March 24, 2017 | Author: proximohitman | Category: N/A
Installation & Commissioning, Operation & Maintenance Manual
Eltek Australia Pty Ltd Unit 1, 22 Narabang Way, Belrose, NSW, 2085, Australia Telephone: +61 2 9479 4200 Facsimile: +61 2 9479 4292
Installation & Commissioning + Operation & Maintenance manual for FlatPack2 SEF29-X-149, ‘150, ‘156 and A111171.000, A112040.000 and A112041.000 systems REVISION CONTROL Rev
Date
Revision Description
Orig
Check
H
25/10/06
Added extra wall mounting option.
GT
BD
I
29/11/07
Added system for this manual
AL
J
14/04/11
Changed logo and fax number
RB
K
14/06/11
Added Ethernet connection
RB
L
23/11/11
4 Battery Shelves, SP18-RRU, SP18 DA
M
07/03/12
Updated to manufacturing version
App
DA
This manual is in process of revision if you require updated manual please contact with Eltek Australia engineering department
DOCUMENT DISTRIBUTION CONTROL Copy No:
1
Controlled:
X
Uncontrolled:
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 1 of 64
Installation & Commissioning, Operation & Maintenance Manual
Eltek Australia Pty Ltd ACN072 645 446 ABN 90 072 645 446 Unit 1, 22 Narabang Way Belrose NSW 2085 Phone: (02) 9479 4200 Fax: (02) 9479 4292 E-Mail (Sales Dept.): E-Mail (Service Dept.): E-Mail (all departments):
[email protected] [email protected] [email protected]
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 2 of 64
Installation & Commissioning, Operation & Maintenance Manual
TABLE OF CONTENTS 1.
SCOPE ............................................................................................................................................................... 5
2.
SYSTEM OVERVIEW .................................................................................................................................... 5
3.
REQUIREMENTS ......................................................................................................................................... 14
4.
PACKING LIST ............................................................................................................................................. 16
5.
SYSTEM CONFIGURATION ...................................................................................................................... 17
6.
UNPACKING.................................................................................................................................................. 18
7.
CABINET ASSEMBLY ................................................................................................................................. 19 7.1 SPECIALISED WALL MOUNTING KIT ................................................................................................................. 20
8.
FLOOR INSULATION .................................................................................................................................. 22
9.
EARTH CABLING ........................................................................................................................................ 23
10.
CONNECTING THE BATTERIES ....................................................................................................... 24
11.
EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS. ................................. 26
12.
EXPANSION RACK ALARM CONFIGURATION ............................................................................ 28
13.
INSTALATION & REFRESHING VOLTAGES OF BATTERIES .................................................. 29
14.
EXPANSION RACK INSTALLATION CHECK LIST ....................................................................... 30
15.
INSTALLATION AND OPERATION OF RECTIFIER MODULES ................................................ 31
15.1 VISUAL INDICATIONS..................................................................................................................................... 32 15.2 PLUGGING IN RECTIFIERS .............................................................................................................................. 33 15.3 IDENTIFICATION OF DIFFERENT RATED RECTIFIERS ....................................................................................... 33 15.4 REPLACING AND INSTALLING RECTIFIER MODULES ........................................................................................ 34 16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER (ETHERNET CONNECTION) ..................................................................................................................................................... 35 17.
OPERATION OF THE SMARTPACK CONTROLLER .................................................................... 38
17.1 FRONT PANEL OPERATION............................................................................................................................. 38 17.2 OPERATING MENUS, (MENU MODE) .............................................................................................................. 40 17.3 FRONT KEYPAD MENU TREE FOR SMARTPACK CONTROLLER: ........................................................................ 41 USER ..................................................................................................................................................................... 41 Service ......................................................................................................................................................... 41 18.
REMOTE ALARM CONNECTIONS.................................................................................................... 42
18.2 DIGITAL INPUTS. ............................................................................................................................................ 45 19.
+24 V DC/DC CONVERTER .................................................................................................................. 47
20.
AC MAIN SUPPLY INSTALLATION .................................................................................................. 49
21.
DC DISTRIBUTION INSTALLATION ................................................................................................ 51
LOAD CABLE INSTALLATION CONSIDERATIONS .................................................................................................... 52 22.
TEMPERATURE COMPENSATION ................................................................................................... 52
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 3 of 64
Installation & Commissioning, Operation & Maintenance Manual
23.
COMMISSIONING ................................................................................................................................. 54
PRE-START / INITIAL CHECKS ............................................................................................................................... 54 SYSTEM START-UP ................................................................................................................................................ 54 CHECKING THE ALARMS ....................................................................................................................................... 55 DEFAULT -48V SYSTEM SETTINGS ........................................................................................................................ 58 24.
GENERAL MAINTENANCE CHECKS ............................................................................................... 58
25.
MODULE MAINTENANCE .................................................................................................................. 59
26.
GENERAL PROCEDURES.................................................................................................................... 59
27.
SYSTEM COMPONENTS MINIMUM OPERATING LIFE ............................................................. 59
28.
USING SMART SUITE SOFTWARE ................................................................................................... 60
28.1 INSTALLATION OF SMART SUITE SOFTWARE ................................................................................................. 63 SETTING UP COMMUNICATION BETWEEN PC AND SMARTPACK ............................................................................. 63 28.2 USING SMARTSUITE: A START UP GUIDE. ...................................................................................................... 63 29.
ATTACHMENTS .................................................................................................................................... 64
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 4 of 64
Installation & Commissioning, Operation & Maintenance Manual
1. SCOPE This Installation and Commissioning Manual provides simple instructions as to the installation requirements for the Eltek -48 Volt DC Flatpack2 systems. All maintenance & installation work must be carried out by suitably trained personnel. This manual also includes Operation & Maintenance information and technical data regarding the Flatpack2, Smartpack controller and DC/DC converters (factory fitted option.) 2.
SYSTEM OVERVIEW
The Flatpack2 Mobile systems are 18kW -48V DC power system comprising of:
1 Main System Cabinet (fig 2.2, 2.3, 2.4, 2.7 & 2.8) Up to 9 FlatPack2 -48V 2kW or 1.8kW rectifiers 1 Smartpack Control Module 4, 5 or 6 Battery strings Expansion Battery Cabinet (optional, fig 2.5, 2.6 & 2.9) Up to 4 off +24V 1.1kW DC/DC converters (factory fitted option in 600D rack only)
The Main System Cabinet is available in 2 configurations, a 600 deep cabinet option and a 400 deep cabinet option. The 600 deep cabinets can accommodate up to 6 strings of 100Ah 12FFT100 batteries or 4 strings of 190Ah SBS190 batteries, and the 400 deep cabinets can accommodate up to 5 strings of 100Ah 12FIT100 batteries. If required, the main system cabinets for either option can be supplemented with a battery expansion cabinet for increased battery capacity. Details of the expansion battery cabinets are given later in this manual. The system is also available with an optional DC/DC converter rack to supply +24V supply as needed. This extra rack can deliver up to 4.4kW at 24V and has an extendable alarm output. It input is supplied via an MCB on the -48V load distribution, with the 24V output given via a top mounted Anderson connector. Anderson connector for battery expansion rack
Output cable management rail +48VDC bar (SPC)
AC mains input
Bulk feed point for external battery connection (Available only in SP18&SP18-RRU) Monitor fail PCB
Alarm PCBs
Battery Alarm for the Expansion rack
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Serial Number
Page 5 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.2, Front and side views of an A111105.000 (SEF29-X-156). 2200(H)x 600(W)x 600(D)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 6 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.3, Front and side views of an A1110886.00x (SEF29-X-149). 2200(H)x 600(W)x 400(D)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 7 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.4, Front and side views of an A111160.00x (SEF29-X-150). 2200(H)x 600(W)x 600(D)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 8 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.5, Front and side views of an A451028.000 (SEB5-12FIT100-002) battery cabinet. 2200(H)x 600(W)x 400(D)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 9 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.6, Front and side views of an A461032.000 (SEB6-12FFT100-002) battery cabinet. 2200(H)x 600(W)x 600(D)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 10 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.7, Front and side views of a SP18-RRU A112040.000. 2200(H)x 600(W)x 600(D)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 11 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.8, Front and side views of a SP18 A112041.000. 2200(H)x 600(W)x 600(D)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 12 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig 2.9, Front and side views of a SP18 Battery Expansion Rack A401049.000 2200(H)x 600(W)x 600(D) TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 13 of 64
Installation & Commissioning, Operation & Maintenance Manual
3.
REQUIREMENTS
Installation:
Termination or configuration of the AC Mains connection is only to be performed by a licensed electrical installer. Standard tools used by an authorized Electrician A torque wrench for installing the battery cables nuts.
The system should only be installed into locations that have restricted access to personnel. Note: All tools should be insulated
For communication with the controller:
A laptop computer running either windows 2000 or windows XP. SmartSuite software on CD (supplied with system) Standard A-B type USB cable.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 14 of 64
Installation & Commissioning, Operation & Maintenance Manual
WARNINGS
Communications Grade valve regulated gas recombination lead acid cells and monoblocs are electrically live at all times and must be treated with care. The products are generally capable of supplying high short circuit currents even if the case or lid is damaged. Remember that the battery is electrically live at all times and cannot be isolated in the conventional sense, although the voltage at any point can be reduced by removal of appropriate inter battery links. Take care that short circuits are not caused by accidentally dropping or touching metal objects onto the cell or monoblocs terminals.
Before connecting batteries and cables remove all metallic objects such as rings, watches etc from your hands and wrists to avoid causing a short circuit.
Do not smoke or permit open flames near batteries. Avoid any activity near the batteries that may cause sparks.
If the rectifier module is damaged in any way or develops a fault it should be replaced immediately. This should only be done by appropriately qualified personnel. Refer to the operations manual for instructions.
The equipment contains voltages that may be lethal. The AC distribution front cover plate should not be removed without first isolating the AC supplies. AC supply connection should only be done by appropriately qualified personnel.
Allow for adequate ventilation around the units. A 5 –10 mm clearance should be kept between the batteries as they may expand in high temperatures.
Be aware that the rectifier is rated for high temperature operations. Therefore care must be taken when handling the modules as they can reach temperatures of 60oC
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 15 of 64
Installation & Commissioning, Operation & Maintenance Manual
4.
PACKING LIST
A fully equipped Flatpack2 system is dispatched from Eltek in a number of packages. Each package is clearly marked indicating its content. The packages include the following. 1 x Rectifier Cabinet box Including: Rectifier Cabinet, Manual on CD, lifting eye bolts, floor insulation kit and dyna bolts/dynasets. May contain up to 9 x 2kW FlatPack2 rectifiers already fitted. (see packing list). 1 x Battery Cabinet box (if ordered) Including: Battery Cabinet, Floor Insulation Kit, dynabolts and battery rack to rectifier rack DC power connection cable with Anderson connectors, earth cable & alarm extension cable. (See packing list on box.) Batteries crates Each Crate contains batteries (Monoblocs) as required, including solid links & washers.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 16 of 64
Installation & Commissioning, Operation & Maintenance Manual
5.
