( 9) o Installing PowerSuite PC software ( 9) AC Mains 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) o Mains Phases vs. Rectifier ID Phase Balancing & Monitoring (16-17) Battery Monitoring o Battery Symmetry Connections ~ 48V Systems (18 ) o Battery Symmetry Connections ~ 24V Systems ( 19) o Terminals & Pin-out Location, Battery Interface Card ( 20) Alarms & Monitoring o Standard Alarm Relays & Digital Inputs Connections ( 21) o Terminals & Pin-out Location, Alarm Interface Card ( 21) Internal Connections o Terminals & Pin-out Location, System Interface Card (22 ) o LVD Latching Contactors Connections (22 ) Flatpack2 Integrated System, 2U o Location of Major Components ( 23)
pullout forms

Installation Check List Circuit Distribution List Commissioning Procedure Maintenance Procedure

Introduction
The Smartpack based Product Range
Eltek Energy'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 Distributions

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 PowerSuite Application Remote Monitoring Smartpack ctrl. unit
USB cable

Flatpack2 Cabinetized

Fuse Alarm

CAN Bus

Flatpack2 rectifiers LVLD Telecom equipment

AC Fuses, external (230VAC or 400VAC

AC mains supply selector Symmetry Alarm & Temp. Sensor LVBD Load Fuses & MCBs DC distribution DC Supply (24V, 48V or 60V*)
*Available from 2007

AC Supply (Single- or three-phase)

Battery string #1

Battery Fuses

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.

Quick Start Guide Flatpack2 PS System

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Installation
Installing Smartpack and Rectifier Modules
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

Mounting or Removing Smartpack and Flatpack2 Modules Note that cables are plugged to the Smartpacks rear panel. When mounting the controller, you must plug the cables before step 2. When removing it, unplug the cables during step 2.
Smartpack controller

Hole to release the handles spring mechanism

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 proper contact (for Smartpack, plug cables first) or 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
Electric shock

Handle in locked position


Flatpack2 rectifier

Handle in unlocked position

Removing Blind Panels 1. Release the panels upper left and right corners by Screwdriver to inserting a small screwdriver into the panels upper left gap and release the locking carefully press down and out to release the locking tabs. Repeat tabs on the upper right gap. 2. Remove the blind panel by using you hand to pull the panel loose

Blind panels upper locking tabs

Mounting Blind Panels 1. Insert the panels upper edge by pressing gently so that its upper locking tabs engage 2. Lock the panels lower edge by pressing with your hand so that the blind panels lower tabs lock into position.

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Installation
Installation Steps
Check off in the Installation Check List, that you find in the pullout section of this folder. Also, refer to the systems specific drawings.
Preparing the Installation Site
200 mm

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) Prepare the installation tools o Use insulated tools suitable for telecom installations 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

EMC regard

2
600 mm

For external AC fuses and AC input cable ratings, refer to your sites 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!

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. Device o Inspect the equipment for physical damage (report any damages) hazard o Leave rectifier modules in their packaging or in the selves, if factory installed. To be installed under commissioning 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 7 Mount the batteries on the shelves o Start (if applicable) placing the batteries on the lower shelf first, and continue upwards Electric shock o Do not terminate the battery cables yet!

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Installation

Electrical Installation

Power is OFF!

Carry out the following: (Refer to the systems specific drawings)


General Torque
Recommended Ratings, FP2 Systems Application, Torque Type & Size (Nm) Circuit Breakers SIEMENS 18 mm, 5SX2, 5SX5 3.5 SIEMENS 27 mm, 5.0 5SX6, 5SX7, 5SP4 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

Link 2 (DC Earth) Battery Fuse EG

Chassis Common DC Rail

Card Art.200576 2-1 15 pins D-Sub


(male)

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 o Check AC configuration: the AC terminals are correct configured to the external AC supply, otherwise reconfigure the terminals o Connect the AC Earth wire (PE) to the terminals AC Earth (PE) o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond 10 DC Connections Load Circuits o 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 o 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 o Refer to your systems connection drawings and configuration, or to the Miscellaneous, Alarms & Monitoring section (Factory Settings) o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output terminals 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 guides Miscellaneous section. For each battery shelf:
(In cabinetized systems, steps b, d and f are usually performed in factory)

Electric shock

Temp. Sensor cable 1

a b-c d-e
Temp. sensor

Battery Cable

f-g

(-48V) Outer Terminal

- + - + - + - +
Block1 Block3 Block4

Mount 3 intercell links to connect in series 4 battery blocks Connect battery cables to fuses and common DC rail, and to the shelfs outer terminals; black (+); blue (-) 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 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

Symmetry 1

Intercell Links

+
0V Outer Terminal
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Quick Start Guide Flatpack2 PS System

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

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: 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

Device hazard

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!

Device hazard

1. Disconnect all rectifier modules, without removing them (keep original location) 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 cabinets mains connection box o Verify the AC voltage is within range

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Commissioning
4. Mount all Flatpack2 rectifier modules in the power shelves (keep original location) 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 controllers 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 controllers front keys or via PowerSuite 8. Verify the alarm relays are working correctly (alarm relay test) o Run the alarm relay test using the controllers 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 controllers 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 controllers 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.) 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

Device hazard

Device hazard

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

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Operation
Front Keys and display, menus, etc.
Graphical Display
16 char. x 2 lines LCD display

Alarm
LED Lamp (red)

Warning
LED Lamp (yellow)

Warning
LED Lamp (yellow)

Power
LED Lamp (green)

Alarm
LED Lamp (red)

Enter key Up arrow key Down arrow key


Smartpack control unit

Power
LED Lamp (green)

USB
0ype B port
Flatpack2 rectifier

Smartpack Control Unit front keys, display, etc Display: is in Status Mode (displays the systems status) or in Menu Mode (displays the menu structure). key to change from Operation: Press on the or Status Mode to Menu Mode. Press the 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.

