Installation Guide FP2 9kW48V Fan OD 1.8m (B-351677.033-1-3) PDF

 

 

Installation Guide

Flatpack2 System

DC Power Supply System, 9kW, 48VDC  Fan Cooled 1.8m Outdoor Cabinet 

351677.033

 

1 Welcome  Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek.  No part of this document may be reproduced or transmitted in any form or by any means —  electronic or mechanical, including photocopying and recording —  for any purpose without the explicit written permission of Eltek . Copyright ©: Eltek , Norway 2013

Certificate no: 900005E

NS-EN ISO 14001:  1996 Certificate No: 900005E

Certificate no: 900005Q

NS-EN ISO 9001:   1994 Certificate No: 900005Q

This product is CE marked and complies with all current requirements for rrelevant elevant standards and directives. This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).

EMC

EN61000-6-2 Industrial Environment EN61000-6-3 Residential, Commercial and Light Industry ETS 300386 Telecommunication Telecommunication Equipment 

LVD

LVD73/23/EEC Low Voltage Directive EN60950 Safety of Technology Equipment

 has Eltek part no. C20334.004 and CS code CS7112200 “FP2 9kW/48V Fan OD 1.8m” 1.8m” has CS7112200  

351677.033

Issue 3, 2012 December 

Published MMGA

2 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

1 Welcome 

Table Of Contents 1. 

5   About this Guide ............................................................................................................................. .............................................................................................................................5  Definitions .................................................................................................................................... ....................................................................................................................................... ...5   Abbreviations .................................................................................................................................. ..................................................................................................................................5 

2. 

System Description

Welcome

6 

General ............................... General ................................................. .................................. ................................. .................................. .................................. .......................... .........6  Applicable standards................... ......... ................... .................. ................... ................... ................... ................... .................. ................... ................... ......... 6  Electrical Safety ..................................................... ........................................................................................................................... ......................................................................... ... 6 EMC............................................................................................................................... EMC............................................................ .................................................................................... .................6   Environment ................................................................................................................................... ...................................................................................................................................6 

System Modules - General Arrangement ....................................................................... 7  Cabinet ................................................................... ........................................................................................................................................ ........................................................................ ...7  Heat Management System (HMS) ................................................................................... ................................................................................................. ..............8 

Fan Filter / Forced air cooling - FAC .......................................................... ........................................................................................................ .............................................. 8 

Cable Management .......................................................................................................... ........................................................................................................................ ..............9 

Cable glands / entries .............................................................................................................................. ................................................................................................... ........................... 9  Cable strain relief ................................................................. ................................................................................................................................ .................................................................... ..... 9  Cable support ............................................................ .......................................................................................................................... ............................................................................ .............. 10 

DC Earth connection terminal term inal ..................................................................................................... ......................................................................................................10 .10 

Location of Components ~ General Arrangement.................. ......... .................. .................. ................... ................... ......... 11 

External AC Fuses ~ Recommended Ratings .............................................................................12  Mains Reconfiguration ~ AC Terminal Block ...............................................................................12  Surge Protection Device – SPD ................................................... ...................................................................................................13 ................................................13 

 

 Alarm Relays& &Pin-out DigitalLocation, Inputs .......................................................................................................15 .................................................................. .....................................15 Terminals Alarm Interface Card, ................................................................ ............................................................................. ............. 16 

Terminals & Pin-out Location, System Interface Card ................................................................ ........................................................................... ........... 17  Terminals & Pin-out Location, I/O monitor .......................................................................................... ............................................................................................. ... 17 

LVD Latching Contactors .............................................................................................................19 .............................................................................................................19 

Monitoring, Control and Signal Interface ..................................................................... 20  System Monitoring ................................................................................... ........................................................................................................................20 .....................................20 

System Specification ................... ......... ................... .................. ................... ................... ................... ................... .................. ................... ................. ....... 21 

3. 

Installation

22 

Safety Precautions......................................................................................................... 22 

General Safety Saf ety Precautions ......................................................... .........................................................................................................22 ................................................22  Electrical Safety ..................................................................................................... ............................................................................................................................23 .......................23  Mechanical Safety ........................................................................................................................24 ........................................................................................................................24  Battery Safety .............................................................................................................................. ...............................................................................................................................24 .24 

Installing Insta lling the Modules Modules ................................. .................................................. ................................. ................................. ................................. ................25 

 

Smartpack  Flatpack2 Modules Mounting and or Removing  and...................................................................................................  and Modules..................................................... ................................................................... .............. 25 Mounting Removing Blind Panels ....................................................... ............................................ 26  Correct Rectifier Position in Power Shelves ......................................................... .......................................................................................... ................................. 26  Cabinet cooling capacity c apacity for v various arious rectifier modules installed .......................................................... ............................................................. ... 27 

System Installation ........................................................................................................ 28 

Site Preparation ..................................................................................................... ............................................................................................................................28 .......................28  Mechanical Installation .................................................................................................................28 .................................................................................................................28  Electrical Installation.....................................................................................................................31 Installation.....................................................................................................................31 

4. 

Commissioning

34 

Pre-Start Check Pre-Start Check ................................. ................................................. ................................. .................................. .................................. ........................... ..........34  Commissioning Steps, Startup ..................................................................................... 35 

Startup and No-Load Adjustments ......................................................................................................... ............................................................. ............................................ 35  Load Adjustments ................................................................ ............................................................................................................................... .................................................................. ... 36 

5. 

Maintenance

  6.

Forms, Schematics & Drawings

37 

  39 Installation Check List ...................................................................................................................................... 39  Commissioning Commiss ioning Procedure...................... ............................................ ............................................ ............................................ ........................................... ........................................ ................... 39  Maintenance Procedure .................................................................................................................................... 39 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

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1 Welcome  Battery current readings check and calibration.................... .......................................... ............................................ ........................................... ................................. ............ 39  Breakers derating table ..................................................................................................................................... 39  General Arrangement Drawing ........................................................................................................................ 39  System Schematic Schematic Drawing.................... .......................................... ............................................ ............................................ ........................................... ........................................ ................... 39  Configuration Configura tion Settings ~ Flatpack2 PS System, 9kW/48VDC Fan OD 1.8m ..................... .......................................... ............................. ........ 39  Outdoor cabinet cabinet Fan 1.8m drawing ................... ......................................... ............................................ ............................................ ........................................... ............................. ........ 39  Plinth drilling pattern........................................................................................................................................ pattern........................................................................................................................................ 39 

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Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

1 Welcome 

1. Welcome The Flatpack2 PS System, 9kW, 48VDC, Fan OD 1.8m  is a DC power supply for telecom equipment suitable for outdoor fan cooled applications.

About this Guide This booklet provides users of the FP2 9kW/48V Fan OD 1.8m with the required information to perform system installation, commissioning and maintenance. The booklet also describes the system’s technical specifications, and includes check lists, arrangement and schematic drawings. Operating instructions about the Smartpack controller, Flatpack2 rectifier modules and the I/O monitoring unit are also included in this guide. For user instructions about the PowerSuite PC software (on CD-ROM) it is possible to utilize the Help function in the PowerSuite program.

Definitions  

WARNING: Text highlighted in this way provides the installer i nstaller with information that it will be b e DANGEROUS for people (including possible loss of life) and extensive damage to the equipment if not all of the instructions in this special notice are followed. 

 

CAUTION: Text highlighted in this way provides the installer with information that it may damage the equipment not to follow f ollow the instructions stated in this special notice.