SYSTEM CONFIGURATION
The different configurations of the Flatpack2 system and expansion battery cabinets are listed below: Part #
Dimensions
A1110886.00x (SEF29-X-149)
2200(H)x600(W)x400(D)
Battery Type
Max # strings
Notes
12FIT100
5
Can accommodate up to 10 strings using the SEB512FIT100-002 Cabinet. Battery Expansion To suit SEF29-X-149
A451028.000 (SEB5-12FIT100.002)
2200(H)x600(W)x400(D)
12FIT100
5
A111160.00x
2200(H)x600(W)x600(D)
12FFT100
6
Can accommodate up to 12 strings using the SEB612FFT100-002 Cabinet.
A111105.000 (SEF29-X-156)
2200(H)x600(W)x600(D)
12FFT100
5
A461032.000 (SEB6-12FFT100.002)
2200(H)x 600(W)x600(D)
12FFT100
6
2200(H)x600(W)x600(D)
SBS190(Default)
4(Default)
PWL100 (Optional)
6(Optional)
SBS190(Default)
4(Default)
PWL100 (Optional)
6(Optional)
SBS190(Default)
5
As SEF29-X150, but with a DC/DC converter rack factory fitted Battery Expansion To suit SEF29-X-150 / SEF29-X-156 Can accommodate up to 9 (or 11) strings using the A401049.000 SP18 battery expansion rack Can accommodate up to 9 (or 11) strings using the A401049.000 SP18 battery expansion rack Battery Expansion To suit A112040.000 A112041.000
(SEF29-X-150)
A112040.000
A112041.000
A401049.000
2200(H)x600(W)x600(D)
2200(H)x600(W)x600(D)
PWL100 (Optional)
Fig 5.1 System Part numbers
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 17 of 64
Installation & Commissioning, Operation & Maintenance Manual
Component name Smartpack Controller Smartpack Controller Flatpack2 Rectifier Flatpack HE Rectifier DC/DC Converter SP18-RRU Label Kit
Part number 242100.100 242100.118(later type) 241115.002 241115.105 241114.503 A641031.000
Fig 5.2 Component Part numbers 6.
UNPACKING
All equipment is suitable for being moved with a normal pallet truck whilst packed. When unpacked, cabinets may weigh 145kg and are heavier at the top end of the cabinet.
CAUTION: THESE UNITS ARE TOP HEAVY, AND CAN TIP OVER UNEXPECTEDLY IF NOT HANDLED WITH CARE. Appropriate lifting equipment should be used, and suitable care must be taken while handling these units. The most appropriate method of moving the racks is with the use of a hand trolley. Some packaging material should be placed between the trolley and the rack to avoid damage to the rack. It is however recommended that the complete boxes be positioned as close as possible to the actual location where the system is to be installed.
If lifting using eye bolts, a spreader bar must be used.
Lifting Cables
Spreader bar, used to prevent eyebolts from bending inwards Eyebolt, placed in the wall mounting brackets bolt positions Cabinet
Fig 6.1 Lifting arrangement for the cabinet, using eyebolts and spreader bar.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 18 of 64
Installation & Commissioning, Operation & Maintenance Manual
7.
CABINET ASSEMBLY
The Cabinets will arrive packed in a box. The following are step by step instructions for assembling this cabinet. 1. Inspect the installation site and determine where the system will be located. Position the packages close to the final systems destination. 2. Each package will have affixed to it a complete packing list listing the contents of each package and the quantity. Check to ensure that you have all items marked on the packing list. 3. Unpack the cabinet from its box. 4. Follow the floor fixing instructions in the next section to fix the cabinet in position. 5. Attach the cabinet to the wall using wall mounting brackets as below.
600mm Cabinet example
400mm Cabinet example
Fig 7.1 Wall mounting brackets. Note: the distance between the top of the cabinet and the wall will be 100mm larger for the 600mm cabinet type than for the 400mm cabinet, due to the greater battery depth.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 19 of 64
Installation & Commissioning, Operation & Maintenance Manual
7.1 Specialised Wall mounting kit This section details the mounting of an optional wall mounting kit, for mounting in transportable huts.
Contained with the kit (Part number): 2 wall mount brackets (MB300) 12 ‘top hat’ washers (XZ045) 2 short wall insulators (KZ207) 2 Long wall insulators (KZ208)
Fig 7.2
Fig 7.3 Assembled brackets with insulators & ‘hat washers’ in place. Remove the ‘X’ brace from all shelves. Drill a counter sunk hole here to correspond with the holes in the vertical wall mount. Two extra holes will need to be drilled in each of the top five shelves. (See TG6308 in attachments for a drawing) The existing cross brace attachment hole can be used as the 2nd mounting position.
61mm
Fig 7.4 TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 20 of 64
Installation & Commissioning, Operation & Maintenance Manual
Each vertical bracket uses 4 ‘hat washers’ & one long wall insulator to insulate from the wall.
Place the short edge of the bracket against the wall in the location shown to align with the holes drilled in the rear of the battery shelves.
Remove the ‘X’ bracing from all shelves.
Use the short wall insulator with 2 hat washers to insulate the top ‘L’ bracket from the wall. The insulator is installed between the wall & bracket; shown here beside the ‘L’ bracket. Fig 7.5 TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 21 of 64
Installation & Commissioning, Operation & Maintenance Manual
8.
FLOOR INSULATION
All cabinets include an insulation kit, which isolates the racks from earth. One insulation kit consists of appropriate insulation plates, 4 insulation washers, 4 round washers and 4 M8 dynabolts/dynasets. The insulating plate can be used as a template to mark the positions of the holes on the concrete floor. After the holes have been drilled, position the insulating plate between the cabinet and the cabinet floor. Bolt through the 4 holes in the bottom battery tray using the dynabolts/dynasets provided. Note: the insulating plate may be provided in separate pieces that need to be positioned on the floor.
Nut Washer Cabinet
Insulating Washer
Dyna-bolt/ Dyna-set
Insulating Plate
Concrete Floor
Fig 8.1 Dynabolt Fixing
556mm
400mm 288mm
600mm Fig 8.2 Floor template and insulating plates 400mm option TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 22 of 64
Installation & Commissioning, Operation & Maintenance Manual
563mm
600mm 540mm
600mm Fig 8.3 Floor template and insulating plates, 600mm option 9.
EARTH CABLING
Each cabinet should be bound to earth using links. There is one 95mm² earth cable shipped with each cabinet (Except SP18-RRU system). Ensure this converter cubicle bond is bonding the cabinet M8 bolt to the positive common bar (SPC) inside the cabinet. Also ensure flat and spring washers are used and the links are secure. External earthing should be done to relevant company standards. Also connect the battery extension cabinet, if being used, to the SPC inside the rectifier cabinet with the 95mm² earth cable supplied with the extension cabinet. There is also a M6 bolt that is connected to the protective earth on the AC input terminals that needs no further connections .
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 23 of 64
Installation & Commissioning, Operation & Maintenance Manual
10.
CONNECTING THE BATTERIES
The FlatPack2 system is supplied with a 100A battery circuit breaker with auxiliary for each string. The battery CB’s are located on the left-hand side of each battery shelf. System is supplied with cables from the battery CB’s to the battery trays already fitted. Ensure that the battery CB’s are turned OFF before connecting the batteries. NOTE: For battery shelves not being used, ensure cable ends remain insulated with heat shrink provided. Installation Steps 1. Before commencing the installation, ensure that each battery is in good condition and has not been damaged during transport. 2. Monoblocs are heavy; and accordingly the recommended lifting equipment should be used. 3. Remove retaining strap. 4. Position the batteries on shelves as per fig 10.1. We suggest that one monobloc be lifted into place at a time. Leave a clearance space of between 5 – 10 mm between the batteries. Slide the batteries gently back to the rear of the system to avoid any risk of damaging them on the rear of the shelf. 5. Particular care should be taken when placing on the shelves to ensure the correct positioning of the +ve and –ve terminals. 6. Connect inter battery flexible cables and inter tier links. To ensure a low resistance joint clean the flat contact making surfaces of the terminal posts and connectors with a soft clean cloth. The links do not normally require cleaning and can be fitted without any operation. However in some cases the links could show encrustation and this should be removed using Scotchbrite or fine grade abrasive paper. Do not use a wire brush and be especially careful not to break through the lead plating. Apply a light coating of grease to the contact – mating surfaces and place a solid connector strap or flexible link in position. Tighten the nuts firmly: 7-8 Nm for a Stud type terminal; (12FIT100 [M6], SBS190 [M6]), 8-10 Nm for a socket type terminal (12FFT100 [M8]) using an insulated torque wrench. (A non-torque insulated wrench is supplied with the batteries. This should be used only when the installer is familiar with battery installations and knows from experience what level of torque needs to be applied) Lightly smear grease on the washer and nut. WARNING: Particular care should be taken to ensure the batteries are not shortcircuited during this procedure. 7. Place terminal boots and battery link caps on all battery terminals. 8. Place the battery numbering labels in place starting at the first battery (on the bottom shelf) and working to the last. Replace the battery 9. Wait 24 Hours and re-torque the battery terminals. You will find the following colour coding on the battery cables. Blue (–) negative and Red (+) Positive
The system must not be located in an explosive atmosphere, i.e. in the presence of flammable gases and fumes. Suitable ventilation for the battery must be provided.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 24 of 64
Installation & Commissioning, Operation & Maintenance Manual
Battery Circuit breaker. Retaining bracket
(Cables / links are not shown) Fig 10.1 Front view of batteries, showing spacing & battery circuit breaker position Note: the solid battery links have slots that allow the batteries to be easier positioned and connected, but may allow the batteries to come too close together if not installed correctly. Please enure that there is proper spacing maintained between the batteries to allow for ventilation of heat.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 25 of 64
Installation & Commissioning, Operation & Maintenance Manual
11.
EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS.
The Flatpack2 system can be supplied with an expansion battery cabinet. The following table outlines which expansion cabinet is supplied with which system. Part #
Dimensions
Type of battery
Number of battery shelves
A451028.000 (SEB5-12FIT100.002)
2200(H)x 600(W) x 400(D)
12FIT100
5
A461032.000 (SEB6-12FFT100.002)
2200(H)x 600(W) x 600(D)
12FFT100
6
A401049.000
2200(H)x 600(W) x 600(D)
SBS190 12FFT100
5
To suit System
A1110886.00x (SEF29-X-149) A111160.00x (SEF29-X-150) A112040.000 A112041.000
To install extra strings of batteries: 1. Position expansion cabinet and fix it to the floor in the same manner as the rectifier cabinet. 2. Ensure that all the individual string MCB’s are turned OFF 3. Install the batteries as detailed in section 10. 4. Double check all the string MCB’s are OFF and connect the flying lead with the Anderson connector to the existing rectifier cabinet as in fig.11.2 below.