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
AlarmReset

Level 3

Level 2

Level 3

User menu <UserOption>


NomVolt BoostVolt LoBattMaj LoBattMin HiBattMaj HiBattMin LVBD LVLD 1.1 Message

Service menu <ServiceOption>


NomVolt BoostVolt LoBattMaj LoBattMin HiBattMaj HiBattMin LVBD LVLD 1.1 VoltCal Password

VoltAdjustment
Firmware 402073.003 1v00 Smartpack, Distributed

Firmware 402073.003 1v00 Smartpack, Distributed

VoltageInfo

Software Menus

DisplayMessages SoftwareInfo SerialNumber

VoltCalibration ChangePassword SetManBoostTime Start/StopBoost Auto Boost Conf. Batt Test Setup Start/Stop Test NoOfRects. ; nn Charge Curr Lim. Battery Setup Output Control Change Date/Time RelayTest

Rectifier Info

NoOfRects. nn RectCurrent RectSerialNumber Rect.PrimaryVolt Rectifier Status Rectifier Temp Rect. OutputVolt Rectifier SW Ver NoOfPhases nn Mains Status Mains Voltage Level NoOfString Nn BattStringCurr BattStringTemp BattBlockVolt

Enable/Disable & Threshold Nxt Test DateTime Date Time End Volt MaxTestDur Test Int Guard Time Reset Enable/Disable & Max NumOfString CellCap Ah nn VoltageCtrl / TempComp Date Time Alarm Output 1 Alarm Output 2 Batt Contactor Load Contactor Alarm Output nn

Mains Info Temp Level Info

Battery Info

BattLifeTime Rst

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Communication

Miscellaneous

CAN Bus Addressing and Termination


Flatpack2 systems are shipped from factory with the CAN bus already terminated with 120 resistors.
USB A-B cable (standard)
1 End-of-Line Resistor

CAN bus (twisted-pair internal CAT5 cable)

120
End-of-Line Resistor

120 Flatpack2 DC Power System


01 02 n

To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120 resistors, one at each end of the line (60 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 Smartpacks ID numbers (1, 2) are assigned by DIP switches on the controllers side.
Controller ID DIP Switch Position # 1 2 3 4 Master 1 OFFOFFOFFOFF Slave 1 2 ONOFFOFFOFF Slave 2 3 OFF ONOFFOFF Slave 3 4 ON ONOFFOFF Note that the controllers ID # corresponds to the DIP switchs binary value plus one. 120
End-of-Line Resistor

CAN bus Addressing Elteks CAN bus may address a maximum of 60 nodes. Among them, you may connect a maximum of 8 Smartpack controllers and or 50 rectifiers.

Master controller DIP switch configuration

Alarm Outputs NC-C-NO Digital Inputs

Slave controller DIP switch configuration

Alarm Outputs NC-C-NO Digital Inputs

ID <2> ID <1>
(All switches OFF) 1 End-of-Line Resistor (Switch #1 ON, the rest OFF) Smartpack controller Master 2 Smartpack controller Slave 1

120 Flatpack2 DC Power System


01 02 3 4 n n+1 n+2 m

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. Install PowerSuite Insert the CD in your PC drive, start the PowerSuite installation and follow & accept the wizard default steps 2. Switch Smartpack ON and plug USB cable (Part 202073) to Smartpack and to any available USB port in the PC

1 2

New hardware is ready to use

3. Wait for Windows to install USB drivers Follow & accept the wizard default steps to automatically install the USB drivers; the wizard runs twice 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). PowerSuites newest version is always available on our FTP server. Call your Elteks contact person.

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Miscellaneous
External AC Fuses Recommended Rating
4 AC inputs per shelf, each feeding 1 rectifier

AC Mains

4AC Power Shelves

205VAC Inputs

The sites AC supply quality is of great importance. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.

AC Mains Type

No of Power Shelves

400VAC +N 3 phase 230VAC 3 phase 230VAC 1 phase

1 2 1 2 1 2

Current Max. (A) 2000W Rect. 22.1 33.1 29.2 57.3 44.1 88.2

Ext. Fuse Type

25A-D 40A-C 32A-D 63A-C 50A-C 100A-C

2 AC inputs per shelf, each feeding 2 rectifiers

2AC Power Shelves

AC Mains Type

No of Power Shelves

230VAC 3 phase 230VAC 1 phase 1 2

OR
If you are unsure or know that the voltage may drop below 205VAC use the 185VAC table recommendations.

1 2 3

58.3 76.4 44.1 88.2

AC Mains Type

No of Power Shelves

185VAC Inputs

For installations in USA and Canada only


For external fuses above 50A, only the high current
backplane can be used

400VAC +N 3 phase 230VAC 3 phase 230VAC 1 phase

1 2 1 2 1 2

Current Max. (A) 2000W Rect. 24.4 36.7 32.3 63.5 48.9 97.7

Ext. Fuse Type

25A-D 40A-C 40A-C 80A-C 50A-C 100A-C

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

2 AC inputs per shelf, each feeding 2 rectifiers

2AC Power Shelves

AC Mains Type

No of Power Shelves

400VAC +N 3 phase 230VAC 3 phase 230VAC 1 phase

1 2 3 4 1 2 3 1 2

Current Max. (A) 2000W Rect. 24.4 48.9 48.9 73.3 42.3 64.6 84.6 48.9 97.7

Ext. Fuse Type

External AC Input Wires Recommended Ratings


Current Wire Section Max. (A) (mm2) (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

25A-D 50A-C 50A-C 80A-C 50A-C 80A-C 100A-C 50A-C 100A-C

1AC Feed to 1 Rectifier

External AC Fuses
Recommended Ratings 1AC Feed to 1 Flatpack2 rectifier AC Mains Type Ext. Fuse Type FS=I FS=0

FS=I (Fuse Selectivity: Internal) which means that the Flatpack2 rectifiers internal 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.