 

Note: Text highlighted in this way signifies that the installer will be given additional information or special instructions which are essential for the equipment or when installation is being performed.

Abbreviations PS CB FAC FP2 SP HMS MCBOD SPD VRLA-

Power Supply Circuit Breaker Forced Air cooling Flatpack 2 Smartpack controller Heat Management System Magnetic Circuit Breaker Outdoor Surge Protection Device Valve Regulated Lead Acid battery

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2 System Description 

2. System Description The Flatpack2 PS System, 9kW, 48VDC Fan OD 1.8m is a DC power supply system based on the Flatpack2 HE (High Efficiency) 48VDC rectifiers. The system contains AC termination blocks, DC distribution, Flatpack2  Power Rack, Flatpack2  rectifier modules and the Flatpack2  Smartpack control unit. The system is designed for cable entry from bottom and the cabinet size is 1800x820x700mm x32.3” x27,6 x27,6”) (HxDxW). (70,9” x32.3

General The Outdoor Cabinet is a cost effective enclosure solution for outdoor applications where the equipment inside needs protection from outside environment. The Cabinet door is lockable and prevents unauthorized access to the inner compartment. Eltek’s Smartpack based product range utilizes the Smartpack controller and Flatpack2 rectifiers as building blocks for implementing effective DC power systems, suitable for a wide range of applications and power ratings.

Applicable standards Electrical Safety IEC 60950

EMC ETSI EN 300 386 V.1.4.1 (2008-4) EMC for Telecommunication network equipment EN 61000-6-1 (2007-01) Immunity for light industrial environments EN 61000-6-2 (2005-01) Immunity for industrial in dustrial environments EN 61000-6-3 (2007-01) Emission for light li ght industrial environments EN 61000-6-4 (2007-01) Radiated and conducted emission FCC part 15B Subpart 109 Radiated and conducted emission

Environment ETS 300 019 2.1 Storage, 2.2 Transport, 2.4 Operation Ingress protection: EN60529 2002/95/EC RoHS Compliant WEEE compliant

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Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

2 System Description 

System Modules - General Arrangement Cabinet

Filter

Heat

Management

Cable glands

Battery Shelf

Plinth

Figure 1 – Cabinet Overview (example showing the Fan Filter solution in the door)

Cabinet The cabinet is an aluminum single skinned outdoor enclosure for base assembly. It is designed for cable entry from bottom and the cabinet size is 1800x820x700mm (70,9” x32.3 x32.3” x27,6 x27,6”) (HxDxW).

It is designed with adapters to fit 19” components and equipment. The cabinet accommodates a dust and water protection rating of IP55. The cable entry is located at the bottom of the cabinet by means of a cable gland plate and cable tie brackets. The Eltek cabinet is designed with an over-pressure system to minimize the consequences of leakage of dust and water into the cabinet caused by possible damages to gaskets or cable glands.  

Note! The rating of the heat management system within the cabinet is based on the color that the cabinet was delivered with. If the color is altered with paint, dirt etc the cooling may depreciate.

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2 System Description  The cabinet is lockable and can be equipped with a door lock (profile Euro half cylinder). The door can be hinged either left or right and the door can open to a maximum angle of 120°. The Heat Management System will always be integrated in the door.

Heat Management System (HMS) The cabinet is delivered with  “Fan Filter / Forced air cooling” (FAC) heat management system (HMS). The setup ofand the thermal cooling system is done and frommust the factory maintainwithout the specified heat dissipation requirements, not betomodified consulting Eltek’s service or technical support department. 

Fan Filter / Forced air cooling - FAC

Equipment O u tp u t F il te r

In

Batteries

p u F n

t a F il te r

Figure 2 – Cooling principle – Free Cooling

The free cooling principle is an open loop system that is based on pulling cool air from the outside and into the cabinet through the lower part of the filter in the door. The hot air is pushed out through the upper part of the door filter due to overpressure in the cabinet. The free cooling has the advantage that a large amount of air can be exchanged, giving very high cooling performance with low power consumption. The temperature inside the cabinet will always be higher than outside. (+∆t)  To prevent dust and other particles from entering the cabinet the air input and output has to be filtered. The filter change interval will depend on filter type, thermal requirements, heat dissipation, solar load and pollution on the site. The filter has to be changed when the cabinet is no longer able to maintain the desired temperature level (high temperature alarm).   Note! It is of great importance that ONLY Eltek original filters are used when changing the filter. To keep the level of dust and water protection for the equipment inside the cabinet. The fan runs as soon as the temperature in the cabinet passes 25oC (77°F). Hysteresis is 1°C (1.8°F). With moderate ambient temperatures or low power dissipation the fans will be running at low speed. As the ambient temperature or provides internal power dissipation increases, the the fan speed will increase. The system controller linear control of the fans where fan speed will be dependent on the internal cabinet temperature.

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Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

2 System Description 

Cable Management Cable glands / entries The basic cabinet has cable glands making it possible to enter with a wide range of cable sizes. The cabinet is delivered with the Multigate MC 25.

Figure 3 – Multigate MC 25 IP65/67.

The Multigate MC 25 standard cable gland plate can receive the following cable/conductor dimensions:   1 x 20-26 mm 4 12x x14-20 10-14mm mm   4 x 08-12 mm   4 x 05-07 mm The Multigate MC 25 is suitable for leading through both low and medium power current cables as well as various types of tubing.    

Cable strain relief

Cable tie brackets

Figure 4 – Cable tie bracket  

At the cable entrance (left side on lower battery shelf) there is placed a cable tie bracket for cable strain relief.

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2 System Description 

Cable support

Figure 5 – Cable support (inside wall)

The OD cabinet has beams on the sidewalls with holes where cables and conductors can be supported using cable ties, strips or similar.

DC Earth connection terminal

Figure 6 – Grounding point

Pull the cable through the cable entry and connect the grounding cable with a cable lug and M6 screw to the DC Earth (TE) point in the cabinet. Make sure that the cables are secured tightly. See General Arrangement for alternate position.

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Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

2 System Description 

Location of Components ~ General Arrangement AC input and Earth terminals

Battery DC (+) terminals

16mm2 AWG 5

Battery DC (-) terminals

Surge Protection Device   Device

Alarm terminals 1,5mm2 AWG 16 

DC (+) Load terminals Busbar 35mm2 AWG 2

 S martpack   controller

DC (-) Load Terminals

and CON 4 (monitoring terminals on the controller’s rear panel)

2

25mm , AWG 4,

Flatpack2  HE rectifiers 

Load alarms PCB

Cabinet air outlet filter Flatpack 2 9kW Power system

DIN rail  rail  I/O monitor

2pole AC breaker

DC Fan breaker

DC Earth Telecom Earth (TE) Connection

Battery shelves Cabinet ventilation fan and air inlet filter

Figure 7. General Arrangement Flatpack2 PS Systems, 9kW/48VDC, Fan OD 1.8m Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

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2 System Description 

External AC Fuses ~ Recommended Ratings The site’s AC supply quality is of great impor tance. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.

AC Input recommendations External AC Input Fuses and AC Input Wires Recommended Ratings (The ratings apply only fully populated systems with 3pcs rectifier modules) External Fuse/Breaker AC Mains Max. Current Ext. Fuse Type Amp Type 400VAC 3-phase, 3-wire+N+PE 230VAC 3-phase, 3-wire+PE 230VAC  1-phase 2-wire+PE

External AC Input Wire Size Size mm2  AWG

19,2

25A D-char.

10

6

33,3

50A C-char.

10

6

57,5

63A C-char.