For SP18 and SP18-RRU systems, there is a bulk feed point supplied in the system for direct connection of battery rack without using Anderson connector. (Fig 11.1)
Figure 11.1 Bulk Feed Point for External Battery Connection TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 26 of 64
Installation & Commissioning, Operation & Maintenance Manual
5. Once the battery strings are in place turn on the strings of batteries one by one. Pause between turning each string on to let the system equalize with the string. 6. Check the string voltage and the battery current on the Smartpack display. There should be a small positive current flowing to the batteries. Each expansion battery cabinet is fitted with a flying lead with an Anderson connector on one end to connect to the +ve/-ve bus bars in the system cabinet as shown below: (SP18 Expansion rack has additional bulk feed connection) Rectifier Cabinet
Battery Cabinet Flying Lead with Anderson Connector
Battery CB alarm. Earth cable
Figure 11.2 When connecting extra batteries to the system, the controller needs to be updated manually. Use the keypad menu in Section 17 to change the battery charge current limit setting if no PC is available. The battery charge current limit should be set to = [25% of the C10 rating of the battery] x [the number of strings installed], which in the case of 12FFT100 & 12FIT100 batteries is 25A x [the number of strings.]
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 27 of 64
Installation & Commissioning, Operation & Maintenance Manual
12.
EXPANSION RACK ALARM CONFIGURATION
The battery alarms provide signals to the Smartpack control module via auxiliary switch’s on each battery circuit breaker. The purpose of this signal is to initiate an alarm condition if the battery CB has tripped. This a normally closed loop which if broken, will create an alarm Alarm Interconnection cables Each system cabinet is supplied with an alarm interconnection cable that connects the system cabinet to the expansion battery cabinet. The alarm interconnection cable is a 2000mm long, 2 way cable. Installation Steps for Expansion Cabinet alarm wiring There is a four way terminal block fitted in the rectifier cabinet on the LHS under the distribution. When an external battery cabinet has been installed remove the link wire on the top of the terminals:1. Connect one end of the 2 core alarm interconnection cable to the two terminals located in the top LHS of the cabinet. 2. Run the cable through the top cover of the cabinet to the terminal block located in the top of the battery cabinet. 3. Secure the alarm cable wiring with cable ties.
Figure 12.1 Battery Alarm Schematic showing expansion battery cabinet
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 28 of 64
Installation & Commissioning, Operation & Maintenance Manual
13.
INSTALATION & REFRESHING VOLTAGES OF BATTERIES
If the batteries are in service on a temperature compensated power supply in temperatures above an ambient of 20°C, the service life of the battery will be affected. See table 13.1 below. Ambient temperature (deg C) 20 25 30 35 40 45 50
Expected life (% of nominal) 100 70 50 35 25 18 15
Table 13.1
To check if a refresh is needed, follow the below procedure. 1. Check the open circuit voltage of each battery. The minimum monobloc open circuit voltage that the battery can be considered as not requiring refresh is 12.72V. Any monoblocs that are below this voltage will have to be refreshed as below. Above this value, they may be considered acceptable for use & do not need to be refreshed. 2. Put the batteries on a float voltage charge of 54.48V for a period of 48 hours at 20degC. 3. After float charging leave the batteries to settle for a further 48 hours. 4. Check the open circuit voltages of the monoblocs. The minimum monobloc open circuit voltage after refresh is 12.72V. Any monoblocs that are below this voltage cannot be considered as serviceable.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 29 of 64
Installation & Commissioning, Operation & Maintenance Manual
14.
EXPANSION RACK INSTALLATION CHECK LIST
Check these points 1. Check that the cabinet is fixed to the wall securely. 2. Check that the battery connections are all of correct polarity. 3. Check that the terminal boots and battery link caps are fitted on all the batteries. 4. Check that the Anderson flying lead is connected. 5. Check that the battery rack expansion rack earth cable is securely connected to the common positive bar (SPC) inside the rectifier cabinet. 6. Check that battery string voltage is between -48 and -55 V. 7. Check that the MCB alarm cabling to the main rack is installed and terminated.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
OK
Page 30 of 64
Installation & Commissioning, Operation & Maintenance Manual
15.
INSTALLATION AND OPERATION OF RECTIFIER MODULES
If for any reason any of the rectifiers have to be removed, or additional rectifiers are being fitted, please refer to the following procedure. See also section 25, for important information regarding rectifier operation and positioning. It is to be noted that the FlatPack2 rectifier module is a “Hot” plug rectifier allowing expandability and serviceability without power shutdown. The current share functionality of the modules ensures all modules deliver the same amount of current. The FlatPack2 rectifier cabinet accommodates up to 9 rectifier modules. Installing rectifiers 1. Unpack the rectifier modules from their packaging. 2. Refer to section 15.3: for information regarding the correct rectifier positioning. 3. With the system on, slide each module into place, but do not push the rectifier all the way home at this point. Make sure the pull out handles have been released as shown in figs 15.1 and 15.2 below, then push the unit into place and lock the rectifier into position by pushing the handles firmly into their housing. Hole to release the handles spring mechanism
Handle in locked position
Fig. 15.1 To remove a rectifier, follow the steps below: 1. Unlock and release the handles by inserting a small screw driver into the holes in the upper corners of the rectifier front panel and carefully push it downwards. The handle will release and pop out.
Handle in unlocked position
2.
Fig. 15.2 Use the handles to pull the rectifier loose.
During continuous operation, the metal case of the rectifier unit can become hot. There is no danger of contact burns occurring, but care should still be taken when handling recently unplugged rectifiers.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 31 of 64
Installation & Commissioning, Operation & Maintenance Manual
Fig. 15.3 Flatpack2 front view
The Flatpack2 is intended for use as a stand-alone unit or in systems with multiple modules and an external alarm / control module. The Flatpack2 will operate in a default mode if the control module fails The Flatpack2 Rectifier Module has the following LED indications: “Power” (green) indicates whether the power supply is OFF, ON, or communicating. “Alarm” (red) indicates an alarm situation. “Notice” (yellow) indicates an atypical situation. 15.1 Visual Indications LED Power (green)
Status
Description
ON Flashing OFF
Rectifier is powered Smartpack controller accessing information on the rectifier Mains are unavailable Rectifier is in Shut-down Mode due to low mains (0 – 85VAC) or high internal temperature (+75 °C or higher)
Alarm (red)
ON
Interna CAN bus failure No alarm situation is present
OFF
Notice (yellow)
Flashing
Rectifier is in Derating Mode (reduced output power) due to high internal temperature (+45 to 75 °C) or low input voltage (lower than 185VAC) or fan failure The remote Current Limit is activated The rectifier is communication with the controller over a current sharing / current limiting issue AC input voltage is out o Rectifier in stand-alone mode (or loss of communication with the Smartpack controller Rectifier is in Over-voltage Protection Mode
OFF
No atypical situation is present
ON
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 32 of 64
Installation & Commissioning, Operation & Maintenance Manual
15.2 Plugging in Rectifiers 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”. This ID number (or CAN bus address) and the rectifier’s serial number are stored in both SmartPack and Rectifier modules. 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 and serial numbers, 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 power shelves, one module at a time, starting with shelf position 1, 2, 3 and so on.
During continuous operation, the metal case of the rectifier unit can become hot. There is no danger of contact burns occurring, but all care should still be taken when handling recently unplugged rectifiers.
15.3 Identification of different rated rectifiers Three different types of Flatpack2 rectifiers are compatible these systems; a 1.8kW rectifier & a 2.0kW rectifier and a 2.0kW HE rectifier. These interoperate fully, including alarms & current sharing (current sharing is by a percentage of total output). The only functional difference between the 1.8kW and 2.0kW rectifiers is their maximum power output. For easy identification, the 1.8kW rectifier has a silver front, the 2kW rectifier has a light blue front and 2kW HE rectifier has a black front. HE and 2000W label
Silver Black 1.8kW 2.0kW
Blue 2kW
‘2000w’ label
Fig. 15.4 Flatpack2 1.8kW & 2kW and 2kW HE rectifiers.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 33 of 64
Installation & Commissioning, Operation & Maintenance Manual
15.4 Replacing and installing rectifier modules
If a upgrading a system with additional rectifiers: Place the new rectifiers into the next highest rectifier position, in order. See table below. Their existence will be automatically logged by the controller, no further configuration is required.
If a replacing a faulty rectifier and a replacement rectifier is immediately available: 1. Unclip handles of faulty rectifier as shown above and pull out rectifier. 2. Fit the new rectifier into the position left by the faulty rectifier. 3. Eliminate any rectifier alarm by performing a ‘rectifier recount’ [rectifier reset, under rectifier info] that resets the number of rectifiers using the front keypad, under user menu (see section 17.3)
If a replacing a faulty rectifier and a replacement rectifier is not immediately available: 1. Unclip handles of faulty rectifier as shown above and pull out rectifier. 2. Remove the highest ID rectifier (important) and fit into the vacant faulty rectifier position, in order to maintain continuity. 3. Eliminate any rectifier alarm by performing a ‘rectifier recount’ [rectifier reset, under rectifier info] that resets the number of rectifiers using the front keypad, under user menu (see section 17.3) NOTE: The highest ID rectifier is now reassigned to the ID of the faulty rectifier in the system 4. When a new rectifier is obtained, fit it into the highest vacant ID position. Its existence will be automatically logged by the controller (as in the above scenario, ‘upgrading a system with additional rectifiers’.)
Smartpack (controller)
ID1
ID4
ID7
(Blank)
ID2
ID5
ID8
(Blank)
ID3
ID6
ID9
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 34 of 64
Installation & Commissioning, Operation & Maintenance Manual
16.
INSTALLING AND REMOVING THE SMARTPACK CONTROLLER (ETHERNET CONNECTION) The Smartpack controller is physically held in place using similar method as the Flatpack2 rectifiers: It incorporates handles that serve both to lock the module into position and to pull it out of its housing. CAUTION: Do not hand-carry the controller by its handles. Cables are plugged to the controller’s rear panel. If in the event that the Smartpack needs to be removed for any reason the following procedure should be used: 1. Release the handles (using similar method as the Flatpack2 rectifiers as described above) 2. Grasp the Smartpack by the handles at either side of the unit and pull the unit out. The connection cables are attached to the rear of the controller via several ‘D’ type connectors. Pull out the controller enough to access the rear of the unit, and unplug the cables as detailed over page. NOTE: make a record of which positions the connectors were removed from for future reference.
Open the handles before inserting the controller into the power shelf. To refit the Smartpack: 1. Carefully reconnect the cables to the appropriate positions in the rear of the controller. 2. Slide the controller unit into place making sure that all cables are not overly bent. 3. Fasten the unit by firmly pushing the handles into their housing. Removing the Smartpack controller
Open the handles (insert a screwdriver into the holes to release the spring mechanism) Remove the module
Use both handles to pull the module gently loose; support it from underneath; hidden cables are connected to the rear panel.