185VAC 205VAC

25A-D 25A-D

13A-B 10A-B

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

10

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Only difference between the 205 and the 185VAC recommendation tables

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

400VAC +N 3 phase

1 2 3 4

Current Max. (A) 2000W Rect. 22.1 44.1 44.1 66.1 38.2

Ext. Fuse Type

25A-D 50A-C 50A-C 80A-C 40A-C 63A-C 80A-C 50A-C 100A-C

4 AC inputs per shelf, each feeding 1 rectifier

4AC Power Shelves

AC Mains

Miscellaneous

Identifying Power Shelves, 4AC or 2AC


Flatpack2 rectifiers are accommodated in one or several power shelves. Two types of power shelves are available: Flatpack2 System, 1U DC Distr. 4AC Power Shelves, or single AC feed (4 AC inputs per shelf, each feeding 1 rectifier) 4AC Power Shelves 2AC Power Shelves, or dual AC feed Power Shelf (2 AC inputs per shelf, each feeding 2 (rear view) rectifiers) AC Mains & PE terminals You can identify the type of power shelves used by your system by reading the shelfs label, or by looking at the shape of the shelfs AC mains terminals, at its rear. (Also 2AC Power Shelves viewable by removing the rectifier in the shelfs 4th position)

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 shelfs 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.

Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

Mains Three-phase & N, 400VAC L1 L2 L3 N PE

Mains Three-phase, 230VAC L1 L2 L3

Mains One-phase, 230VAC L (L1) N (L2) PE

4AC Power Shelves

PE(CON12) L1(CON11) L2(CON10) PE(CON15) L1(CON14) L2(CON13) PE(CON18) L1(CON17) L2(CON16) PE(CON21) L1(CON20) L2(CON19)

PE(CON12) L1(CON11) L2(CON10) PE(CON15) L1(CON14) L2(CON13) PE(CON18) L1(CON17) L2(CON16) PE(CON21) L1(CON20) L2(CON19)

PE(CON12) L1(CON11) L2(CON10) PE(CON15) L1(CON14) L2(CON13) PE(CON18) L1(CON17) L2(CON16) PE(CON21) L1(CON20) L2(CON19)

Mains Three-phase & N, 400VAC L1 L2 L3 N PE


Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers

Mains Three-phase, 230VAC L1 L2 L3 PE


Power Shelf CON13
(PE)

Mains One-phase, 230VAC L (L1) N (L2) PE


Power Shelf CON13
(PE)

2AC Power Shelves

Power Shelf CON13


(PE)

CON9
(L1 1/2)

CON9
(L1 1/2)

CON9
(L1 1/2)

CON11
(L1 3/4)

CON11
(L1 3/4)

CON11
(L1 3/4)

CON10
(L2 1/2)

CON10
(L2 1/2)

CON10
(L2 1/2)

CON12
(L2 3/4)

CON12
(L2 3/4)

CON12
(L2 3/4)

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11

Miscellaneous

AC Mains

II Mains Reconfiguration ~AC Terminal Block


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

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.

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 shelf, each feeding 1 rectifier) Mains, TN Three-phase & N, 400VAC
(1 Y Mains input will feed 2 power shelves)

Mains, IT Three-phase, 230VAC


(1 Mains input will feed 2 power shelves)

Mains One-phase, 230VAC


(3 Mains inputs will feed 2 power shelves)

3 AC Mains Cables AC Mains Cable AC Mains Cable

AC Mains wires Chassis 1 fish plate AC Mains Terminal Block Chassis

AC Mains wires 3 fish plates AC Mains Terminal Block Chassis

AC Mains wires 0 fish plates AC Mains Terminal Block

X:******
(To internal connections for 2 power shelves) Flatpack2 DC Power System (To internal connections for 2 power shelves) Flatpack2 DC Power System

X:******
(To internal connections for 2 power shelves) Flatpack2 DC Power System

X:******

2009604, v7

Chassis

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.

Fixed Individual Mains Input Terminal Block 4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier) Mains One-phase, 230VAC
8 AC Mains Cables

AC Mains wires 0 fish plates AC Mains Terminal Block


To rectifier 1 To To To rectifier 2 rectifier 3 rectifier 4 To To To rectifier 5 rectifier 6 rectifier 7 To rectifier 8

X:******
2009604, v7

(To internal connections for 2 power shelves) Flatpack2 DC Power System

12

Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

PULLOUT

Check Lists Pullout

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

INSTALLATION CHECK LIST


System Data
Flatpack2 Power Supply System, type: Site, name: Serial No.: AC Input Voltage, measured: Software, version No.: Battery Type: Battery Capacity: Rectifiers, type & number of: Installation carried out by, name: Article No.:

Flatpack2 PS System

Site Preparations
CARRY OUT FOLLOWING: OK

1. Organize the installation site


EMC regard o o o o o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm Check that the levelled surface is able to support 600 kg (cabinetized systems) Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas Check that insulated tools suitable for telecom installations are used Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated

2. Prepare the installation tools 3. Prepare AC Supply: AC input cable(s) and fuses

Mechanical Installation
CARRY OUT FOLLOWING:

Power is OFF!
OK

4. Remove packaging and check equipment


Device hazard o o o o o o o o Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc Inspect the equipment for physical damage (report any damages) Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task) Check that cable entry from the top is possible Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor Subassemblies in existing 19 or in ETSI cabinets, using brackets. Mount the support & heat deflecting plate Start (if applicable) on the lower shelf first, and continue upwards Do not terminate the battery cables yet!

5. Remove top cover and dummy front panels 6. Position and fasten the cabinet or subassembly 7. Mount the batteries on the shelves
Electric shock

Electrical Installation
CARRY OUT FOLLOWING:

Power is OFF!
OK

8. Make the system completely voltage free


o o o o o o o o o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses Check AC configuration: The AC terminals are correct configured to the external AC supply 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 Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB Refer to your systems connection drawings and configuration, or to the Factory Settings in the Quick Start Guide Terminate Alarm Circuit cables to the relay output terminals Terminate Signal Circuit cables to the digital input/output terminals

9. AC Connections

10. DC Connections Load Circuits


Electric shock

11. DC Connections Alarm & Signal Circuits

12. DC Connections Battery Cables


o o o o

Careful! Use correct polarity.