10

6

Note:  An external AC breaker is required on all sites, and it must be switched off under

installation.

Mains Reconfiguration ~ AC Terminal Block  Block   The AC terminal block is factory configured for mains supply type: 230/400 V, 3 phase 3-wire +N + PE. To reconfigure the system’s AC mains feed, perform the following: foll owing:  1.  Switch OFF the AC supply fuses in external fuse boards 2.  Connect  the AC Mains wires to the AC terminal block, and mount  the crossconnection plate(s) shipped with the cabinet, according to the type of AC mains to be used, as shown in the actual example in this section. Customer connections

Customer connections

Customer connections

 

  PE

N

1

2

L1

3

4

L2

5

6

 

L3

7

8

9

PE

N

1

2

 

L1

3

4

5

6  

PE

7

8

9

L1

1

2

L2

3

4

L3

5

6

7

8

9

  100-250V/170-430V, 3W+N+PE

100-250Vac, 2W+PE 

100-250Vac, 3W+PE 

Figure 8. Mains terminals - reconfiguration

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Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

2 System Description 

Device –  – SPD  SPD Surge Protection Device This system is equipped with an SPD device to protect against possible surges and transients in incoming mains. Technical specification: Model

RPM280-40/3N+NPG

Max. continuous operating voltage(Uc)

280V

Voltage protection level(Up)

L-N ≤ 1600V  N-PE ≤ 1000V 

Max discharge

40kA/Line

current(8/20μs)  Protection mode

Live-Neutral, Neutral-Protective Earth

Range of frequency

40-60Hz

Earth-leakage current Response time

＜

10μA 

≤25ns 

Figure 9. Surge Protection Device

This SPD is a 4-pole device providing maximum protection for either 3phase Y configuration (3W+N+PE) or 1phase Y configuration (L+N+PE) with a differential protection mode (L-N) and common protection mode (N-PE).

Figure 10. Surge Protection Device correct installation

a) 3phase Y configuration (3W+N+PE)

The SPD is factory configured to provide protection in this configuration.

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

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2 System Description  b) 1phase Y configuration (L+N+PE)

If this type of mains configuration is used please remove unnecessary cables connecting L2 (black) and L3 (white) to SPD as shown in the picture below. Only two of the poles will be used.

Figure 11. SPD installation for 1phase Y configuration.

c) 3phase ∆ configuration (3W +PE)  +PE)  

Although it is possible to use 3phase ∆ as a mains conf iguration iguration to feed this system, the SPD (installed in this system) will not provide full protection against surges and transients. For optimum protection a 6pole device is required to protect the system in both common and differential mode (see drawing below).

Figure 12. SPD installation for 3phase ∆ configuration. 

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2 System Description 

Alarm Relays & Digital Inputs The alarm outputs in Flatpack2  systems use the Fail-Safe Operation Mode  (relay coils energized in the system’s normal operation mode). When the system is in alarm mode, the alarm relay coils are de-energized. The figure shows the position of the relay contacts when the relay coils are de-energized (PS system in alarm mode) Alarm Relays & Digital Inputs

Alarm Relay Specification Normal Mode Relay X (Energized coil)

NO Com NC

+ — 

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

+

30 VDC, 2A 60W (resistive load) 220 VDC 2A DC

Nominal switching capacity Maximum switching power Maximum switching voltage Maximum switching current

— 

Correct Use of Alarm Outputs (example) Digital Input X (Normal mode) Digital Input X (Activated)

+

Normal Mode

— 

External Relay Y (Energized coil)

+

 Alarm  A larm Mode

— 

External Relay Y (De-energized coil)

Flatpack2 PS System

In order to implement monitored fail-safe digital inputs circuits, the external relay coil must be energized and the contacts closed

in the system’s normal mode of operation.

Correct Use of Digital Inputs (example) Figure 13. Alarm Relays & Digital Inputs

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

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2 System Description 

Terminals & Pin-out Location, Alarm Interface Card, The Smartpack   controller’s alarm and digital input monitoring signals are accessible from the Alarm Interface Card  (Art.  (Art. 105954) – located on top of the controller; see page 11.

For detailed information about the card’s pin -out location and terminal block connections, refer to the figures in this section. Alarm Outputs & Digital Inputs   Voltage free relay outputs and Configurable monitoring digital inputs  

FUNCTION

SIGNAL PIN-OUT

Card Art.105954

In

Battery Connections Card, Art. 200576

CON2  Alarm Outputs Outputs & Digital Inputs Card, Art. 105954

CON2A CON1A

   1    N    O    C

Smartpack

CON1A

Battery Connections Card, Art. 200576

CON2A

*X1

1

 ,      k   1     c   N     a   O     p   C      t     r     a     m      S   o    T

*X2

10

1

20

 Alarm Outputs & Digital Digital Inputs Card, Art. 105954

Figure 14. Alarm Interface card

*X1:

Digital Input 1

+

Digital Input 2

+

   

NO  COM  NC 

Terminals &&PIin-Out locations  Terminals Pin-out Location System Connections Card, Art. 200625

Out

 ,      k   2     c   N     a   O     p   C      t     r     a     m      S   o    T

Relay 1 OVP & Door Alarm, Heat He at Man Mana a eme ement nt Relay 2 NO  High Battery Alarm COM  NC 

1 2 3 4 5 6 7 8 9 10

Input Circuit 1 Input Circuit 2

 Alarm Circuit 1  Alarm Circuit 2

*X2: + 1 Digital Input 3   2 + 3 Digital Input 4   4 5 + Digital Input 5   6 + 7 Digital Input 6   9 Relay 3 NO  8 Low Battery Alarm COM  10 NC  11 NO  12 Relay 4 13 Fuse Alarm COM  14 NC  Relay 5 NO  15 Major Alarm  COM  16 & Rectifier Alarm NC  17 NO  18 Relay 6 COM  19 Mains Alarm NC  20 (Customer Connections)

   )    t     n   e   m   m   o   p   r    i    f   u    d  q   n  e   a    l   o  a   n    T    (   r   e    t   x   e

Input Circuit 3 Input Circuit 4 Input Circuit 5 Input Circuit 6

 Alarm Circuit 3  Alarm Circuit 4  Alarm Circuit 5

   )    t   n   e   m   p    i   u   q   e    l   a   n   r   e    t   x   e     m   o   r    F    (

   )    t   n   e   m   p    i   u   q   e    l   a   n   r   e    t   x   e   o    T    (

 Alarm Circuit 6 1.5 mm mm , max. max. wire section

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

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2 System Description 

Terminals & Pin-out Location, System Interface Card Flatpack2 systems are shipped from factory with the CON5 signals already connected. Some of the Smartpack   controller’s internal system signals are accessible on D -Sub

connector CON5, on the controller’s rear panel. Using the System Interface Card   (Art. (Art. 200625) and a standard 15 pins D-Sub cable, the signals on CON5 may be accessible at any suitable location inside your system. For detailed information about the card’s pin -out location and terminal block connections, refer to the figures in this section. In

Terminals& & Pin-Out Pin-out Location Terminals location      A    5

System Connections    N    O Card, Art. 200625    C  Alarm Outputs Outputs & Digital Inputs Card, Art. 105954

Battery Connections Card, Art. 200576

CON5

Smartpack

Battery Connections Card, Art. 200576 Pos. Distr. Neg. Distr.

JP1 3 2 1

JP2

JP1

JP2 1 2 3

X***** 1

11

CON5A

Neg. Distr. Pos. Distr.