Fig. 16.1
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 35 of 64
Installation & Commissioning, Operation & Maintenance Manual
WARNING: the rear cables from the system carry live -48V voltages. If completely disconnecting the controller from the system, ensure that the cable to CON5 is removed last, as this cable provides the controller with its 48V power. When removing, be careful that the male plug doesn’t make contact with any metallic material that can cause a short circuit on the pins. There is no danger to personnel.
Early controllers rear view:
Later controllers with Ethernet connection (242100.118) rear view:
Ethernet port
For connection to the internet for remote monitoring, connect CAT5 cable to the back of the Smartpack and route the cable out through the letterbox aperture at the top rear of the power rack. Refer to Webpower section of accompanying CD for information on setting up the network connection. NOTE: Do not plug networked cables in to the CAN1 connector, this will damage the CAN bus internally on the controller.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 36 of 64
Installation & Commissioning, Operation & Maintenance Manual
Removing the cables for replacement purposes:
Remove the controller until the rear connectors are exposed.
Unplug the cables, leaving CON5 (red surrounds) until last.
Reverse the procedure when reconnecting the new controller Fig. 16.2 Note, CON 3 is unused, and CON 4 is only used for connection of the temperature compensation probe.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 37 of 64
Installation & Commissioning, Operation & Maintenance Manual
17.
OPERATION OF THE SMARTPACK CONTROLLER
The Smartpack unit controls, monitors and regulates each FlatPack rectifier module and provides battery & system surveillance in order to protect and optimize the battery lifetime. If the alarm module is removed, voltage control / regulation will be lost and system voltage will equal to default rectifier voltage. 17.1 Front Panel Operation This chapter describes the Smartpack controller’s keys and indicators, and how to operate the Flatpack2 DC power system from the controller’s front panel. Description of Keys, Display and Indicators The Smartpack controller’s front panel consists of two functional areas: the presentation area (LCD display and LED lamps) and the control area (keys).
`
LED indicators The Smartpack controller has the following LED indications: “Power” (green LED) indicates that the power supply is ON or OFF “Alarm” (red LED) indicates an alarm situation (major alarm) “Notice” (yellow LED, or minor warning) indicates an atypical situation.
LCD Display The graphic display is an important part of the power supply system’s user interface. The display can be shown in Status Mode (displays the system’s status) or in Menu Mode (displays the menu structure). Depending on the display’s mode, the upper line shows the output voltage or menu options, while the lower line displays battery and load current, alarms, or information about which key to press.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 38 of 64
Installation & Commissioning, Operation & Maintenance Manual
Front Keys You can control the whole Flatpack2 DC power system via a network of software menus accessed with the controller’s front keys. o Press the
key to change from Status Mode to Menu Mode.
o Press the or keys to scroll up or down and navigate to find menu options (function or parameter). o Press then the
key to select the function.
Modes of Operation The controller’s display is either in Status Mode or in Menu Mode. Status Mode When the front keys are not in operation, the display is in Status Mode. The following information is then scrolled through the display: The upper line continuously displays the battery voltage. The lower line continuously scrolls the following information: Battery Current Load Current Active alarms Other messages Menu Mode When the front keys are in operation, the controller’s display switches to Menu Mode and the following information is scrolled through the display:
The upper line shows the name of the active menu or sub-menu The lower line indicates which key to press Notice: If no keys are pressed within 30 seconds the display will automatically switch from Menu Mode to Status Mode.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 39 of 64
Installation & Commissioning, Operation & Maintenance Manual
17.2 Operating Menus, (Menu Mode) The Flatpack2 DC power system’s functionality is accessed via a network of software menus and submenus, enabling you to configure and control the whole power system. The functionality is divided in two different hierarchical menu structures: the User Options menus and the Service Options menus (password protected, only authorized personnel have access to them). Special, not so frequently used options — such as calibration and adjustments — are accessible in the Service Options sub-menus. User Options When you “enter” Menu Mode, you access the User Options. How to browse the display menus:
o
o o
To enter Menu Mode Press on the key to change from Status Mode to Menu Mode Browsing “down” to a menu option Press the key, to scroll down within the same menu level, and find menu options (functions or parameters) Selecting a menu option Press the key to select the displayed menu option or parameter Browsing “up” to a menu option or level Press the key to scroll up to the previous menu option, and out to the previous menu level. Service Options When you enter Menu Mode, you access the User Options. You may then scroll down to the password protected Service Options. The Service Option’s password is factory-programmed to . If the wrong password is entered three times, the controller will be locked out for a period of time. Notice: If no keys are pressed within 30 seconds the display will automatically switch from Menu Mode to Status Mode.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 40 of 64
Installation & Commissioning, Operation & Maintenance Manual
17.3 Front keypad menu tree for Smartpack controller: Service
User
Password = Service password
Alarm Reset
Alarm Reset
Voltage Info
NomVolt
VoltAdjustment
NomVolt
BoostVolt
LowBatt1 BoostVolt Volt Calibration
VoltCal LowBatt2
LowBatt1 Change Password
Password HighBatt1
LowBatt2 SetBoostTime
BoostTime
Start/StopBoost
StartBoost/StopBoost
High Batt2 HighBatt1 LVD1 High Batt2 Auto Boost Cfg
Enable/Disable LVD2
LVD1 Threshold LVD2 Batt. Test Setup Display messages
Display messages
Serial Number
Controller S/N
Sw Info
SwInfo
Rectifier Info
NoOfRects. Nn RECTIFIER RESET
RectCurrent
RectSerialNumber
Nxt Test Date Time
Start/Stop Test
StartTest/StopTest
End Volt
Charge Curr Lim
Enable/Disable
Max Test Duration
Max ChargeCurr
Test Interval
Battery Setup
NumOfString
Guard Time
OutputControl
Temp.Comp
Change Date/Time
VoltageControl
Rect.PrimaryVolt
Rectifier Status
Relay Test
Alarm Output 1 Alarm Output 2
Rectifier Temp Batt Contactor Mains Info
NoOfPhases nn
Load Contactor
Mains Status
Alarm Output nn
Mains Voltage BattLifeTime Rst Temp Level Info
BattLifeTime Rst
Temp Level Info
Fig 17.1 TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 41 of 64
Installation & Commissioning, Operation & Maintenance Manual
18.
REMOTE ALARM CONNECTIONS
The Smartpack controller incorporates 6 alarm relay outputs and provides both normally open and normally closed states on the output relay. See table 18.1 for pin connections.
Relay Output Card 1
Relay Output Card 2
Relay Output Card 3 (SP18, SP18-RRU)
PLEASE NOTE: Normal operation is when the system is energized and there are no alarms present on the system.
Monitor fail
DCDC converter alarm terminal block. Black: common. White: normally closed (failsafe) Brown: normally open.
Battery fuse alarm extension. Fig 18.1 Alarm terminal blocks
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 42 of 64
Installation & Commissioning, Operation & Maintenance Manual
ALARM
CONTACT
Mains Fail
COM
RELAY #
5
NC
High Load / Low Load
1
7
NC
8
2
COM
10 11 12
NC
Off Normal
9 9
3
COM NO
Rectifier Fail
TB2
10
NC
Battery Fuse/CB fail
6
NO
NO High Float / Low Float
TB PIN #
4
COM
13
NO
14
NC
15
5
COM
16
NO
17
NC
18
6
COM
TB1
19 20
NO NC Monitor Fail
External PCB
NO COM
Figure 18.2 Output relay pin out assignment for SP18 and SP18-RRU Systems ALARM
CONTACT
Mains Fail
NO
Mains Fail
COM
Mains Fail
NC
High Load / Low Load
NO
High Load / Low Load
COM
High Load / Low Load
NC
High Float / Low Float
NO
High Float / Low Float
COM
RELAY #
RELAY OUTPUT CARD #
1
1
PIN # 5 6 7 8
2
1
9 10 9
3
2
10
High Float / Low Float
NC
11
Load / Battery CB fail
NO
12
Load / Battery CB fail
COM
Load / Battery CB fail
NC
14
Rectifier Fail
NO
15
Rectifier Fail
COM
Rectifier Fail
NC
17
Off Normal / BCM
NO
18
Off Normal / BCM
COM
Off Normal / BCM
NC
Monitor Fail
NO
Monitor Fail
COM
Monitor Fail
NC
4
5
6
2
2
2
13
16
19 20
External PCB located LHS, above Smartpack controller
Table 18.3 Output relay PIN connection for other systems TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 43 of 64
Installation & Commissioning, Operation & Maintenance Manual
Normally closed Normally open Common
Figure 18.4 Top view of monitor fail PCB showing connection points for monitor fail alarm
Alarm name
Trigger
Failed AC supply
Total loss of any one phase or all phases AC supply to the system.
Battery CB tripped Load CB tripped High Load voltage High Float voltage Low Load voltage Low Float voltage Failed Rectifier
Failure of any battery CB Failure of any load fuse System voltage is above 57.0Vdc System voltage is above 55.70Vdc System voltage is below 48Vdc System voltage is below 52.8Vdc Loss of output and input information from a rectifier, Loss of communication between Smartpack controller and rectifier Smartpack output failure
System monitor failure
Table 18.5 Alarm trigger conditions
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 44 of 64
Installation & Commissioning, Operation & Maintenance Manual
18.2 Digital inputs. For SP18 / SP18-RRU Systems: The alarm PCB also has up to six digital inputs that can be used on, two of which are pre set for Generator Feed and Off Normal (but disabled). Input 1: Generator input. Input 2: Off normal input. Alarm Input 1 Input 1 Input 2 Input 2
State TB Pin + 1 2 2 + 3 2 4
Alarm Input 3 Input 3 Input 4 Input 4 Input 5 Input 5 Input 6 Input 6
State TB Pin + 1 1 2 + 3 1 4 + 5 1 6 + 7 1 8 Figure 18.6 Alarm PCB showing digital input pin outs Input voltage range 0-75V Terminal impedance 200kΩ Operating current between terminals 30mA Figure 18.7 Digital input specification
Input 1: Generator input (Disabled). When operating on AC mains, the digital input is left open, (its normal state.) If this input is closed (shorted), the controller will assume that it is now operating from a generator. The controller will then limit the battery charge current down to a small value in order to limit the strain introduced on the generator. In this way, the generator can be used to supply only the load, and not be burdened by also trying to recharge discharged batteries at the same time.
Input 2: Off normal input (Disabled). When in a normal state the digital input is left open. If this input is closed (shorted), the controller will extend an off normal alarm on the alarm relay output (relay 6.), This could be used in combination with a switch to indicate someone is on site. Input 3: Spare Connection. Input 4: Load MCB fail alarm. When a load MCB is in the off position and alarm will be generated and sent to the Smartpack which will change the state for relay #4. (see Fig 13-3) TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 45 of 64
Installation & Commissioning, Operation & Maintenance Manual
Input 5: Used for external load fuse alarm (Disabled). Input 6: Spare Connection. For more information, refer to Quick Start Guide: Flatpack2, PS System (356804.103).