For each battery shelf, Mount 3 intercell links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks) Connect battery cables to fuses and common DC rail, and to the shelfs outer terminals; black (+); blue (-) Connect battery symmetry cables, if applicable, to the input terminals Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the end of the cable) to a suitable place in the middle of the installed battery bank

Approval
Responsible of installation, sign.: Date: Approved by customer, sign.:

Form 173-gb-v2-C01_356804-103_qstart_flatpack2-pssyst.doc_mfm_2006-11-25

Eltek Energy AS Tel. +47 32 20 32 00

Internet: www.eltekenergy.com

E-Mail: eltek@eltekenergy.com

CIRCUIT DISTRIBUTION LIST


System Data
Flatpack2 PSS, type: Site, name: Article No.:

CIRC.

NO.

FUSE TYPE
KNIFE MCB

LVLD
CONTROLLED

DESCRIPTION

FUSE
AMPERE

CABLE
mm2

LOAD

BATT.

Fb1 Fb2 Fb3 Fb4 Fb5 Fb6 F1 F2 F3 F4 F5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30.
Continue

Form 172-gb-v2-C01_356804-103_qstart_flatpack2-pssyst.doc_mfm_2006-01-06

Eltek Energy AS Tel. +47 32 20 32 00

Internet: www.eltekenergy.com

E-Mail: eltek@eltekenergy.com

CIRCUIT DISTRIBUTION LIST


CIRC. NO. FUSE TYPE
KNIFE MCB

LVLD
CONTROLLED

DESCRIPTION

FUSE
AMPERE

CABLE
mm2

LOAD

Eltek Energy AS Tel. +47 32 20 32 00

Internet: www.eltekenergy.com

E-Mail: eltek@eltekenergy.com

Form 172-gb-v2-C01_356804-103_qstart_flatpack2-pssyst.doc_mfm_2006-01-06

31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66.

MAINTENANCE PROCEDURE
System Data
Flatpack2 Power Supply System, type: Site, name: Serial No.: AC Input Voltage, measured: Software, version No.: Battery Type: Battery Capacity: Rectifiers, type & number of: Maintenance carried out by, name: Article No.:

Flatpack2 PS System

Electric shock

WARNING: Maintenance work on live equipment is only to be performed by authorized and qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.

System Inspection
CARRY OUT FOLLOWING:

Power is ON!
OK

1. Site specific parameters and settings are known.


User manuals and site specific connection & arrangement drawings are available.

2. The battery bank has been fully charged in advance.


At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration

3. The equipment is free from damage, dust or dirt; verify.


Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.

4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.

5. The Smartpack & all rectifier modules are ON, no alarm present; verify.
Otherwise, correct and put the PS system in normal mode of operation.

6. All rectifiers functionality & Smartpacks keys and display work OK; verify
Correct possible abnormalities before continuing.

7. Connect the PS system to a PC (install the PowerSuite application if required)


The PowerSuite program in the PC enables system configuration from the PC.

8. Rectifiers load current sharing; verify.


Use the PowerSuite PC application to check all rectifiers output the same amount of current (1A)

9. Display the stored log of Alarm Messages.


Using the keypad on the Smartpack controller or from the PC.

System Adjustment
CARRY OUT FOLLOWING: OK

1. DC Output Voltage Calibration; ensure correct display readings.


If measured DC output voltage at the load terminals deviates more than 1% from the display reading, calibrate the output voltage from the Smartpacks keypad or the PC.

2. Load & Battery Current Calibration; verify correct display readings.


Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery current. If the calculated total values deviate more than 1% from the display readings, calibrate the current from the PC (calibration value>50% of systems max. capacity)

3. DC Output Voltage Adjustment; measure and adjust.


Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery manufacturer. (Voltage measurements to be done at the DC rail, with little load current)

4. Alarm Relay Test; verify all alarm relays are working correctly.
From the Smartpacks keypad or PC use the Relay Test function; verify activation of external equipment

5. Battery bank control; measure and verify battery specifications.


Follow the recommendations of the actual battery manufacturer.

Approval
Responsible of maintenance control, sign.: Date: Approved by customer, sign.:

Form 171-gb-v2-C01_356804-103_qstart_flatpack2-pssyst.doc_mfm_2006-01-06

Eltek Energy AS Tel. +47 32 20 32 00

Internet: www.eltekenergy.com

E-Mail: eltek@eltekenergy.com

PULLOUT

COMMISSIONING PROCEDURE
System Data
Suppliers Order No.: Site, name: Serial No.: AC Input Voltage, measured: Software, version No.: Battery Type: Battery Capacity: Rectifiers, type & number of: Commissioning carried out by, name: Flatpack2 Power Supply System, type: Article No.:

Flatpack2 PS System

I
Device hazard

Pre-Start Check
CHECK FOLLOWING:
1.

Power is OFF!

OK
The Flatpack2 Installation Check List is filled in. All cabling is securely terminated with correct polarity

Flatpack2 system installation is completed;

2. All battery and load MCBs/ fuses are disconnected 3. AC input cable(s) and AC earth wire (PE) are terminated 4. Site specific parameters and settings are known 5. AC supply and all MCBs/ fuses are switched OFF

II
Device hazard

Start-up, No-Load & Load Adjustments


CARRY OUT FOLLOWING:

Power is ON!

OK

1. Disconnect all rectifier modules, without removing them (keep original location) 2. Switch ON the system (external AC fuses ON) 3. AC input voltage is correct;
Measure and verify

4. Insert all Flatpack2 rectifiers in their original locations in the power shelves 5. The Smartpack and all rectifier modules are working, LEDs are ON; 6. Connect a PC to the PS system 7. DC output voltage; 8. Alarm relay test; 9. System Setup is in accordance with configuration
Verify

Install the PowerSuite software, if required Measure and adjust Verify all alarm relays are working correctly Enter site spec. info in PowerSuite Check correct polarity!