System Connections Card, Art. 200625

Figure 15. System Interface card

Out 10    5   s    2   ) 15   n    6   5   o    0    i 6    0    N    t    2   c  .   O 7   e    t    C   n   r  , 12   n    A      k   o  ,     c 13

   d    a    C     r     p9+, Neg.D.   a     t   m   o    r     a   e    B    t    l     m11,Pos.D.   s   a     S1+/    y   n    S    i   o3+/    m   r   T    (   e    T

2+/ 

X:***** +   +   +      2    P    J

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

(Internal Connections)

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

Terminals & Pin-out Location, I/O monitor The I/O Monitor CAN Bus Node enables you to decentralize and increase the number of input monitoring and output controlling signals in your Smartpack   based DC power supply system. Also, it monitors and controls the compartment temperature inside fancooled outdoor cabinets.

DIN Rail mounting clips

Screw head mounting slot (2x) (Head’s diameter >5 mm and 300Vac the rectifier will go into self protective mode. At no load, the rectifier will survive 350Vac. With load or battery connected, it will survive 420Vac.

Stand by power consumption Part

Stand by Consumption

Smartpack Cabinet ventilation fan

Max. 10W DC 100W DC

Note

5-10W depending on state of relays, display backlight etc. 0-100W DC depending on the fan speed (temperature).

Specifications are subject to change without notice Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

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3 Installation 

3.

Installation

This section describes how to install the FP2 9kW 48V Fan OD 1.8m.  Step-by-step procedures will guide you through the installation.

Safety Precautions General Safety Precautions Please read and follow all safety instructions or warnings before installing or maintaining the power system. Review any supporting documentation regarding the power system and its components prior to installation. i nstallation.  

To be iinstalled nstalled only iin n re restricted stricted access areas or th the e lik like, e, in accordance with articles 110-16, 110-17, and 110-18 of the National Electrical Code, ANSI/NFPA 70 For supply connectors use wires suitable for at least 75˚C (167˚F) Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar. Use copper conductors only

 

The equipment described in this manual must only be operated by Eltek personnel or by persons who have attended a suitable Eltek training course



CAUTION: Even though the product incorporates protection circuitry and other safeguards, it can be damaged, perform poorly or have a reduced lifecycle if it is exposed to incorrect treatment during transport, installation or service.



The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty 



There are hazardous voltages inside the power system. As the modules incorporate large charged capacitors, it is dangerous to work inside the system even if the mains supply is disconnected

 

This system is also designed for IT power distribution systems

 

Products into which our components are incorporated have to comply with a number of requirements. Installation is to be in accordance with the recommendations recommendati ons herein

 

Please read the manual carefully before using the equipment 

 

The enclosure must be installed, serviced, maintained, and operated by a qualified technician who is familiar with electrical wiring, electrical equipment, and enclosure deployment techniques and best practices for

 

22 

safety The enclosure must remain locked at all times, except when authorized service personnel are present Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

3 Installation   

Remove all conductive jewelry or personal equipment prior to servicing equipment, parts, connectors, wiring, or batteries

 

Read and follow all installation, equipment grounding, usage, and service instructions included in this manual

 

Use proper lifting techniques whenever handling the enclosure, equipment, parts, or batteries

 

Do not roll the cabinets on their sides

Electrical Safety  

Lethal voltages are present within the power supply and electrical boxes. Never assume that an electrical connection or conductor is not energized. Check the circuit with a volt meter with respect to the grounded portion of the enclosure (both AC and DC) prior to any installation or removal procedure

 

An external electrical service disconnect must be used that is properly sized as required by the NEC and/or local codes

 

The supply neutral conductor must be bonded to earth ground at the disconnect panel

 

Do not work alone under hazardous conditions

 

A licensed electrician is required to install permanently wired equipment

 

Ensure that utility power is disabled before beginning beginning installation or removal

 

Ensure no liquids or wet clothes contact internal components

 

Hazardous electrically live parts inside the enclosure are energized by batteries even when the AC input power is disconnected. Make sure the power is removed via the battery disconnect d isconnect breaker before servicing any of the equipment

 

The internal equipment may be powered by AC circuits. Make sure power is removed via the appropriate breaker before servicing any of the equipment

 

Prior to installation, verify that the AC input voltage to the enclosure and its equipment with respect to voltage and frequency

 

Prior to installation, verify that the output voltage from the enclosure or its equipment match the voltage requirements of the connected equipment loads

 

Prior to installation, verify that the enclosure’ s utility service panel is equipped with a properly rated circuit breaker for use with the equipment inside. Refer to the manufacturer’s recommendations 

 

Prior to installati installation, on, contact local utilities, local building mainten maintenance ance departments, and cable/pipin cable/piping g locating services to ensure that installation does not interfere with existing utilities or building cables/piping

 

Fuses/circuit breakers may not be provided with the equipment. Refer to the documentation for the proper hardware. Use only the parts specified in the documentation. Installing fuses or circuit breakers not specified for use in this equipment may result in injury to service personnel or equipment damage

 

Where required for installations in the United States or Canada, use listed/certified compression connectors to terminate listed/certified listed/certified field-installed conductors. If the proper connector for the country of installation is not provided, obtain the appropriate connectors and follow all manufacturer and local requirements requiremen ts for proper connections

 

Torque the electrical connections to the values specified on labels or in the product documentation

 

The DC distribution is considered a Safety Extra Low Voltage (SEL V) with the return side connected to the chassis (earth ground) inside the enclosure

 

The supply neutral conductor must be grounded at the external service supply disconnect panel

 

Do not use other methods for cable entry than what is specified in the documentation for this product

 

Ensure proper cable support is used to support the weight of cables and cable conduits that enter/exit the cabinet

 

Do not drill new holes or use other methods for cable entry than what is described in the product documentation

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

23 

 

3 Installation 

Mechanical Safety  

Keep hands, hardware and tools clear of the fans. Fans are thermostatical thermostatically ly controlled and will turn on automatically as a function of temperature automatically

 

Rectifiers can reach extreme temperatures under load and normal operation

 

Use caution around sheet metal components and sharp edges

 

Do not climb on the enclosure to access the cable entrance. Always use the proper ladder and safety precautions as dictated by the site conditions

Battery Safety

Note

Note: Note: -Battery lifetime depends on working temperature (halved every +10°C above 20°C temperature), on the lack of proper preventive maintenance, and on the depth and frequency of the charge / discharge cycles. Actual lifetime is specified under normal conditions and regular preventive maintenance routines as an approximate expected value and cannot be guarantied as it depends on many local and unpredictable factors not controlled by the sys system tem supplier. Lifetime is specified by the battery manufacturer and is not a system supplier's responsibility.