For other Systems: The Smartpack controller accepts up to 6 inputs to the system, 2 are used. Input 1: Generator input. Normally closed. Input 2: Off normal input. Normally closed.
Alarm Input 1 Input 1 Input 2 Input 2
State TB Pin + 1 1 2 + 3 1 4 Pin 1
Alarm Input 3 Input 3 Input 4 Input 4 Input 5 Input 5 Input 6 Input 6
State TB Pin + 1 2 2 + 3 2 4 + 5 2 6 + 7 2 8
Pin 10 TB1
Pin 1 TB2
Pin 20
Input 1: Generator input. When operating on AC mains, the digital input is left open, (its normal state.) If this input is closed (shorted), the controller will assume that it is now operating from a generator. The controller will then limit the battery charge current down to a small value in order to limit the strain introduced on the generator. In this way, the generator can be used to supply only the load, and not be burdened by also trying to recharge discharged batteries at the same time. Input 2: Off normal input. When in a normal state the digital input is left open. If this input is closed (shorted), the controller will extend an off normal alarm on the alarm relay output (relay 6.)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 46 of 64
Installation & Commissioning, Operation & Maintenance Manual
19. +24 V DC/DC CONVERTER The Flatpack DC/DC 48/24, a modular hot plug-in DC/DC converter.
Fig 19.1 A DC/DC converter module The converter is specially designed to provide a high quality and highly reliable DC output voltage. The module has a soft start power-up and an internal blocking diode allows hot plug-in and isolates any faults in the converter output from the DC bus. Several internal protection circuits ensure safe operation, even outside specified limits for normal operation.. A module failure alarm is given if the module shuts down due to high output voltage, or in case of an internal failure. Converters connected in parallel will exhibit active load sharing via CAN bus. Front LEDs show power ON/OFF and alarm status in addition to a LED bar graph for output current indication. The Flatpack DC/DC 48/24 will operate in ambient temperatures up to +75°C (+167°F). At temperatures above +65°C the output power may be derated. This unit has the part number: 241114.503, and is only included in SEF29-X-156 systems . The output of the 24V DC/DC converter is found on top if the cabinet, via a 175A red Anderson connection. The 24V output of the SEF29-X-156 systems are floating. That is, to achieve a non floating +24V output with respect to the -48V output, the negative of the DC/DC converter will need to be brought back to the common positive bar inside the distribution at the top of the cabinet. The alarms extended from the DC/DC converter are to be found on a labeled terminal block inside the -48V distribution area.
See the attachments for more data regarding the DC/DC Converter.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 47 of 64
Installation & Commissioning, Operation & Maintenance Manual
DCDC converter rack with 4 modules in place
Do not use this top battery shelf if the DCDC converter rack is being used.
Fig 19.2 Do not use the top battery shelf if the DCDC converter rack is being used. If additional battery strings are needed, please use a battery extension rack. Note: This is relevant only for systems with a DCDC converter rack fitted.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 48 of 64
Installation & Commissioning, Operation & Maintenance Manual
20.
AC MAIN SUPPLY INSTALLATION
AC mains connection terminals are provided for the AC mains connection. The terminals are pre-connected to the rectifier modules. Cables of up to 10mm2 size can be connected to these terminals. Termination or configuration of the AC Mains connection is only to be performed by a licensed electrical installer. When connecting power to this system, a nearby AC mains disconnect device should be integrated into the circuit to facilitate servicing. This could be an isolating switch, circuit breaker or equivalent device. Phase distribution on rectifiers The system is pre-wired to suit a 3-phase +N and Earth AC supply. Other configurations are possible, see above. The phase distribution for the rectifiers is shown below. While installing the rectifiers please ensure that they are distributed evenly between phases to ensure a balanced load on each phase where possible.
Figure 20.1 Cabinet Front view.
Distribution controller L1 L1 L1 (Blank) L2 L2 L2 (Blank) L3 L3 L3 DC/DC Converter DC/DC Converter DC/DC Converter DC/DC Converter Figure 20.2 AC Phase arrangement 9 Way Rectifier Rack – showing AC Phase positions and (optional) DC/DC converters
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 49 of 64
Installation & Commissioning, Operation & Maintenance Manual
Termination or configuration of the AC Mains connection is only to be performed by a licensed electrical installer. Three-Phase Input Remove the top panel to access the AC mains terminals. 1) Bring the mains cable into the cabinet through the top of the cabinet. The cable entry is through the punch out holes on top of the cabinet. Cable grommets (gland) need to be installed around the hole for cable protection.
L1 L2 L3 N N N PE
2) Ensure that the neutral bridges are in place. 3) Connect Earth conductor to terminal PE, Phase conductors to terminals L1, L2 and L3, and Neutral conductor to terminal N. 4) Tie the incoming AC cables securely with cable ties for support. Ensure that cables do not pass through any sharp edges. N Bridges in place 3 x Single-Phase Input(s) Remove the top panel to access the AC mains terminals. 1) Bring the mains cable into the cabinet through the top of the cabinet. The cable entry is through the punch out holes on top of the cabinet. Cable grommets (gland) need to be installed around the hole for cable protection.
Figure 20.3 Three-Phase
L1 L2 L3 N1 N2 N3 PE
2) Ensure that any neutral bridges are removed. 3) Connect Earth conductor to terminal PE, Phase conductors to terminals L1, L2 and L3, and Neutral conductors to terminals N1,N2,N3. 4) Tie the incoming AC cables securely with cable ties for support. Ensure that cables do not pass through any sharp edges.
Remove bridges
1 x Single-Phase Input Include bridges across the active terminals to activate all 9 rectifier positions, as well as bridges across the neutral terminals.
Figure 20.4 3xSingle-Phases
L1 L2 L3 N N N PE
Alternatively, if no active bridges are on hand and the system has need for only three rectifiers, it is possible to only use the three rectifier positions that are powered by the single connected phase.
In all these cases the system must be labeled accordingly.
Active bridges
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Figure 20.5 1xSingle-Phase
Page 50 of 64
Installation & Commissioning, Operation & Maintenance Manual
21.
DC DISTRIBUTION INSTALLATION
The FlatPack2 System is equipped with a 24-way distribution module fitted at the top of the cabinet. The circuit breakers that can be fitted on the standard comb bus are 6x 80-125A (27mm pitch) + up to 18x 1-63A standard width (18mm pitch) type. The common terminal bar is located behind the load circuit breakers and is accessible by removing the top cover. Note: -48V will be present on the output terminals of the MCB’s even when in the off position and no load is connected, due to MCB monitoring. There is no risk to personnel from this voltage. The current available from the source for the fuse fail diode matrix (through the reverse biased diode) at short circuit using a 20MOhm multimeter= 0.0052A when direct connection is made to the cathode of the sensing diodes. This can be considered a safe level.
When installing DC load cables, be aware of the position of the AC input terminal block, behind the positive common bar. The circuit breakers are arranged from left to right as: Position # from left 1 2 3
Accommodate CB size 80 to 125A 80 to 125A 80 to 125A
4
80 to 125A
5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
80 to 125A 80 to 125A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A 1 to 63A
CB Factory fitted 100A 100A 125A (125A for DCDC converter if fitted)
32A 32A 32A 32A 32A 32A 32A 32A
10A 4A 4A 4A
Fig 21.1 DC distribution
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 51 of 64
Installation & Commissioning, Operation & Maintenance Manual
Load Cable Installation Considerations Consideration should be given to the entry arrangement of load cables to ensure easy installation of additional load cables when the system is operating. Ensure protective edging is fitted to any sharp edges over which cables pass. Ensure cables are suitably supported by a cross beam, making sure not to over stress the common positive bar and circuit breakers. 22.
TEMPERATURE COMPENSATION
The system is supplied with a temperature-sensing probe for temperature compensation charging. The temperature compensation cable is temporarily cabled tied to the system. The cable should be carefully untied and the transistor probe should be placed in the middle of the battery string(s) for measurement of air temperature as close as possible to the batteries. Do not rest the probe directly against any of the batteries as this will give a false reading in the event of that individual battery having a fault.
Fig 22.1 Temperature probe deployment should be near, but not touching, the middle string of batteries.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 52 of 64
Installation & Commissioning, Operation & Maintenance Manual
Installation Checklist Check these points
OK
Check that the incoming AC connections are correct.
Check that the terminal boots and battery link caps are fitted on all the batteries. Check that the load connections are of correct polarity Check that battery string voltage is between -48 and -55 Vdc Check that the external alarm cabling is installed and terminated Check that the temperature probe is extended to the batteries. Check that the temperature compensation is on (activated by default).
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 53 of 64
Installation & Commissioning, Operation & Maintenance Manual
23.
COMMISSIONING
Pre-Start / Initial Checks Check the following:
OK
System installation is completed Check that the system installation has been correctly performed (ref. Installation sections of this manual).
Battery and load are disconnected Verify that the battery circuit breakers and load circuit breakers are in the OFF position.
Rectifier modules are connected Verify that all rectifier modules are plugged in properly & the front pull out levers are pushed in. NOTE: Rectifiers are allocated with a ID that is relevant to its position in shelves.
Rectifier system connected to mains supply and Protective Earth Check that the system’s mains cable is connected to the mains supply.
System Start-Up Check the following:
OK
Turn the system ON from the AC input supply Read output voltage* (approx. 54- 55V) Wait for about 1 min. and check there is DC output voltage* on the alarm module’s display Measure output voltage Use a Digital Voltmeter* to verify that the output voltage is in accordance with VDC the system’s Default Settings (end of this section) and note in the section immediately to the right. Rectifier modules are ON and without fault alarms Verify that the Flatpack2 modules are in normal operating mode (not reporting alarms) Check and calibrate voltage reading in the alarm display If the measured voltage deviates more than 0.2V from the display reading, re-calibrate the alarm module.
Measure Display in DVM* Alarm Mod.
Switch the system OFF at the Input supply
Connect the load MCB Battery circuit breakers are NOT connected Switch the system ON at the input supply.