III
Device hazard

10. Adjust DC output voltage to equal measured battery voltage 11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs 12. Adjust DC output voltage to equal nominal battery or load voltage 13. Plug in again all rectifiers, and verify the rectifiers current sharing 14. Connect all load MCBs/ fuses, and verify no alarms are displayed

Approval
Responsible of commissioning, sign.: Date: Approved by customer, sign.:

Form 170-gb-v4-C01_356804-103_qstart_flatpack2-pssyst.doc _mfm_2006-01-06

Eltek Energy AS Tel. +47 32 20 32 00

Internet: www.eltekenergy.com

E-Mail: eltek@eltekenergy.com

Check Lists Pullout


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

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 1 surge arrestors. Such systems have to be configured at the factory prior to delivery.

NON Configurable Mains Input Terminal Block with OVP 4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier) 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) Flatpack2 DC Power System

X:******
2009604, v7

NON Configurable Mains Input Terminal Block with OVP 4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier) Mains, IT Three-phase, 230VAC
(1 Mains input will feed 2 power shelves)

AC Mains wires

4 fish plates AC Mains Terminal Block (To internal connections for 2 power shelves) Flatpack2 DC Power System

X:******
2009604, v7

Over Voltage Protection, OVP

Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

13

Miscellaneous

AC Mains

IV Mains Reconfiguration ~AC Connection Box


AC Mains Connection Box For external AC Mains cable

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.
For external AC Mains cable

Rewire the internal cables

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

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 systems AC Mains connection box, according to the type of AC mains to be used, as shown in the actual example in this section.

PS1:CON20

PS1:CON17

PS1:CON14

PS1:CON11

PS2:CON20

PS2:CON17

PS2:CON14

PS2:CON11

PS1:CON19

PS1:CON16

PS1:CON13

PS1:CON10

PS2:CON19

PS2:CON16

PS2:CON13

PS2:CON10

4AC Power Shelves


Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

Mains, TN Three-phase & N, 400VAC


AC Mains Cable

Mains, IT Three-phase, 230VAC


AC Mains Cable

Mains One-phase, 230VAC


AC Mains Cable

L3

L1

PE
Chassis

L2

L3

L1

PE
Chassis

L2

L (L1)

PE
Chassis

N (L2)

Rewire the box as shown

X:******
AC Mains connection box
PS1:CON20 PS1:CON17 PS1:CON14 PS1:CON11 PS2:CON20 PS2:CON17 PS2:CON14 PS2:CON11

Rewire the box as shown

X:******
AC Mains connection box
PS1:CON20 PS1:CON17 PS1:CON14 PS1:CON11 PS2:CON20 PS2:CON17 PS2:CON14 PS2:CON11

Rewire the box as shown

X:******
AC Mains connection box
PS1:CON20 PS1:CON17 PS1:CON14 PS1:CON11 PS2:CON20 PS2:CON17 PS2:CON14 PS2:CON11

PS1:CON19

PS1:CON16

PS1:CON13

PS1:CON10

PS2:CON19

PS2:CON16

PS2:CON13

PS2:CON10

PS1:CON19

PS1:CON16

PS1:CON13

PS1:CON10

PS2:CON19

PS2:CON16

PS2:CON13

PS2:CON10

(To internal connections) Flatpack2 DC Power System

PS1:CON19

PS1:CON16

PS1:CON13

PS1:CON10

PS2:CON19

PS2:CON16

PS2:CON13

PS2:CON10

(To internal connections) Flatpack2 DC Power System

(To internal connections) Flatpack2 DC Power System

14

Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

AC Mains
2AC Power Shelves

Miscellaneous
Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers

Mains, TN Three-phase & N, 400VAC


AC Mains Cable

Mains, IT Three-phase, 230VAC


AC Mains Cable

Mains One-phase, 230VAC


AC Mains Cable

L3

L1

PE
Chassis

L2

L3

L1
N

PE
Chassis

L2

L (L1)

PE
Chassis

N (L2)

L1

L2

L3

Rewire the box as shown

X:******
AC Mains connection box
PS1:CON11 PS2:CON11 PS3:CON11 PS4:CON11 PS1:CON9 PS2:CON9 PS3:CON9 PS4:CON9

Rewire the box as shown

X:******
AC Mains connection box

Rewire the box as shown

X:******
AC Mains connection box
PS1:CON11 PS2:CON11 PS3:CON11 PS4:CON11 PS1:CON9 PS2:CON9 PS3:CON9 PS4:CON9

(To internal connections) Flatpack2 DC Power System

About AC, DC Earthing Systems


To prevent the risk of electric shock, all cabinets chassis are to be electrically connected to AC Earth (PE). Also, it is a common practice for telecom equipment to have its common DC output rail (+ or -) connected to a separate Telecom Earth (TE) or DC Earth. Earth connections are in particular important where frequent lightning might induce high voltage levels in AC supply and in battery and load cables.
Link 2 (DC Earth) AC Mains EG Chassis Common DC Rail TE

PE (Protective Earth) TE (Telecom Earth) EG (Exchange Ground) AC Mains Input (L1,L2,L3,N)

PS1:CON12

PS1:CON10

PS2:CON12

PS2:CON10

PS3:CON12

PS3:CON10

PE Chassis

Link 1 (AC Earth)

Refer to your systems specific drawings to identify how these links are implemented in your DC power system. Common Positive DC Output Rail is usual in 48 and 60V DC supply systems: Negative DC Distribution. Common Negative DC Output Rail is usual in 24V systems: Positive DC Distribution.
Common DC Rail + Common DC Rail + + + + DC Load wires DC Load wires

Quick Start Guide Flatpack2 PS System

PS4:CON12

PS4:CON10

PS1:CON12

PS1:CON10

PS2:CON12

PS2:CON10

PS3:CON12

PS3:CON10

PS4:CON12

PS4:CON10

(To internal connections) Flatpack2 DC Power System

(To internal connections) Flatpack2 DC Power System

Cabinet

DC Load Circuit

AC Earth (PE) and DC Earth (TE) are connected to chassis via Link 1 and Link 2. Remove the links (floating earth) for compliance with other local earthing systems.