 

Always wear eye protection, rubber gloves, and a protective vest when working near batteries. Remove all metallic objects from hands, wrists, and neck

 

Batteries contain dangerous voltages and current, as well as corrosive material. Battery maintenance, maintenance, service, and replacement must be performed by authorized personnel only

 

Never use non-insulated tools or other conductive materials when installing, maintaining, servicing, or replacing batteries

 

Use special caution when connecting or adjusting battery cables. An improperly connected battery cable can result in arcing, fire, or possibly an explosion

 

A battery showing signs of cracks, swelling or leaking must be replaced immediately immediately by authorized personnel using a battery of identical type and make

 

Do not smoke or introduce sparks in the vicinity v icinity of a battery

 

Follow the battery manufacturer’ s approved transportation and storage instructions

 

Prior to handling the batteries, touch a grounded metal object to dissipate any static charge that may have developed in your body

 

Batteries contain or emit chemicals chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Battery post terminals and related accessories contain lean and lead compounds. Wash hands after handling

 

If any battery emission contacts the skin, wash immediately and thoroughly with water. Follow your company’ s approved chemical exposure procedures

 

Neutralize any spilled battery emission emission with a special solution contained in an approved spill kit or o r with a solution of 1 lb bicarbonate of soda to 1 gallon of water. Report a chemical spill using your company’ s spill reporting procedures and seek medical attention, if necessary

 

Each individual battery should have at least 0.25 inches of space between it and surrounding surfaces, or per the battery manufacturer’s manufacturer’s specification to allow for convective cooling

 

Battery cables must be dressed to avoid damage to the conductors. Damage or stress can be caused by routing around sharp edges or in areas where wires could get pinched

 

Follow battery manufacturer’s approved instructions instructions to set all battery related parameters accordingly

24 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

3 Installation 

Installing the Modules

Device hazard

CAUTION: CAUTION: - The modules may be warm, but do not hand-carry them hand-carry them by their handles - Open the handles before inserting them into the power shelves (hot-pluggable) The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing

Mounting or Removing S ma marr tpa tpacc k  and  and Flatpack2 Modules Note that cables are plugged  to the Smartpack’s   rear panel. When mounting the controller, you must plug the cables before step 2. When removing it, unplug the cables during step 2.

Smartpack   controller

Hole to release the handle’s spring mechanism

Flatpack2   rectifier

Handle in unlocked position Handle in locked position

1.  Unlock the handles by inserting a screwdriver into the holes to release the spring mechanism 2.  Insert or remove the module  by  sliding it fully into the power shelf, so that the module makes pr proper oper contact (for Smartpack, plug cables first)

or using both handles to pull the module loose. Support from underneath before the unit is completely free. Unplug the cables, when removing the Smartpack   module 3.  Lock the handles by pushing the handles up into i nto their housings (locked position). Then, the module will be securely locked in the shelf, or ready for transport Electric shock

4.  Mount blind panels in unused module locations

Please note:

If the Smartpack is replaced in the system it is recommended to check battery current calibration as occasionally new controllers may present some minor differences in their readings from actual value due to inaccuracy of shunt installed in the system. Please refer to page  page  45 for “Battery Current Reading Check and Calibration ” on how to perform the check and calibration (if necessary).

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

25 

 

3 Installation 

Mounting and Removing Blind Panels Screwdriver to release the locking tabs

Blind panel’s upper locking tabs

To remove blind panels, carry out the following: 1.  Release the panel’s upper left and right corners by

inserting a small screwdriver into the panel’s upper left gap and carefully press down and out to release the locking tabs. Repeat on the upper right gap. 2.  Remove the blind panel by using you hand to pull the panel loose  To mount blind panels, carry out the following: 1.  Insert the panel’s upper edge by pressing gently so that its upper locking tabs engage 2.  Lock the panel’s lower edge by pressing with your hand so that the blind pane l’s lower tabs lock into position.

Correct Rectifier Position in Power Shelves Flatpack2  DC power systems are normally shipped from factory with empty power

shelves. The rectifier modules are shipped in separate packaging, and you have to install the modules in the correct position in the power shelf, with respect to their ID number (or CAN bus address). Do not relocate already pre-installed rectifiers. Follow the scheme below to install the Flatpack2 rectifier modules:   Insert & hot-plug the rectifiers in the indicated power shelf positions,

o

one module at a time, allowing a 2s delay between them and starting with ID number 1, 2, 3.

1

Phase 1

2

Phase 2

3

Phase 3

Figure 20. Rectifiers’  positions  positions

26 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

3 Installation 

Cabinet cooling capacity for various rectifier modules installed Cabinet Cooling Capacity Maximum heat Maximum heat Cabinet max. dissipation from dissipation, other DC output (W) rectifiers (W) equipment (W)*

Description

Eltek Part number

Flatpack2 48/2000

241115.100SC

CS7160011

6000

522

178

Flatpack2 48/2000 HE

241115.105SC

CS7160015

6000

237

463

Flatpack2 48/3000 HE

241119.105SC

CS7160020

9000

524

176

NSN CS code

* Maximum allowed total heat dissipation from other equipment installed in the cabinets’  19" equipment area. * Note, any equipment installed inside the cabinet must be able to operate in temperatures of up to 15°C above expected cabinet ambient temperature. Testing/evaluation may be needed, especially for any fan cooled equipment.

Rectifier modules that cannot be installed in this cabinet: Do not install "Back-to-Front airflow" type rectifier modules in this cabinet (rectifiers with a fan direction icon printed on their front panel, see below and User Guide for further details). Do not install any of the following rectifier modules into this cabinet Description

EV Part Number

NSN CS Code

Airflow

Flatpack2 48/2000 B-to-F Fan

241115.110SC

CS7160000

Back-to-Front

Flatpack2 48/2000 B-to-F High Temp

241115.120SC

CS7160000

Back-to-Front

Flatpack2 48/2000 B-to-F Fan HE

241115.115SC

CS7160010

Back-to-Front

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

27 

 

3 Installation 

System Installation Check off in the Installation Check List, that you find in the last section of this folder. f older.

Site Preparation Refer also to chapter “Location of Components ~ General Arrangement”  on  on page 11. Step - Site Preparation 1.  Organize the installation site

2.  Prepare the installation tools

Action Power is OFF! The site should be suitable and ready for the outdoor cabinet. Minimum Clarence for cabinet access:   250mm to the left hand side for open the door to an angle of 115° (For a right hinged version 250mm on right hand side).   570mm to the front side (door open) others minimum 50mm are   All recommended.

OK

Use insulated tools when performing installation. The following tools are required for a safe installation of the cabinet: Socket wrench. Screwdriver sets, regular, pozidrive and torx.   Torque spanner.   M10 bolts for cabinet base.   Standard tools for electricians.

   

3.  Prepare AC Supply: AC input cable(s) and fuses

Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated. Refer to page 12 page  12

Mechanical Installation  

WARNING: Do NOT open the cabinet’s door before the cabinet is securely fastened to the ground, as the door’s weight may overturn the cabinet. cabinet.  

 

CAUTION: Do not step or walk on the cabinet’s roof.  roof.  

 

Note! Do not install the batteries until the cabinet has been properly fasten fastened ed

 

Note! The condensation stopper (yellow plastic) prevents humidity from entering the cabinet and must therefore not be removed before cabinet is powered up. Humidity before powering up the system may cause serious damage to the system.

28 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

3 Installation 

Step - Mechanical Installation

Action

4.  Remove packaging and check equipment

CAUTION: Do

Power is OFF!

OK

not step nor walk on the cabinet’s

roof.   Check you have received all the parts,

o

5.  Cabinet placement

correct cabinet, documentation, batteries (if applicable), etc Inspect the equipment for physical damage o  (report any damages) o  Leave rectifier modules in their packaging or in the shelves, if factory installed. (commissioning task) A lifting arrangement which can be found inside i nside the cabinet can if necessary be used when placing pl acing the cabinet. Lock the cabinet door so the door does not swing during lifting. Remove the top by unscrewing the two M6 screws in front and lifting the top. Unhook the top from the clamps on the rear top. Fix the lifting legs to upright position. Lift the cabinet by the use of straps and move it to the floor/position. Balance the cabinet to prevent it from swinging.   Note! Do not lift the cabinet with batteries installed. Maximum cabinet lifting weight is 300 kg. Note! The straps must have an angle on o  approximately 60 degrees when lifting.   Note! Make sure that no items are

o

scratching the cabinet paint during lifting.