Measure the Battery Voltage* Using a DVM measure the battery voltage
Measured with DVM*
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 54 of 64
Installation & Commissioning, Operation & Maintenance Manual
Adjust output voltage to equal the measured battery voltage from the alarm module’s keypad adjust the rectifier output voltage to equal ( 1 V) the measured battery voltage. Temperature-compensated charging must be deactivated when adjusting the output voltage. Close the battery circuit breakers It is important that the system is switched ON before connecting the batteries. Otherwise, the battery terminals could be damaged by high currents trying to charge the rectifiers’ internal capacitors. Measured Adjust output voltage (float voltage) from the alarm module’s with DVM* keypad to the voltage recommended by the battery manufacturer (54.0Vdc at 25°C) Verify that the Low Battery Alarm is not activated. Record the voltage*
* DVM must be a Calibrated True RMS meter
Checking the Alarms The Alarms are factory preset and should not require any re-setting on site. To verify the operation of the Alarms use the following procedure. Check the following: 1. Mains Fail Turn off the mains power at the input MCB’s and let the batteries supply the load. Verify if the Alarm LED is illuminated on the Alarm Module. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. Refer to table 18.1. Please ensure batteries are connected prior to starting this test. Turn on the mains again and verify that the Active alarm is automatically reset.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
OK
Page 55 of 64
Installation & Commissioning, Operation & Maintenance Manual
2. The voltage alarms can be tested using any method in which the system voltage can be varied, or the alarm setting can be adjusted. Two methods are listed here. Refer to table 18.1 for relay outputs:
External Power Supply Method
ISOLATE THE BATTERIES FROM THE SYSTEM AND CONNECT A 0-60VDC EXTERNAL POWER SUPPLY TO THE OUTPUT BARS. ENSURE THE CORRECT POLARITY WHEN CONNECTING!
Once the mains to the system is turned off, the controller will display the output voltage of the external power supply. The power supply can then be adjusted to activate the various high and low voltage alarms. This method will have a constant mains alarm as well as the alarms being tested. Adjusting Alarm Activation Level Method Connect a PC/laptop to the Smartpack controller and run the latest version of Powersuite. Note: Once each of the alarms (below) have been tested, ensure you change their alarm levels back to their original values. Each alarm is to be tested, one at a time.
To test High Battery Alarm 1 (High Float), change its value to at least 0.5V below the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. To test High Battery Alarm 2 (High Load), change its value to at least 0.5V below the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. To test Low Battery Alarm 1 (Low Float), change its value to at least 0.5V above the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. To test Low Battery Alarm 2 (Low Load), change its value to at least 0.5V above the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. 3. Off Normal This alarm indicates that a battery test initiated by a PC is in progress, and can be tested using a PC and the Powersuite software.
Alternatively, short pins 3 & 4 on TB1 to create an off normal ( see section 18.2 Digital inputs) 4. Rectifier Fail Ensure the rectifier is off then insert a plastic object into the fan of the rectifier. Turn ON rectifier; this should give a rectifier fail alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. The fan should never be stopped by inserting an object into it while running, as this could damage the fan. TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 56 of 64
Installation & Commissioning, Operation & Maintenance Manual
5. Load Fuse Turn off one of the load circuit breakers. (Note: The CB must be connected to a load). This will activate an Alarm on the Display and at the alarm PCB. Using a Continuity Tester check the operation of the N/O N/C relays at the alarm PCB.
6. Battery Fuse NOTE: All battery CB’s have to be ON for there to be NO Battery fuse alarm. Ensure all vacant battery shelves have heatshrink on their loose cables When the Battery is connected, simply switch off one Battery circuit breaker. This will activate an Alarm on the Display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.
7. Monitor Fail: Unlock and release the handles of the SmartPack alarm module by inserting a small screw driver into the holes in the upper corners of the front panel and carefully push it downwards. The handle will release and pop out. Remove CON5 from the rear on the Smartpack controller. This will activate the Monitor Fail Alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the Monitor Fail PCB.
8. DCDC Converter Fail. Ensure the Converter is off then insert a plastic object into the fan of the rectifier. Turn ON converter; this should give a converter fail alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the converter alarm PCB. The fan should never be stopped by inserting an object into it while running, as this could damage the fan. The DCDC converter alarm terminal block is located to the left of the cabinet below the monitor fail alarm, and is mounted with the battery expansion alarm extension. See section 18.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 57 of 64
Installation & Commissioning, Operation & Maintenance Manual
Default -48V System Settings Alarm & Boost Settings
Factory set Default 54.00
System Voltage High Load Voltage (High Batt 2)
57.60
High Float Voltage (High Batt 1)
55.70
Low Load Voltage (Low Batt 2)
48.00
Low Float Voltage (Low Batt 1)
52.80
Boost Voltage
52.00 -56.00
Checked
Disabled
24. GENERAL MAINTENANCE CHECKS The following general maintenance checks should be performed on all equipment. Detailed maintenance procedures for specific equipment is included later in this document. Step
Comments
Documentation available
Ensure that all relevant site-specific drawings are available i.e. Layouts, cabling schedule, signal connections. Allowing access to system components.
Remove front Panels Carefully vacuum inside underneath and on top using an insulated hose Ensure that all connections are correct Ensure that all equipment is free from damage Check the alarm voltage settings using the “User” menu via the front keypad Check alarm relay operation to remote monitoring by toggling individual relays using the “Service” menu via the front keypad.
Ensuring the system is free from dust and dirt. Look for any possible defective or loose connections, and excessive temperatures. Verify that damage has not occurred since installation and commissioning Verify that all alarm voltage settings are set as the system default settings. Call remote monitoring station and confirm operation as required.
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 58 of 64
Installation & Commissioning, Operation & Maintenance Manual
25.
MODULE MAINTENANCE
The Flatpack2 rectifier has no customer serviceable components
The DC/DC converter has no customer serviceable components.
Should a rectifier exhibit a fault, simply pop the handles out, and pull out using these same handles on the front of the module (Contact Eltek Pacific for repairs/ replacement) Should a converter exhibit a fault, simply pop the handles out, and pull out using these same handles on the front of the module (Contact Eltek Pacific for repairs/ replacement)
26. GENERAL PROCEDURES As a general requirement we would recommend the following checks be made to the system at six monthly intervals. Check Frequency Purpose Visual inspection Monthly To identify any obvious problems. Such as corrosion to terminal posts, leaking batteries, not excessively dirty or dusty, not mechanically damaged in any way Battery Discharge 6 monthly To determine battery performance Test via control module Check and adjust 6 Monthly To ensure rectifier is charging at correct DC output voltage voltage level. Torque battery 6 Monthly To ensure correct level of torque as per battery terminals manufacturers install instructions. General clean 6 Monthly Wipe down systems remove any dust build up
27.
SYSTEM COMPONENTS MINIMUM OPERATING LIFE
Description
Minimum Operating Life (years) >15
FlatPack2 Rectifier Smartpack >15 Control Module DC/DC Converter >15
Potential Failure
Indication
Action
Fault LED lit Monitor Failure Failure
Red LED lit
Replace Module Replace Module Replace Module
Monitor fail relay Red LED lit
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 59 of 64
Installation & Commissioning, Operation & Maintenance Manual
28. POWERSUITE AND WEB POWER Installation and Using of PowerSuite Software. The PowerSuite system communication software must be installed on your personal computer. PowerSuite is available on CD-ROM. By inserting the CD-ROM in the CDROM drive. The installation program will guide you through a complete installation. Setting up Communication between PC and Smartpack. There are two methods to build the connection between a computer and a SMARTPACK. Firstly, a connection can be set from a computer, via an A-B USB cable, to the USB port in the front panel of a SMARTPACK. The following steps show how to login to PowerSuite. 1. Via USB connection open PowerSuite 3.3, go to “Connect” “Serial (Virtual USB) 1” “Find COM Port #” enter Password “3” and click “Connect”.
Figure 28.1 Connect to the Smartpack 2. If you have an Ethernet connection plugged into the back of the Smartpack, then you can communicate with the Smartpack. You will need to setup the IP address of the Smartpack following the Webpower system manual (which is on the accompanying CD). To open an Ethernet connection, open PowerSuite 3.3, go to “Network” “New Connection”, fill in the IP address, enter password “3” and click “Connect”. On the CD you will find “Webpower install” folder and the EVIPsetup file in the Eltek Network Utility folder that can be used to set up the IP address of the Smartpack. Following the manual (also in this folder) will show how to setup the IP and log into the PowerSuite via local network.
Figure 28.2 Contents of accompanying CD TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 60 of 64
Installation & Commissioning, Operation & Maintenance Manual
Configuration of the Smartpack The Smartpack is pre-configured before shipment, and all the pre-configuration is saved in an “xml” file on the CD. To upload the configuration to the Smartpack, simply import the “xml” file to Smartpack via PowerSuite. If it is necessary to re-configure it, please follow the step below. 1. Import the required “.xml” file into Smartpack. Go to “Power Suite” “Tools” “Import/Export Configuration” “Source” “Read from file” .Click “Open…”
Figure 28.3 Import “xml” file (a) 2. Check the box “Read from file” and click “NEXT”, browse to your xml file on the CD and follow the prompts.
Figure 28.4 Import “xml” file (b)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 61 of 64
Installation & Commissioning, Operation & Maintenance Manual
Using PowerSuite to Monitor the Smartpack The site information should be updated at the beginning of the commissioning (Fig 15.6). Message 1 and 2 will be filled out already with some information.
Figure 28.5 Site Information Window The status of each part of the power system can also be read form PowerSuite. To check the status of any particular part of the system, simply double click the name of the coloured indicator in the “Power Explorer”. Alarm indicators: The “Green” shows working normally. The “Red” means a failure is present or power is disconnected.
Figure 28.6 Power Explorer bar
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 62 of 64
Installation & Commissioning, Operation & Maintenance Manual
The other parameters of the power system can be read and set in the function block above the Power Explorer.
Figure 28.7 Other Configuration Tools
The Active alarm group window under “Alarms Overview” will give you a quick snapshot of the alarms that are on the system.
Figure 28.8 Activate Alarm Group Window
For more detailed information on using PowerSuite see the attachment: PowerSuite User Guide (356807.063)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 63 of 64
Installation & Commissioning, Operation & Maintenance Manual
29. ATTACHMENTS 29.1 29.2 29.3 29.4 29.5 29.6 29.7 29.8 29.9 29.10 29.11 29.12 29.13 29.14 29.15 29.16 29.17 29.18 29.19 29.20 29.21 29.22 29.23 29.24 29.25 29.26 29.27
Flatpack2 2kW rectifier Datasheet Flatpack2 1.8kW rectifier Datasheet Smartpack Datasheet Flatpack DC/DC -48/+24 Datasheet 12FFT100 Battery Datasheet 12FIT100 Battery Datasheet Battery MSDS TG6209 Battery bracket label swatch TG5537 Front panel label swatch TG5536 Black on Yellow self adhesive vinyl labels TG6208 Software setting file FP2 TG6223 Alarm matrix FP2 TG6228 Alarm matrix DC/DC converter TG6217 Alarm pinout FP2 TG6210 General arrangement SEF29-X-149 TG6211 General arrangement SEF29-X-150 TG6215 General arrangement SEB5-12FIT100-002 TG6216 General arrangement SEB6-12FFT100-002 TG6222 General arrangement SEF29-X-156 TG6308 Cabinet to wall support channel TG6224 Wiring diagram (Legacy) TG6682A Schematic for SP18 System TG6683A Schematic for SP18-RRU System TG6678A General arrangement SP18 system TG6667D General arrangement SP18-RRU system TG9280A General arrangement SP18 Battery Extension Rack PowerSuite User Guide (356807.063)
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and A112041.000 FlatPack2 systems
Page 64 of 64
Flatpack2 48/2000 HE
Rectifier Module
The most efficient rectifier in the industry! The combination of innovative design, efficiency and reliability makes the Flatpack2 HE stand out. With an efficiency up to 96.5%, the losses have been reduced by 50% compared to the current industry standard. In a global perspective, considering the high energy consumption in the telecom industry, this technology breakthrough is not only reducing operational cost for the operators, but it can also have a significant environmental impact.