Negative DC Distribution
356804.103, v5-2006-11

Positive DC Distribution

15

Miscellaneous
Mains Phases versus Rectifier ID

AC Mains

Phase Balancing & Monitoring

When Flatpack2 systems are fed with a 3-phase AC Mains input circuit, each rectifier is internally connected to the 230VAC phases, in such a pattern that loads the 3 phases evenly. The distribution of rectifiers among the phases is implemented both via internal wiring to the power shelves, and how the shelfs back-wiring card routes the phases to each rectifier position. There are two types of shelves: 4AC and 2AC power shelves. Read also the Identifying Power Shelves section, page11.
Load Balancing of Mains Phases
Even distribution of Flatpack2 rectifiers on the Mains phases

Mains Three-phase & N, 400VAC


L3 Phase 3 L1 Phase 1 Phase 2

L1 Phase 3 AC Mains 230VAC L3 Flatpack2 rectifier 02 05 08 n Phase 2 L(L1) Phase 1

Mains 400VAC, 3ph+N

230VAC

Mains Three-phase, 230VAC

09

06

03

01

04

07

02

05

08

L2 ID number (Assigned CAN bus address)

09

06

03

01 L2

04

07

Mains One-phase, 230VAC


AC Mains 230VAC N(L2)

01

02

03

Plug-and-Play Rectifiers versus Phase Monitoring

When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller assigns the next available ID number to the rectifier, starting with 01. The controller registers the rectifiers Serial Number and ID number. When a previously installed (hot plugged) Flatpack2 rectifier is inserted in a power shelf, the Smartpack controller recognizes the module, and assigns the same ID to the rectifier. In other words, the controller and the rectifier remember the assigned ID number, even after removing and reinserting the rectifier in the shelf. To achieve a more controlled ID assignment, you should always insert & hot-plug new Flatpack2 rectifiers in the indicated power shelf position, one module at a time, starting with ID number 1, 2, 3, and so on. The sequence is indifferent after ID number 6. You find more information on page 17. This position-versus-ID number relationship is very important for the correct monitoring of the mains three phases, as the Smartpack controller always uses rectifier ID01, 02 and 03 to monitor the Mains phase 1, 2 and 3 respectively. If these rectifiers malfunction, rectifier ID 04, 05 and 06 will automatically take over. For example: accidentally inserting a rectifier with ID02 in a power shelf position internally connected to mains phase 1, will cause the controller to monitor phase 1 thinking it monitors phase 2. Then a phase 1 fault will be alarmed as a phase 2 fault.

16

Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

AC Mains
Correct Rectifier Positions in Power Shelves

Miscellaneous

Flatpack2 DC power systems are normally shipped from factory with empty power shelves. The rectifier modules are shipped in separate packaging, and you have to install the modules in the correct position in the power shelves, with respect to their ID number (or CAN bus address). Do not relocate already pre-installed rectifiers. For first time installations of rectifiers in Flatpack2 systems, follow the scheme below: 1. Find out your systems power shelf type, by reading the Identifying Power Shelves section, page11 2. Find out if your systems AC mains feed is <230VAC, 3 phase> or <400VAC, 3 phase and N> 3. Insert & hot-plug the rectifiers in the indicated power shelf positions, one module at a time, allowing a 2s delay between them and starting with ID number 1, 2, 3, and so on. (indifferent after ID# 6) Follow one of the four figures below:
Smartpack Located in Distribution Shelf Correct Rectifier Position in 4AC Power Shelves
Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier and Mains Three-phase, 230VAC

Correct Rectifier Position in 2AC Power Shelves


Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers and Mains Three-phase, 230VAC

Mains Three-phase & N, 400VAC


Flatpack2 rectifier

Mains Three-phase & N, 400VAC


Flatpack2 rectifier

Smartpack controller

Smartpack controller

01
Position 1

02 06 -----

03 -------

04 -------

Position 4

01
Position 8 Position 1

04 06 -----

02 -------

05 -------

Position 4 Position 8

05
Position 9

03
ID number (Assigned CAN bus address) Position 9

-----

-----

ID number (Assigned CAN bus address)

Phase 1

Phase 2

Phase 3

Smartpack Located in Power Shelf Correct Rectifier Position in 4AC Power Shelves
Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier and Mains Three-phase, 230VAC

Correct Rectifier Position in 2AC Power Shelves


Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers and Mains Three-phase, 230VAC

Mains Three-phase & N, 400VAC


Flatpack2 rectifier

Mains Three-phase & N, 400VAC


Flatpack2 rectifier

Smartpack controller

Smartpack controller

02
Position 1

03 04 -----

01 -------

Position 4 Position 8 Position 1

01 03 06 -----

02 04 -----

05 -------

Position 4 Position 8

05
Position 9

06 -----

-----

ID number (Assigned CAN bus address)

Position 9

-----

ID number (Assigned CAN bus address)

Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

17

Miscellaneous

Battery Monitoring

Battery Symmetry Connections 48V Systems


Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors CON4 and CON3), enabling symmetry measurement of: 8 battery strings using the Mid-Point Measurement Method 4 battery strings using the more accurate Double Mid-Point Measurement Method 2 battery strings using the even more accurate Block Measurement Method You can implement any of these methods using one or two Battery Connection Kits (refer to the illustration on page 20) and the appropriate number of Battery Symmetry Kits, which contain a single wire with suitable cable lugs, etc.
Battery Symmetry Mid-point Measurement
One measurement per string Card, Art. 200576 Serial Switches X:**** 2-1 Batt. Symmetry Kit, Art. 200830

Single Wire Cable Lugs

Battery Symmetry Block Measurement


Four measurements per string (Serial measurement) Card, Art. 200576 Serial Switches 2-1 X:**** 3 5 7

Symmetry 1

Symmetry 1

Symmetry 2

Set all 4 switches ON (down)

Examples of Battery Symmetry Connections

+ -

Symmetry 3 +
Block3

Symmetry 4 +
Block4

Set all 4 switches OFF (up)

48V DC Supply Systems (-48V) Outer Terminal

- + - + - + - +
Block1 Block3 Block4

(-48V) Outer Terminal

- + - + - + - +
Block1

Intercell Links

+
0V Outer Terminal

Intercell Links

+
0V Outer Terminal

Battery Symmetry Double-point Measurement


Two measurements per string, from the middle to the outer terminals Card, Art. 200576 Serial Switches 2-1 X:**** 3

Notice that, if you open the serial switches in card, Art. 200576 setting all to OFF (up) you have to connect the + and wires of every symmetry input.