Figure 21. Lifting arrangements 6.  Mounting on floor / ground with plinth

See drawing in Appendix page  page  53  “Figure 27 Plinth drilling pattern” for the actual plinth drilling pattern holes. Note! Do not install the batteries until the cabinet has been properly fastened. Make 4 holes in the floor according to the drilling pattern holes. Make sure that the floor/ground is level. Mount the cabinet/plinth to the ground using M10 bolts with plain and spring washers (bolts and washers for fixing the plinth to the ground are not supplied). The torque depends on the floor material. Make sure the cabinet is properly fastened.

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

29 

 

3 Installation  Step - Mechanical Installation 7.  Remount cabinet top.

8.  Cable entry / cable sizes

Action Power is OFF! After mounting the plinth and cabinet, the four lifting brackets (if used) on top of the cabinet should be removed. Remount the cabinet top when done. Cable entry for mains, alarms, load, external batteries and main DC ground is done in the bottom of the cabinet. For easy installation the plinth’s front and right/left side covers can be removed. These covers may remain withdrawn if cables and conduits are entered here.

OK

Please note:  If you would like to to have the front c cover over mounted then fix it with the M6 screw until the cover and screw are in their final  positions. Neglecting this may may prevent the door from being able to close.

M6 Screw

Figure 22 – Remove front plate on plinth

Start with removing the front by loosening the M6 screw in the middle of the front and pull the plate towards you.

Self locking nut

Rear lip to lock the back section. Figure 23 – Remove side plates

Remove the desired side plate(s) by unfixing the 2 self locking nut M5 from the inside of the plinth. Push away from the cabinet and pull the side plate towards you

30 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

3 Installation  Step - Mechanical Installation 9.  Batteries

Action Power is OFF! Please note that the battery shelves have following space available:   Shelf 1 (height)  – 329 mm (the lowest)   Shelf 2 (height)  – 326 mm (middle)   Shelf 3 (height)  – 330 mm (top shelf)

OK

  Start (if applicable) mounting them on the

o

lower shelf first, and continue upwards. Do not terminate the battery cables yet! Do not remove Condensation Stopper yet!

The condensation stopper (yellow plastic) prevents humidity from entering the cabinet and must therefore not be removed until the system is powered up during commissioning. Humidity before powering up the system may cause serious damage to the system. The condensation stopper is attached to the filter fil ter on the inside of the door.

Electrical Installation Refer also to chapter chapter “  “Location of Components ~ General Arrangement”  on  on page 11. Step - Electrical Installation

Action

10.  Make the system completely voltage free

Switch OFF ALL load breakers, battery breakers (Fb1, Fbx) and external AC supply fuses

11.  Insert the cables

Marcon 25 multigate 

Power is OFF! OK

Cable (all phases in one cable) max 6mm 2 each Single phase cable (one cable per phase) max 35mm2 Use a screw driver to puncture the o  appropriate grommet(s) of the Marcon 25 multigate. Do not use a knife! The cut must be smaller than the cable . diameter. The pictures show how to cut the grommets.   Push cable(s) through the grommet(s):

o

  Then pull the cable(s) back out of the

o

grommet, approx. 10mm. This will lock the cable in the grommet and ensure full IP protection Ensure that the fixing screws of all Marcon o  25 multigate cable entry plates and metal blind plates are properly tightened

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

31 

 

3 Installation  Step - Electrical Installation 12.  AC Connections

Action

Power is OFF! OK

  Check AC configuration: 

o

- The AC terminals are correctly configured to the external AC supply. Refer to page 12 page 12 for “Figure 8. Mains terminals reconfiguration  reconfiguration  o  Connect the AC Earth wire (PE) to the terminals AC Earth (PE) 

- Terminal AC Earth (PE) is mechanically connected to cabinet chassis     Connect the AC input cable(s) to the terminals.. Cable and terminal block terminals

o

labelling are to correspond. Read pages 12. pages  12.     Fasten the AC cables  cables 

o

Figure 24. AC terminals

13.  DC Connections Load Circuits

Fasten the AC cable(s) to the rear cable support bar located behind the power system

  Terminate DC Earth (TE) 

o

- DC Earth connection bar (TE) is mechanically connected to cabinet chassis. Refer to page 11 page 11 for "General Arrangement Flatpack2 PS Systems, 9kW/48VDC, Fan OD 1.8m”  

- 

The Common Positive busbar is mechanically grounded to the cabinet thus the positive output of the rectifiers is connected to ground (TE), and the negative output represents the –48VDC supply voltage.   Terminate DC Load Circuits   o - Connect the positive cable(s), max 35 mm2 (AWG 2), to the common positive bus bar on the top of the power core. 2   - Connect the negative (-48V) cables, max 25 mm sq each (AWG 4), to the top of the MCBs. 14.  DC Connections Alarm & Signal Circuits

2

  Terminate Alarm Circuit cables to the relay

o

output Refer toterminals. chapter “Terminals & Pin-out chapter “ Location, Alarm Interface Card”  on  on page 16.

 The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.

32 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

3 Installation  Step - Electrical Installation 15.  DC Connections Battery Cables

Action Power is OFF! OK The positive and negative (-48V) battery cables are connected from factory to the common positive po sitive bus bar and to the battery MCBs. For additional battery cables follow the procedure: o  Connect positive battery cable to Common positive DC output busbar Connect negative battery cable to required o  battery MCB busbar connection Connect cables to batteries: Connect all battery inter-cell links o  Connect the loose end of the battery cables o  to the battery terminals; blue cable to the negative terminal and black cable to the positive terminal. The battery temperature sense cable is also prewired to CON4, and temporally fixed to the cabinet’s wall.    Place the temperature sensor, located at

o

the end of the battery temperature sense cable, on top of the topmost battery string  

Note: Placing the temperature sensor not in the recommended place will result in inaccurate (lower) readings of the temperature in battery compartment

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

33 

 

4 Commissioning 

4. Commissioning The commissioning of Flatpack2 PS System consists of following stages: I.  Perform a pre-start check before the PS system is switched ON II.  Switch ON the system with disconnected load; adjust output voltage III.  Adjust the nominal output voltage with connected batteries and load

I Power is OFF!

Pre-Start Check Check off in the Commissioning Procedure, that you find in the last section of this folder. If you have just finished the system installation successfully and filled in the Installation Check List, jump over the Pre-Start Check and continue with stage II. Before you switch ON the Flatpack2 PS system, verify the following: 1.  System installation is completed o  Ensure a correctly performed system installation, with correct polarity on all connections, has been carried out ( Installation Check List  filled  filled in) o  All cabling and copper bars are securely terminated and supported o  All components, terminal blocks, MCBs etc. are clearly labeled

Device hazard

2.  Battery and load MCBs are disconnected o  Verify that all battery and load MCBs are switched OFF 3.  AC input cable(s) and AC Earth wire (PE) are terminated o  Make sure that the AC input cable(s) are connected to correctly configured

AC terminals   Verify that the AC input cable(s) and external AC fuses are sized and rated

o

as specified terminat ed o  Check that AC Earth (PE) is terminated 4.  Site specific parameters and settings are known o  Read the system specific drawings and documentation 5.  AC supply and all MCBs, fuses fu ses are switched OFF o  Make sure that all external AC fuses and internal MCBs are switched OFF

34 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

4 Commissioning 

Commissioning Steps, Startup Check off in the Commissioning Procedure, that you find in the last section of this folder. After the” PrePre-start Check” is performed, you can begin with stage II. During the stage, you will switch ON the Flatpack2 PS — while the batteries and load are disconnected     then then measure the output voltage, and adjust it if required. Carry out the following:

II

Power is ON! 1. 