Applications
Product Features and Advantages
Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost effective and compact DC power systems. Flatpack2 HE delivers an industry leading power density and superb reliability at lowest lifetime cost.
Flexibility and reliability Extensive use of digital controllers has enabled advanced functionality to meet most customers’ requirements. It also provides intelligent self-protective features like reduced output power at high temperatures or low mains.
The HE rectifier also has an extremely high efficiency at low load, which historically has been a drawback with most modern soft switching technologies.
Plug and play Plug a new rectifier into the system, and it automatically logs on, gets an assigned ID, downloads the system set parameters from the control system and starts up with a minimum of installation time, and without interrupting the system or attached equipment.
Broadband and network access Increasing network speed demands flexible and expandable DC power solutions. The Flatpack2 HE rectifiers are your key building blocks for future needs. Small and large Due to the high power density, cost competitive design and a highly flexible system communication interface, Flatpack2 HE rectifiers are used in system solutions from 2kW to 192kW.
The HE rectifier is made fully compliant with the standard Flatpack2 rectifier which means it can be used in any FP2 system solutions, whether it is in new installations, site expansions or replacement programs. Global compliance Eltek Valere is among the market leaders in all regions in the world, and designs the core products to be compliant to all relevant standards and customer requirements. All Flatpack2 rectifiers are CE marked, UL recognized and NEBS compliant. Patents pending Flatpack2 HE is a result of intensive research over many years. Several unique technical solutions are introduced, protected by patent applications.
See reverse side for specifications
www.eltekvalere.com
Flatpack2 48/2000 HE Additional Technical Specifications AC Input
Other Specifications
Voltage
85-300 VAC (Nominal 185 – 275 VAC)
Efficiency
>96% at 30-70% load
Frequency
45 to 66Hz
Isolation
Maximum Current
11.6 Arms maximum at nominal input and full load
3.0 KVAC – input and output 1.5 KVAC – input earth 0.5 KVDC – output earth
Power Factor
> 0.99 at 50% load or more
Alarms:
Input Protection
o Varistors for transient protection o Mains fuse in both lines o Disconnect above 300 VAC
o o o o o o o
Warnings:
o o o o
Visual indications
o Green LED: ON, no faults o Red LED: rectifier failure o Yellow LED : rectifier warning
Operating temp
-40 to +75°C (-40 to +167°F)
Low mains shutdown High temperature shutdown Rectifier Failure Overvoltage shutdown on output Fan failure Low voltage alarm at 43.5V CAN bus failure
Low temperature shutdown Rectifier in power derate mode Remote battery current limit activated Input voltage out of range, flashing at overvoltage o Loss of CAN communication with control unit, stand alone mode
DC Output Voltage
53.5 VDC (adj. range: 43.5-57.6 VDC)
Output Power
2000 W at nominal input
Maximum Current
41.7 Amps at 48 VDC and nominal input
Current Sharing
±5% of maximum current from 10 to 100% load
Static voltage regulation
±0.5% from 10% to 100% load
Storage temp
-40 to +85°C (-40 to +185°F)
Dynamic voltage regulation
±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms
Cooling
Fan (front to back airflow)
Fan Speed
Temperature and current regulated
Hold up time
> 20ms; output voltage > 43.5 VDC at 1500W load
MTBF
> 350, 000 hours Telcordia SR-332 Issue I, method III (a) (Tambient : 25°C)
Ripple and Noise
o < 100 mV peak to peak, o 30 MHz bandwidth o < 2 mV rms psophometric
Acoustic Noise
Output Protection
o o o o
< 20dBA at nominal input and full load (Tambient 40°C)
Humidity
Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing
Dimensions
109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)
Weight
1.950 kg (4.3lbs)
Overvoltage shutdown Hot plug-in - Inrush current limiting Short circuit proof High temperature protection
Applicable Standards Electrical safety
IEC 60950-1 UL 60950-1 CSA 22.2
EMC
ETSI EN 300 386 V.1.3.2 EN 61000-6-1 (immunity, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-4 (emission, industry) Telcordia NEBS GR1089 CORE
Mains Harmonics
EN 61000-3-2
Environment
ETSI EN 300 019-2-1 Class 1.2 ETSI EN 300 019-2-2 Class 2.3 ETSI EN 300 019-2-3 Class 3.2 ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant
Efficiency 100%
95%
90%
96%
95%
85% 200
400
600
800
1000
1200
1400
1600
1800
2000
Output Load (W)
241115.105.DS3 – v9
Specifications are subject to change without notice
Ordering Information
Part no.
Description
241115.105 Flatpack2 48/2000 HE www.eltekvalere.com Eltek Valere Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
Flatpack2 48/2000
Rectifier Module
Versatile and powerful solution for any application The combination of cost-effective design, power density and reliability makes the Flatpack2 a product family that truly stands outs and provides unparalleled network availability. The versatility of the Flatpack2 rectifier means that it can be used in a wide variety of 48VDC and 24VDC applications across the globe.
Applications
Key Features
Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost effective and compact DC power systems. Flatpack2 delivers an industry leading power density and superb reliability at lowest lifetime cost
Highest efficiency in minimum space Resonant topology makes the module efficiency industry leading and contributes to the rectifier’s ultra compact dimensions. Digital controllers Primary and secondary controls are digitalized, enabling excellent monitoring and regulation characteristics. Thus, the number of component has been reduced by 40% - for highly reliable, long life, trouble free DC power systems. Heat management Front-to-back air flow with chassis-integrated heat sinks gives the module the most suitable working environment and no limitations in the scalability of the desired system solution. Unique connection A true plug-and-play connection system: time-to-install and cost-reducing solution. Global approvals Flatpack2 is CE marked, UL recognized and NEBS certified for worldwide installation.
Broadband and network access Increasing network speed demands flexible and expandable DC power solutions. The Flatpack2 rectifiers are your key building blocks for future needs. Small and large Due to the high power density, cost competitive design and a highly flexible system communication interface, Flatpack2 rectifiers are used in system solutions from 5kW to 96kW.
Product Description The Flatpack2 is a battery charger and rectifier for standalone use or for working in parallel as part of a DC power system controlled and monitored by the Smartpack. Flatpack2 is optimized for a wide range of system sizes. Digital communication over CAN bus with Smartpack simplifies system design and enhances flexibility. Realization of Flatpack2 systems is possible by fitting 4 rectifiers across a 23” or 19” shelf.
See reverse side for specifications
www.eltekvalere.com
Flatpack2 48/2000 Additional Technical Specifications Input
Other Specifications
AC Voltage
85-300 VAC (Nominal 185 – 275 VAC)
Efficiency
Typical 92%, min. 91% at 40-90% load
Frequency
45 to 66Hz
Isolation
Maximum Current
12.5 Arms maximum at nominal input and full load
3.0 KVAC – input and output 1.5 KVAC – input earth 0.5 KVDC – output earth
Power Factor
> 0.99 at 50% load or more
Alarms:
DC Voltage
120-275VDC (Rated 140 – 250VDC)
Input Protection
o Varistors for transient protection o Mains fuse in both lines o Disconnect above 300 VAC
o o o o o o o
Warnings:
o o o o
Visual indications
o Green LED: ON, no faults o Red LED: rectifier failure o Yellow LED : rectifier warning
DC Output
Low mains shutdown High temperature shutdown Rectifier Failure Overvoltage shutdown on output Fan failure, one or two fans. Low voltage alarm at 43.5V CAN bus failure
Low temperature shutdown Rectifier in power derate mode Remote battery current limit activated Input voltage out of range, flashing at overvoltage o Loss of CAN communication with control unit, stand alone mode
Voltage
53.5 VDC (adj. range: 43.5-57.6 VDC)
Output Power
2000 W at nominal input
Maximum Current
41.7 Amps at 48 VDC and nominal input
Current Sharing
±5% of maximum current from 10% to 100% load
Operating temp
-40 to +75°C (-40 to +158°F)
Static voltage regulation
±0.5% from 10% to 100% load
Storage temp
-40 to +85°C (-40 to +185°F)
Cooling
2 fans (front to back airflow)
Dynamic voltage regulation
±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms
Fan Speed
Temperature and current regulated
MTBF
Hold up time
> 20ms; output voltage > 43.5 VDC at 1500W load
> 350, 000 hours Telcordia SR-332 Issue I, method III (a) (Tambient : 25°C)
Ripple and Noise
o < 100 mV peak to peak, o 30 MHz bandwidth o < 0.96 mV rms psophometric
Acoustic Noise
< 55dBA at nominal input and full load (Tambient < 30°C)
Humidity
Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing
Dimensions
109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)
Weight
1.9 kg (4.19lbs)
Output Protection
o o o o
Overvoltage shutdown Blocking diode Short circuit proof High temperature protection
Applicable Standards Electrical safety
IEC 60950-1 UL 60950-1 CSA 22.2
EMC
ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-1 (immunity, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-4 (emission, industry) Telcordia NEBS GR1089 CORE
Mains Harmonics
EN 61000-3-2
Environment
ETSI EN 300 019-2 (-1, -2, -3) ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant
Specifications are subject to change without notice
241115.100.DS3 – v6
Ordering Information
Part no.
Description
241115.100 Flatpack2 48/2000
www.eltekvalere.com Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101
Eltek Valere Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
Flatpack2 48/1800 Switch Mode Power Supply 48VDC
Product Description
Key Features
The Flatpack2 is a battery charger and rectifier for
ü
stand-alone use or for working in parallel as part of a
Resonant topology makes the module efficiency industry
DC power system controlled and monitored by the
leading and contributes to the rectifier’s ultra compact
Smartpack.
dimensions.
Flatpack2 is optimized for a wide range of system sizes.
ü
Digital communication over CAN bus with Smartpack
Primary and secondary controls are digitalized, enabling
simplifies system design and enhances flexibility.
excellent monitoring and regulation characteristics.
Realization of Flatpack2 systems is possible by fitting 5 rectifiers across a 23” shelf and 4 rectifiers across a 19” shelf.
Digital controllers
Thus, the number of component has been reduced by 40% - for highly reliable, long life, trouble free DC power systems. ü
Applications
Highest efficiency in minimum space
Heat management
Front-to-back air flow with chassis-integrated heat sinks
Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost efficient and compact DC power systems. Flatpack2
gives the module the most suitable working environment and no limitations in the scalability of the desired system solution.
delivers the industry leading power density of 21W/in3
ü
and superb reliability at lowest lifetime cost.