Symmetry 1

Set all 4 switches ON (down)

Symmetry 2

Battery Terminology
Battery Block, Battery String and Battery Bank Battery Block (12V) + Battery String #1 (48V)Batt. Battery String #2 (48V)
356804.103, v5-2006-11

(-48V) Outer Terminal

- + - + - + - +
Block1 Block3 Block4

Intercell Links

+
0V Outer Terminal

48V Battery Bank

18

Quick Start Guide Flatpack2 PS System

Battery Monitoring

Miscellaneous

Battery Symmetry Connections 24V Systems


Batt. Symmetry Kit, Art. 200830

Single Wire

Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors CON4 and CON3), enabling symmetry measurement of 8 battery strings using the MidPoint or Block Measurement Method 2 . You use one or two Battery Connection Kits (refer to the illustration on page 20) and the appropriate number of Battery Symmetry Kits, which contain a single wire with suitable cable lugs, etc.

Cable Lugs

Battery Symmetry Mid-point or Block Measurement


One measurement per string Card, Art. 200576 Serial Switches X:**** 2-1

Example of Battery Symmetry Connections

24V DC Supply Systems

Symmetry 1 +

Set all 4 switches OFF (up)

0V Outer Terminal

- + - +
Block1 Block2

Intercell Link

+
24V Outer Terminal

Battery Terminology
Battery Block, Battery String and Battery Bank Battery Block (12V)

Battery String #1 (24V) Battery String #2 (24V)

24V Battery Bank

The Mid-Point and the Block Measurement Methods are identical in 24V systems.

Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

19

Miscellaneous

Battery Monitoring

Terminals & Pin-out Location, Battery Interface Card


The Smartpack controllers battery monitoring signals are accessible on D-Sub connectors CON4 and CON3, on the controllers rear panel.
Battery Connection Kit

15 pins D-Sub cable

Using the Battery Connection Kit which consists of a Battery Interface Card (Art. 200576) and a standard 15 pins D-Sub cable you can make the signals on CON4 accessible at any suitable location inside your system, e.g. near the battery blocks. When extra battery monitoring signals are required, you can use an extra Battery Connection Kit connected to the controllers CON3.

Card Art.200576

For detailed information about the cards pin-out location and terminal block connections, refer to the figures in this section.
Battery Connections (Internal)
Configurable monitoring digital inputs
Battery Connections Card, Art. 200576 Battery Connections Card, Art. 200576 Card Art.200576 FUNCTION SIGNAL PIN-OUT CON4 CON3 CON4A

Terminals & Pin-out Location


System Connections Card, Art. 200625

Smartpack

CON3A

Alarm Outputs & Digital Inputs Card, Art. 105954

CON3A or CON4A X***/X****

For Temp. Sense Kit

X**/X* Serial Switch


14 1

Battery Interface Card, Art. 200576 To Smartpack, CON4

1 Batt. Symmetry 1 + 2 3 Batt. Symmetry 2 + 4 Batt. Symmetry 3 + 5 6 + 7 Batt. Symmetry 4 8 + 9 1 11 Temperature Sense 1 10 11 (NA) 5 15 12 13 (NA) CON3A or 14 CON4A
15-pins D-Sub female 1 11 5 15

In

X:****
(From internal batteries)

Temperature sensor

(Internal Connections) 2 1.5 mm , max. wire section X**/X*


15-pins D-Sub male 15-pins D-Sub female (From area with internal batteries) (From area with internal batteries) (From area with internal batteries) Temperature sensor

Temperature Sense Kit


Temp. Sensor cable Temp. sensor

Temperature Sense 1
Temperature sensor

(Alternative use of Temp. Sense Kit, instead of connecting to X:****, 9-10)

For temperature monitoring of the battery compartment, we recommend the use of the Temperature Sense Kit, instead of connecting the sensor cable directly to the terminals, pin 9-10. The Temperature Sense Kit is connected to the Battery Interface Card (Art. 200576), or directly to the controllers CON3 or CON4, if unused.

Battery Connections (Internal)


Configurable monitoring digital inputs
Card Art.200576 FUNCTION SIGNAL PIN-OUT

To Smartpack, CON3

1 Batt. Symmetry 5 + 2 3 Batt. Symmetry 6 + 4 Batt. Symmetry 7 + 5 6 + 7 Batt. Symmetry 8 8 + 9 1 11 Temperature Sense 2 10 11 Batt Current 2 5 15 12 13 CON3A or Batt Fuse Fail 2 14 CON4A
15-pins D-Sub female 1 11 5 15

In

X:***
(From internal batteries)

(Internal Connections) 2 1.5 mm , max. wire section X**/X*


15-pins D-Sub male 15-pins D-Sub female

Temperature Sense 2

Temperature sensor The Temperature Sense Kits may also be connected directly to the Smartpack controllers CON3 or CON4, if these connectors are unused.

(Alternative use of Temp. Sense Kit, instead of connecting to X:***, 9-10)

20

Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

(From area with internal batteries)

Alarms & Monitoring

Miscellaneous
Connections

Standard Alarm Relays & Digital Inputs


Standard Relays & Digital Inputs
NO Com NC

Normal Mode
Relay X (Energized coil)

NO Com Relay X (De-energized coil) NC Flatpack2 PS System Alarm Mode

The alarm outputs in Flatpack2 systems use the Fail-Safe Operation Mode (relay coils energized in the systems 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)

Correct Use of Alarm Outputs (example)


Digital Input X (Normal mode) Digital Input X (Activated)

+ +

Normal Mode
External Relay Y (Energized coil)

Alarm Mode
External Relay Y (De-energized coil)

In order to implement monitored fail-safe digital inputs circuits, the external relay coil must be energized and the contacts closed in the systems normal mode of operation.