Device hazard

Startup and No-Load Adjustments Disconnect all rectifier modules, without removing them (keep original location)  o  Read how to install modules, on page 23 Also, read about the correct

rectifier position on page 26, page 26, and  and then, , unlock the handles and pull the o  If Flatpack2 rectifier modules are installed  modules partially out (fan housing visible), but do NOT physically ph ysically remove them from the power shelves , release their handles o  If Flatpack2 rectifier modules are not yet mounted  and insert them partially into the correct position in the shelves 2.  Remove the Condensation Stopper   Remove the Condensation Stopper placed in front of both filters, inside the door

o

and in front of the fan. 3.  Switch ON the system o  Switch ON the AC input supply (external AC fuses) to the PS cabinet 4.  Measure and verify that the AC the  AC input voltage is voltage is correct o  Measure the AC input voltage at the cabinet’s mains connection o  Verify the AC voltage is within range

box  

5.  Mount all Flatpack2 Flatpack2 rectifier  rectifier modules in the power shelves (keep original location)  o  Push all rectifiers firmly inwards     one module at a time, allowing a 2s

delay    to   to plug them in the same shelf location. Lock their handles. Refer also to page 23 6.  Ensure that the Smartpack  and  and all rectifier modules are working: LEDs are ON o  Verify correct operation, by monitoring the modules’ LED lamps and display: No alarms are present on rectifiers; The Smartpack  displays  displays fuse

alarms 7.  Connect a PC to the PS system (to facilitate operation)    o  Plug a standard USB A-B cable between the PC and the Smartpack 

controller o  Start PowerSuite on the PC by selecting: Start > All Programs > Eltek> PowerSuite   

o

On the toolbar, click the “Connect” button to establish connection

8.  Measure and adjust DC output voltage  voltage  o  Read the DC output voltage on the controller’s display   o  With a multi-meter, measure the DC output voltage at the most accessible

point, e.g. between the common DC rail and the lower connection of one of the priority load MCBs  

o

If required, adjust the voltage using the controller’s front keys or via PowerSuite 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

35 

 

4 Commissioning  9.  Verify the alarm relays are working correctly (alarm relay test) o  Run the alarm relay test using the controller’s front keys or via PowerSuite  (select the menu Go > Output Test ) 10. Make Make sure the System Setup is Setup is in accordance with configuration o  Verify system settings using the controller’s front keys or via PowerSuite  o  Use the opportunity to enter site related information, number of used AC

phases, type of batteries, etc. 11. Make Make sure Management is working correctly Turn Heat the Fan breaker off and on. o 

The fan will start up and run up to maximum set point in ten seconds and then down to minimum set point in ten seconds before normal operation is established

III

Load Adjustments 

Power is ON!

Now, you can begin with stage III, where you will adjust again the output voltage to the battery voltage, and connect the batteries and the load. Carry out the following: 12. Adjust Adjust DC output voltage to voltage to equal measured battery voltage  voltage    Measure the battery voltage is within range ( check connections have correct polarity ) o  Adjust DC output voltage — using the controller’s front keys or via Device PowerSuite— to equal the measured battery voltage. hazard o

(Important adjustment to avoid arcing when connecting the batteries) 13. Unplug Unplug all rectifiers but one, and connect the battery MCBs (CAUTION: Have only one rectifier connected, when switching ON the battery

fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.)  o  Disconnect all rectifiers but one, by unlocking the handles and pulling them partially out (fan housing visible). Do NOT physically remove them from the power shelves o  Switch ON all battery fuses or MCBs

Device hazard

14. A Adjust djust DC output voltage again to equal the nominal battery b attery voltage   Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to equal the nominal battery voltage (or the nominal load

o

voltage, when not using batteries) 15. Plug Plug in again all rectifiers, and verify the rectifiers’ current sharing sh aring o  Connect all rectifiers again by pushing them firmly inwards    Repeat  Repeat step

4, in stage II o  Wait for about 2 min., and check — using the PowerSuite application —that each of the rectifiers delivers the same output current. A deviation of 1A is acceptable. 16. Connect Connect the load breakers and verify that no alarms are displayed o  Switch ON all load MCBs/ fuses o  Verify correct operation: rectifiers and controller display no alarms

36 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

5 Maintenance 

5. Maintenance You can carry out the DC power system maintenance, by following the steps in the Maintenance Procedure that you find in the last section of this manual. This chapter describes how to perform filter maintenance.  

WARNING: You are operating in a live system. Precaution must be taken when changing filter in front of the fan.   Note: It is of great importance that ONLY Eltek original filters are used when changing the filter, to keep the t he level of dust and water protection for the equipment inside the cabinet. See filter for part number and/or contact your local Eltek company for further details. Lower Door Filter (Fan Filter) Pollution degrees: Low Medium High

 

City roof top: 2 years 2 years 1 year

Non central: 3-4 years 3-4 years 2 years

Note: The filter replacement intervals listed in the above table are only guidelines. Shorter intervals may be required, depending on the level of air pollution on site. Eltek recommends bi-monthly bi-monthly site checks during the first year of operation, to establish actual filter replacement intervals for each individual site  Upper Door Filter Pollution degrees: Low Medium High

 

Locations: Car park/road side: 1 year 1 year 6 months

Locations: Car park/road side: 4 year 4 year 2 years

City roof top: 8 years 8 years 4 year

Non central: 12 years 12 years 8 years

Note: The filter replacement intervals listed in the above table are only guidelines. Shorter intervals may be required, depending on the level of air pollution on site. Eltek

recommends bi-monthly bi-monthly site checks during the first year of operation, to establish actual filter replacement intervals for each individual site 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

37 

 

5 Maintenance 

Replacement of inlet and outlet filters Step

Action

Fig.

OK

1.  Disconnect the fan

Turn off the breaker for fan.

See GA for actual position.

2.  Open the Fan Filter

Remove the filter frame  by removing the screws

Door

indicated in the picture.

Filter Frame

Open the fan filter box  by pushing the two knobs on the door and (if used) by removing the two screws holding the knob/bracket in  place.

Fan Box

Figure 21. Fan Filter door 3.  Replace the filter

Replace the old filters with new ones. Make sure that the smooth side of the filter faces the inside of the cabinet (Bottom For top filter it isfilter). opposite. There are guide pins to help ensure proper orientation.

4.  Close the Fan Filter door

Close the fan filter box and/or filter frame.

5.  Connect the fan

Turn on the breaker for the fan, and verify that the system is operating normally.

38 

See GA for actual position.

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

6 Forms, Schematics & Drawings 

6. Forms, Schematics & Drawings This section includes following forms and schematic drawings:

Installation Check List Commissioning Procedure Maintenance Procedure

Battery current readings check and calibration Breakers derating table General Arrangement Drawing System Schematic Drawing Configuration Settings ~ Flatpack2 PS System, 9kW/48VDC Fan OD 1.8m Outdoor cabinet Fan 1.8m drawing Plinth drilling pattern

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

39 

 

 

INSTALLATION CHECK LIST  System Data

Flatpack2 PS System  

Flatpack2 Power Supply System, System , type:

Article No.:

Site, name: Serial No.:

Software, version No.:

 AC Input Voltage, Voltage, measured:

Battery Type:

Rectifiers, type & number of: Battery Capacity:

Installation carried out by, name:

Site Preparations

Power is OFF! 