A true plug-and-play connection system: time-to-install
Unique connection
and cost-reducing solution.
Broadband and network access Increasing network speed demands flexible and
ü
expandable DC power solutions. Flatpack2 is your key
Flatpack2 is CE marked, UL recognized and NEBS
building block for future needs.
certified for world wide installation.
Global approvals
109 mm 109.00
41.50
Flatpack2 Switch Mode Power Supply 48VDC (coming up…) www.eltekenergy.com
I www.flatpack2.com
41,5 mm
327 327 .22 mm
Flatpack2
Additional Technical Specifications Other Specifications
AC Input 85-290 VAC (Nominal 185 – 275 VAC)
Efficiency
Typical 92%, min. 91% at 40-90% load
Frequency
45 to 66Hz
Isolation
Maximum Current
10.7 Arms maximum at nominal input and full load
3.0 KVAC – input and output 1.5 KVAC – input earth 0.5 KVDC – output earth
Power Factor
> 0.99 at 20% load or more
Alarms:
Input Protection
Varistors for transient protection Mains fuse in both lines Disconnect above 290 VAC
Low mains shutdown High temperature shutdown Rectifier Failure Overvoltage shutdown on output Fan failure, one or two fans. Low voltage alarm at 43.5V CAN bus failure
Warnings:
Rectifier in power derate mode Remote battery current limit activated Input voltage out of range, flashing at overvoltage Loss of CAN communication with control unit, stand alone mode
Visual indications
Green LED: ON, no faults Red LED: rectifier failure Yellow LED : rectifier warning
Voltage
DC Output Voltage
53.5 VDC (adj. range: 43.5-56.0 VDC)
Output Power
1800 W at nominal input
Maximum Current
37.5 Amps at 48 VDC and nominal input
Current Sharing
±3% from true average current between modules
Static voltage regulation
±0.5% from 10% to 100% load
Operating temp
-40 to +70°C (-40 to +158°F)
Dynamic voltage regulation
±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms
Storage temp
-40 to +85°C (-40 to +185°F)
Cooling
2 fans (front to back airflow)
Hold up time
> 20ms; output voltage > 43.5 VDC at 1500W load
Fan Speed
Temperature and load regulated
MTBF
Ripple and Noise
< 100 mV peak to peak, 30 MHz bandwith < 0.96 mV rms psophometric
> 250, 000 hours Telcordia SR-332 Issue I, method III (a)
Acoustic Noise
< 50dBA at nominal input and 70% load (Tambient < 30°C)
Humidity
Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing
Dimensions
109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)
Weight
1.8 kg (3.97 lbs)
Output Protection
Overvoltage shutdown Blocking diode Short circuit proof High temperature protection
Applicable standards Electrical safety
IEC 60950-1 UL 60950-1 CSA 22.2
EMC
ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-4 (emission, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-1 (immunity, light industry) Telcordia NEBS GR1089 CORE
Harmonics
EN 61000-3-2
Environment
ETSI EN 300 019-2 ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant (pending)
Specifications are subject to change without notice.
ORDERING INFORMATION Part no.
Description
241115.001
Flatpack2 48V
Document Rev. No.: 241115.001.DS3 v.05
Location Europe Americas Asia/Pacific China Middle East
Company Eltek Energy AS Eltek Energy, LLC Eltek Energy Pte Ltd. Eltek Energy Ltd. Eltek Middle East
www.eltekenergy.com
Telephone +47 32 20 32 00 +1 815 459 9100 +65 6 7732326 +852 28982689 +971 4 887 1176
I www.flatpack2.com
Fax +47 32 20 32 10 +1 815 459 9118 +65 6 7753602 +852 28983189 +971 4 887 1175
Smartpack Controller Monitoring and Control Unit
Powerful and cost effective control module The Smartpack controller is a monitoring and control unit used as the vital nerve center of the DC power plant. You operate the system from the elegant front panel, using three front keys and the LCD-display. They represent the main interface between you and the system.
Applications
Key Features
CAN bus communication Smartpack utilizes a digital interface architecture (CAN bus communication). It allows the unit to support dedicated communication channel with each rectifier, providing for increased number of functions and greater flexibility.
ü
Front panel LCD and buttons for on-site service without PC. (Not on Basic Slave model)
ü
USB- or RS-232 interface for PC connection locally or remote monitoring and control via modem, Ethernet, web or SNMP.
Modular design The Smartpack is extremely flexible in its expandability. Additional units connected to the CAN bus can be added to provide extended functionality and increased number of measuring points. Accordingly, system components can be set up and upgraded to meet the demand of any tailor-made power solution.
ü
6/2 user programmable relay outputs for traditional remote monitoring
ü
6/2 user programmable inputs for monitoring of other equipment on site
ü
Battery monitoring and testing without site attendance
ü
Temperature compensated charging for increased battery lifetime
ü
Battery lifetime indication
ü
Password protected operator access levels
ü
Alarm/event log with time and date
ü
Windows-based PC communication software
Product Description The Smartpack controller is a powerful and cost-effective module, developed for monitoring and controlling a wide range of Eltek Valere’s DC power supply systems, such as Powerpack, Flatpack2 and Minipack DC power systems. You can also operate the system locally via a PC using the PowerSuite PC application, or remotely via modem, Ethernet and the Web. The module then utilizes the USB- or RS-232 ports to interface with a local PC, SNMP or Web adapters.
See reverse side for specifications
www.eltekvalere.com
Smartpack Controller Additional Technical Specifications Remote Monitoring and Control
Local Monitoring and Control
ü From a PC running PowerSuite a Windows-based communication program installed on a remote computer, the system can be monitored and controlled via modem or Ethernet network ü From a PC running a WEB Browser the system can be monitored and controlled via Ethernet network ü
ü
From an NMS via Ethernet (SNMP) With an SNMP agent connected to the Smartpack, the system can be monitored and controlled from a Network Management System (NMS) through Ethernet on Simple Network Management Protocol (SNMP)
ü From a PC running PowerSuite a Windows-based communication software, can also communicate with the Smartpack through an USB serial or RS-232 cable ü
LCD and three keypads for local operations If any alarm (major or minor) is activated, a (red or yellow) LED is lit in the front panel, the alarm text appears in the LCD and the corresponding alarm relay is activated In normal operation, the front LCD will display the output voltage, battery current, load current and charge mode. (Not on Basic Slave version)
Using alarm relays (voltage free contacts) 6/2 internal failsafe alarm relays provide voltage free contacts that can be connected to equipment used for traditional alarm monitoring
Available Alarms All alarms can be set up with monitoring of minor, major, average and peak levels.
Features System o Output Voltage Measurement o Total Load Current Measurement o Load/Battery Disconnect o Alarm Level Settings (major / minor) o Alarm Log (up to 1000 events, 10k on HW v2) o Real Time Clock with Battery Backup o Site Text/ID o Test of Relay Outputs o Voltage Level setup o Data logging (up to 7000 data points) Battery o Battery Current Measurement o Battery Temperature Measurement (optional) o Battery Testing (acc. to discharge table or set time limit) o Battery Test Information (10 latest tests) o Setup of Battery Data o Battery shunt setup o Battery quality indication o Battery Boost Charging o Battery Cable Voltage Drop Compensation o Temperature Compensated Charging o Protection against Temperature Probe Failure Rectifier o Available information about each rectifier, e.g. serial o number, version, internal temperature o Individual Rectifier Current Measurement o Individual Rectifier Input Voltage o Efficiency Management
System o Mains Failure (individual phases) o Digital Inputs (programmable names) o Load Disconnect (voltage or timer) o Load Fuse o Load Current Battery o High Battery voltage o Low Battery voltage o High Battery temperature o Low Battery temperature o Battery Capacity o Battery Disconnect o Battery Fuse o Symmetry Failure o Battery quality indication Battery discharge current Rectifier o Rectifier Failure o Critical Rectifier Failure (> 1, programmable) o Rectifier Capacity w. programmable level o Rectifier Current Limit o Rectifier Overvoltage Protection o Rectifier Current
Specifications Input Voltage
24/48/60 VDC nominal system voltages
Dimensions (WxHxD)
109 x 44 (1U) x 140mm 4.3 x 1.7 x 5.5”
Specifications are subject to change without notice 242100.100.DS3– v7
Ordering Information
Part no.
Description
242100.110 242100.111 242100.112 242100.113 242100.118 242100.000
Smartpack Extended (6 + 6 I/O, 2 String Battery connection) Smartpack RS-232 front (RS-232, 6 + 6 I/O, 2 String Battery connection) Smartpack RS-232 rear (RS-232, 6 + 6 I/O, 1 String Battery connection) Smartpack WEB/SNMP (Ethernet, 2 + 2 I/O, 2 String Battery connection) Smartpack WEB/SNMP (Ethernet, 6 + 6 I/O, 1 String Battery connection) Smartpack Basic Slave (without display, buttons & internal power for distributed systems)
www.eltekvalere.com Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101
Eltek Valere Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
Flatpack DC/DC | 48/24 DC/DC Converter
The Flatpack DC/DC 48/24 is a modular hot plug-in DC/DC converter prepared for stand-alone use, or for working in parallel as part of a DC/DC rack system. The converter is specially designed to provide a high
A module failure alarm is given if the module shuts down
quality and highly reliable DC output voltage.
due to high/low input voltage, high output voltage (selective), or in case of an internal failure.
Switch mode technology with soft switching and high switching frequency is used to minimise volume and
Converters connected in parallel will exhibit active load
weight, and to obtain fast output voltage regulation.
sharing, even without a Monitoring and
Control Unit via
CAN bus. The module has a soft start power-up. When working in parallel, the converters provide active current sharing. An internal blocking diode allows hot plug-in and
Front LEDs show power ON/OFF and alarm status in addition to a LED bar graph for output current indication.
isolates any faults in the converter output from the DCbus.
The Flatpack
DC/DC 48/24
will
operate in ambient
temperatures up to +75°C (+167°F). At temperatures Several
internal
protection
circuits
ensure
safe
operation, even outside specified limits for normal operation.
above
+65°C
derated.
(+149°F),
the
output
power may
be
OTHER SPECIFICATIONS
FLATPACK DC/DC 48/24
Isolation Voltages
SPECIFICATIONS INPUT Input Voltage range Maximum Current Protection
40.0-60 VDC 32 Amps at 40.0 VDC input Soft start Internal fuse Automatic shutdown for input voltages < 40 VDC and > 62 VDC
OUTPUT Output Voltage Output Power Output Current Current Share Static Voltage Regulation Dynamic Voltage Regulation Ripple and Noise Protection
24-28 VDC 1100 W at 27.5 VDC 40 Amps at 24 VDC ± 2 Amps ±0.5% from 0 to full load ±4.0% for 10-90% or 90-10% load variation
