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351406.033
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.
EMC
EN61000-6-2 Industrial Environment EN61000-6-3 Residential, Commercial and Light Industry ETS 300386 v1.3.1 Telecommunication Equipment
LVD
LVD73/23/EEC Low Voltage Directive EN60950 Safety of Technology Equipment
Head Office:
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
Issue 4,
2004 December
Flatpack PRSB 15kW, 48VDC (Outdoor Site Power Cabinet, Air Conditioned) has part no. CF1032.002
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
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
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4 4 5 6 6 6
INSTALLATION PROCEDURES
SAFETY PRECAUTIONS UNPACKING AND MECHANICAL INSTALLATION ELECTRICAL INSTALLATION RECTIFIER INSTALLATION MAINS SUPPLY BALANCING EFFECT RECTIFIER INSTALLATION HANDLES AND LOCKING MECHANISM COMMISSIONING
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7 7 8 10 10 10
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12 13
4 5
SPECIFICATIONS FLATPACK PRSB 15KW, 48VDC, AIR CONDITIONED APPENDIX: SCHEMATICS, DRAWINGS, FIGURES, ETC.
GENERAL ARRANGEMENT DRAWING SYSTEM SCHEMATIC PRSB 15KW, 48VDC, OUTDOOR CABINET, AIR CONDITIONED ON SITE DOOR REMOVAL OUTDOOR CABINET, AIR CONDITIONED DRILLING TEMPLATE AIR CONDITION UNIT SCHEMATIC DRAWING
14 15
15 16 17 18 19
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
This Installation Guide contains information about how to install the Flatpack PRSB 15kW, 48VDC system 1 , for outdoor site power cabinet, Air Conditioned. Please, refer to the systems Documentation Set (art. 351406.003) for an overview of related user documentation.
DC Load Distribution: MCBs, Mains, Alarm and Signal Terminals MCU, Monitoring & Control Unit Figure 1 Flatpack Power Rack System General Arrangement (top of cabinet) Flatpack 1500 rectifier modules LTE Distribution, MCBs
Battery strings and MCBs inside, in the lower part of the cabinet
Figure 2
1
Location of components
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) L2 (Terminal for incoming wire) L3 (Terminal for incoming wire)
Figure 3
Labels on internal wires (Wires may be reconnected to match the sites type of AC mains supply) 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
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
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
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
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 10. The other positions will not be usable.
400VAC + N 230VAC
L1 N L1 L2
1 phase configurations
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. 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 Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
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 parts.
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
1 TAKE THE FLATPACK POWER SYSTEM OUT OF THE PACKAGING 2 DRILL HOLES IN THE GROUND
ACCORDING TO DRILLING TEMPLATE
Comments
Inspect the unit for any physical or transit damage, and tighten the screws that connect conductors. Report any transit damage to Eltek Energy immediately 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.
OK
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
Warning!
The cabinet has to stand upright (vertical position) for at least 2 hours before the AirCondition devise is started.
Electrical Installation
For location of components, see Figure 2, page 4, Figure 3, page 5, and Figure 9, page 15.
Installation Step
Comments
Connect the AC Earth (PE) and DC Earth (TE) to the copper terminal positioned in the cabinet ceiling. 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.
OK
1. EARTH CONNECTIONS
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 4.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
3. LOAD CONNECTIONS
Alarm connection
100A
150A
Cable gland
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 cable 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 power core. 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 13 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. Connect and fasten the ventilation hose kit (follows the batteries) to every battery block, guiding the exhaust end of the hose out of the cabinet through the upper whole on the side of the cabinet. Fasten the exhaust host to the cabinet with strips. Make sure that the fixings do not limit the airflow in the hose. Please follow chapters Pre Start Check and Start Up Procedure in manual Commissioning Guide Flatpack 1500 DC Rectifier Plant, Doc. No. 360006.163.
Right Corner
6. POWER UP
The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
When possible, mount an equal number of rectifiers on each phase, L1, L2 and L3.
Commissioning
For information regarding system commissioning, please read manual Commissioning Guide Flatpack 1500 Dc Rectifier Plant, art. No. 360006.163.
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Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
The digital inputs are configured as fail-safe, i.e. if the input is enabled, it will trig 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
Pin 10
Terminal
Pin 1
Pin 20
Description
CON 4 CON 5
Customer connections (digital inputs, symmetry, etc.) Customer connections (alarm relay outputs)
Customer connections interface and internal terminals. (Max. 1,5 mm2, AWG 15)
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
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Pin 1 2 3 4 5 6 7 8 9
Function Relay 6: Common Alarm Relay 5: Module Alarm Relay 4: Load / Battery Fuse Alarm
Pin 10 11 12 13 14 15 16 17 18 19 20
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 7 8 9 10
Function Digital Input 1 (Heat Management) Digital Input 2 (programmable) Digital Input 3 (programmable) Digital Input 4 (programmable) 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.)
Pin 1 2 3 4 5 6 7 8
Function Shunt 2: Battery current measurement Shunt 1: Battery current measurement Auxiliary Supply (for Flatpack MCU) Voltage Sense (system signal reference)
Pin 9 10 11 12
Signal + +
Function Battery Fuse State (digital input) Load Fuse State (digital input) LVBD control (Battery Disconnect contactor) LVLD control (Load Disconnect contactor)
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Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
Pin 16
Pin 1
Figure 8
The table below shows the pin assignment for the GMT load fuse card. Pin Assignment for GMT Fuse Pin 1 2 3 4 5 6 7 8 Signal + + + + Function GMT fuse 1 (F4) GMT fuse 2 (F5) GMT fuse 3 (F6) GMT fuse 4 (F7) Pin 9 10 11 12 13 14 15 16 Signal + + + + Function GMT fuse 5 (F8) GMT fuse 6 (F9) GMT fuse 7 (F10) GMT fuse 8 (F11)
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
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CONNECTIONS 10
Battery connections Load MCB connections Alarm connections No. of DC Load breakers No. of Battery fuses No. of Aux. fuses Programmable LVD Isolation Operating temp Storage temp Dimensions Weight
DISTRIBUTION OPTIONS
See Flatpack 1500 48VDC datasheet (241114.100.DS3) 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
OTHER SPECIFICATIONS
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 910 x 2000mm (WxDxH) (30.3 x 35.8 x 78.7) Approx. 235kg excl. rectifiers and batteries Max. 250kg per battery shelf 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
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 tifier current measurements 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
APPLICABLE STANDARDS
Electrical safety EMC
Environment
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Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
Figure 9
General Arrangement drawing, PRSB 15kW, 48VDC Outdoor Cabinet, Air Conditioned
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
15
16
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
Step Description
1 Switch OFF AC supply to Air Condition Remove the AC supply cables from the door terminals. Make sure the AC cable is completely freed from the door. Disconnect the earth connection cable on the bottom of the door Lift the door off the hinges. This might require two or more persons, since the door is heavy. When the door is mounted back on, lift the door back on to its hinges Reconnect the earth and AC supply cable. Fasten the AC supply cable to the door. Switch the AC supply back ON.
Ok
Air Condition AC supply cable.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
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Drilling Template
Figure 11 Top view of the cabinets bottom plate. 700x700 mm external dimensions
The cabinet overhangs by 35 mm outside the plinth on the rear, on the left hand and on the right hand side
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Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
Figure 12
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned Art. No. 351406.033, v42004-12
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Main Office:
Eltek Energy AS
P.O. Box 2340 Strms N-3003 DRAMMEN Norway Phone: Fax: E-Mail: Internet: 47 32 20 32 00 47 32 20 32 10 eltek@eltek.no www.eltekenergy.com