Flatpack2 PS System

Correct Use of Digital Inputs (example)

Terminals & Pin-out Location, Alarm Interface Card


The Smartpack controllers alarm and digital input monitoring signals are accessible from the controllers rear panel, on mini power connector CON1 (2 outputs & 2 inputs) and on D-Sub connector CON2 (4 outputs & 4 inputs). Using the Alarm Interface Card (Art. 105954) and two interface cables, you can make the signals on CON1 & 2 accessible at any suitable location inside your system. For detailed information about the cards pin-out location and terminal block connections, refer to the figures in this section.
Terminals & Pin-out Location
CON2 CON1 Alarm Outputs & Digital Inputs Card, Art. 105954 CON2A CON1A

Alarm Outputs & Digital Inputs


Voltage free relay outputs and Configurable monitoring digital inputs
Card Art.105954 FUNCTION SIGNAL PIN-OUT

In

Out

X:*
Input Circuit 2
(To and from external equipment) (To external equipment) (From external equipment)

Digital Input 1 Digital Input 2

+ +
NC

Relay 1 NO Common Alarm COM Relay 2 Mains Alarm To Smartpack, CON1 9


NO COM NC

System Connections Card, Art. 200625

Battery Connections Card, Art. 200576

1 2 3 4 5 6 7 8 9 10

Input Circuit 1

Alarm Circuit 1 Alarm Circuit 2

X:**
1 2 3 Digital Input 4 4 5 Digital Input 5 6 7 Digital Input 6 8 Relay 3 NO 9 Fuse Alarm COM 10 Load & Battery NC 11 12 Relay 4 NO High Battery Alarm COM 13 NC 14 NO 15 Relay 5 Low Battery Alarm COM 16 NC 17 Relay 6 NO 18 Rectifier Alarm COM 19 NC 20 (Customer Connections) Digital Input 3 + + + + Input Circuit 3 Input Circuit 4 Input Circuit 5 Input Circuit 6

Smartpack

Battery Connections Card, Art. 200576

CON1A X*

CON2A X**

10

20

Alarm Circuit 3 Alarm Circuit 4 Alarm Circuit 5 Alarm Circuit 6 1.5 mm , max. wire section
2

The figure shows the position of the relay contacts when the relay coils are de-energized (PS system in alarm mode. Factory Settings in bold)

Quick Start Guide Flatpack2 PS System

To Smartpack, CON2 5

Alarm Outputs & Digital Inputs Card, Art. 105954 (or Art. 200916 when X** and CON2A are not mounted)

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Miscellaneous

Internal Connections

Terminals & Pin-out Location, System Interface Card


Flatpack2 systems are shipped from factory with the CON5 signals already connected. Some of the Smartpack controllers internal system signals are accessible on D-Sub connector CON5, on the controllers rear panel. Using the System Interface Card (Art. 200625) and a standard 15 pins D-Sub cable, the signals on CON5 may be accessible at any suitable location inside your system. For detailed information about the cards pin-out location and terminal block connections, refer to the figures in this section.
In Terminal Board, Art. 200625 (To Smartpack, CON5) System Connections Terminals & Pin-out Location
System Connections Card, Art. 200625 CON5A Battery Connections Card, Art. 200576 Battery Connections Card, Art. 200576 Pos. Distr. Neg. Distr. JP2 1 2 3

CON5

9+, Neg.D. 11,Pos.D.

JP1

JP2

JP1 3 2 1

1+/ 3+/ 2+/

JP2

Alarm Outputs & Digital Inputs Card, Art. 105954

Out 10 15 6 7 12 13

X:*****
+ + + 1 Power Input 2 3 Batt. Current 1 4 Batt. Fuse Fail 1 5 6 Load Fuse Fail 1 7 LVD1A 8 LVD Common LVD1 9 LVD2A 10 LVD Common LVD2 11
(To latching contactors LVD1 & LVD2)

Smartpack

X*****
1 11

(Internal Connections)

CON5A

Neg. Distr. Pos. Distr.

System Connections Card, Art. 200625

JP1 and JP2 are used to configure the system for Negative DC distribution (48 and 60V systems) or Positive DC distribution (24V systems)
Connections

LVD Latching Contactors

Flatpack2 systems LVBD and LVLD 3 functionality is implemented by the Smartpack controlling magnetically latching contactors.
Latching Contactors, LVD1 & LVD2
A latching contactor changes state only when a reversed pulse voltage is applied to its coil OFF - Pulse
PCB Art. 200625 LVD1A X Latching Contactor

The coil 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 coil.
Warning! The bidirectional diode must always be mounted to avoid damaging the controller.

ON + Pulse

Y
LVD1

X:***** 8 9 10 11
Smartpack Unit

LVD Common LVD2A

Y X

Bidirectional diode X Latching Contactor

Latching Contactor

LVD2
Y LVD Common

Flatpack2 PS System (internal)

Correct Use of Latching Contactors (example)

LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect

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Quick Start Guide Flatpack2 PS System

356804.103, v5-2006-11

Flatpack2 Integrated System, 2U

Miscellaneous
Generic Overview

Location of Major Components

Refer to the specific drawings included with your Flatpack2 PS system, for information regarding the exact location of components in your system

Load Fuses

LVBD

Battery Fuses Smartpack


Control Unit

LVLD position
(not displayed)

CAN bus

DC Load Terminals

(+, )

Rear view

Interface I/O Terminals

AC Terminals Bus Bars Common Battery Connections Supply Battery Connections

Front view Battery Fuses Load Fuses

USB 2.0 type B port PC connection, etc


1U

DC Distribution (1U high) with built-in Smartpack controller, load fuses and MCBs

1U

Power shelf (1U high) with 4 Flatpack2 rectifiers

Quick Start Guide Flatpack2 PS System

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This product is CE marked and complies with all current requirements for relevant standards and directives.

Head Office

Eltek Energy AS
PO Box 2340 Strms; N-3003 Drammen; Norway Tel:+47 32 20 32 00 Fax:+47 32 20 32 10 E-mail: eltek@eltekenergy.com Internet: www.eltekenergy.com

Copyright Eltek Energy AS, Norway 2005 This document may be changed without notice Art. No. 356804.103, Issue 5, 2006 Nov Published 2006-11-25