CARRY OUT FOLLOWING:

EMC regard

OK 

1. Organize the installation site

 

2. Prepare the installation tools

 

3. Prepare AC Supply: AC input cable(s) and fuses

 

Mechanical Installation CARRY OUT FOLLOWING:

Power is OFF!  OK 

4. Remove packaging and check equipment

   

5. Position and fasten the cabinet Device hazard

6. Check required cable sizes and quantity and prepare enough room for routing cables 7. Mount the batteries on the shelves    

o

o

Do not terminate the terminate the battery cables yet! Do not remove the Condensation Stopper!

Electrical Installation

Power is OFF! 

CARRY OUT FOLLOWING: Electric shock

   

OK 

8. Make the system completely voltage free

 

9. Insert the cables

 

10. AC Connections Connections     o  o

o

Check AC configuration: configuration: The AC terminals are correctly configured to the external AC supply Connect the AC Earth wire (PE) to (PE) to the terminals AC Earth (PE) Connect the AC input cable(s) to cable(s) to the terminals. Cable and t erminal block labeling are to correspond

11. DC Connections    Load   Load Circuits   o  o

Terminate DC Earth (TE at Common DC Output Rail c ables to the common DC output rail, and the other directly to the MCB For each DC load , connect one of the cables

13. DC Connections    Battery   Battery Cables

   

12. DC Connections    Alarm  Alarm & Signal Circuits Electric shock

 

Careful! Use correct polarity. 

For each battery shelf, o  Mount 3 intercell links to links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks) o  Connect battery cables to cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-) ( -) o  Connect the temperature sensor cable, cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at t he end of the cable) to a suitable place in the middle of the top most installed battery bank

 

 Approval Responsible of installation, sign.:

40 

Date:

Approved by customer, sign.:

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

41 

 

 

COMMISSIONING PROCEDURE  System Data Supplier’s Order No.:

Flatpack2 PS System   Flatpack2 Power Supply System, System , type:

Article No.:

Site, name:

I

Serial No.:

Software, version No.:

 AC Input Voltage, Voltage, measured:

Battery Type:

Rectifiers, type & number of: Battery Capacity Capacity::

Commissioning carried carried out by, name:

Pre-Start Check

Power is OFF!  

CHECK FOLLOWING: 1.

OK 

Flatpack2 system installation is completed; 

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

2. All battery and load MCBs are disconnected Device hazard

     

3. AC input cable(s) and AC earth wire wire (PE) are terminated 4. Site specific parameters and settings are known 5. AC supply and all MCBs are switched OFF

II

 

Start-up, No-Load & Load Adjustments CARRY OUT FOLLOWING:

Power is ON! 

OK 

1. Disconnect all rectifier modules, without removing them (keep original location) 2. Remove the Condensation Stopper

Device hazard

3. Switch ON the system (external AC fuses ON)  4.  AC input voltage is correct;

Measure and verify 

5. Insert all Flatpack2 rectifiers in their original locations in the power shelves 6. The Smartpack  and  and all rectifier modules are working, LEDs are ON; 7. Connect a PC to the PS system

Verify 

Install the PowerSuite  software, if required   PowerSuite software,

8. DC output voltage;

Verify all alarm relays are working correctly 

10. System Setup is in accordance with configuration

Enter site spec. info in PowerSuite  

11. Heat Management System is working correctly 12. Adjust DC output voltage to equal measured battery voltage

Device hazard

             

Measure and adjust 

9.  Alarm relay test;

III

 

13. Unplug all rectifiers but one, and connect all battery fuses/ MCBs 14. Adjust DC output voltage to equal nominal battery or load voltage 15. Plug in again all rectifiers, and verify the rectifiers’ current sharing   16. Connect all load MCBs, and verify no alarms are displayed

Check correct polarity!  

                 

 Approval Responsible of commissioning, sign.:

42 

Date:

Approved by customer, sign.:

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

43 

 

 

MAINTENANCE PROCEDURE  System Data

Flatpack2 PS System 

Flatpack2 Power Supply System, System , type:

Article No.:

Site, name:

Electric shock

Serial No.:

Software, version No.:

 AC Input Voltage, Voltage, measured:

Battery Type:

Rectifiers, type & number of: Battery Capacity:

Maintenance carried out out by, name:

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

System Inspection

Power is ON! 

CARRY OUT FOLLOWING:

OK 

1. Site specific parameters and settings are known. User manuals and site specific connection & arrangement drawings are available.

 

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

 

3. The equipment and door filters are free from damage, dust or dirt; verify.

 

4.  All cabling and copper bars are securely terminated and supported.

 

 & all rectifier modules are ON, no alarm present; verify. 5. The Smartpack  &

 

’s keys and display work OK; verify  6.  All rectifier’s functionality & Smartpack ’s

 

 At least for 12 hours since start-up or mains failure. Enable Enables s correct measurements & calibration  Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt. Perform filter maintenance.  Correct any loose connections, excessive cable temperature, defective insulation, etc. 

Otherwise, correct and put the PS system in normal mode of operation.   Correct possible abnormalities before continuing.  

7. Connect the PS system to a PC (install the PowerSuite application if required) The PowerSuite  program in the PC enables system s ystem configuration from the PC.  PowerSuite program

8. Rectifiers’ load current sharing; verify. Use the PowerSuite  PC application to check all rectifiers output the same amount of current ( 1A)  PowerSuite PC

9. Display the stored log of Alarm Messages.

   

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

System Adjustment CARRY OUT FOLLOWING:

OK 

Output Voltage Calibration; ensure correct display readings. 1. DC If measured DC output voltage at the load terminals deviates more than 1% from the display reading, calibrate the output voltage from the Smartpack ’s ’s keypad or the PC.

2. Load & Battery Current Calibration; verify correct display readings. Measure with a clip-on ammeter the battery current c urrent & every load circuit current. Calculate the total load & battery current. If the calculated total values deviate more t han 1% from the display readings, calibrate the current from the PC (calibration value>50% of system’s max. capacity)  

3. DC Output Voltage Adjustment; measure and adjust. Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery m anufacturer. (Voltage measurements to be done at the DC rail, with little load current) 

     

4.  Alarm Relay Test; verify all alarm relays are working correctly.

 

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

 

From the Smartpack ’s ’s keypad or PC use the Relay Test function; verify activation of external equipment 

Follow the recommendations of the actual battery manufacturer.  

 Approval

Responsible of maintenance control, sign.:

44 

Date:

Approved by customer, sign.:

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

 

BATTERY CURRENT READINGS CHECK AND  CALIBRATION  This section provides the necessary information on how to test and calibrate the battery current in the Eltek’s system. If you need to calibrate the power system‘s Battery Current follow this procedure, while the power system is operating normally . Please note that in most cases no re-calibration is neccessary as the Smartpacks were  pre-calibrated during system’s assembly. 

The shunt installed inside the system has a value of 200A and has an accuracy tolarance of ±1A (less than ± 0,5%). Use a Digital Voltimeter Voltimeter (DVM) or c clamp lamp – on ammeter for referential current measurements. 1. Preparation

Connect PC to Smartpack via USB cable and start up Powersuite. In the Power Explorer panel in Powersuite, click on SmartPack 1 and choose Shunt configuration tab and Current shunt section. Verify correct shunt value: 200A. 2. Testing the calibration accuracy.   Turn OFF AC mains. The load will draw Power from battteries.   Load the system with a minimum current of 60A (30% of battery current shunt

size of 200A).   Verify that the value displayed in Powersuite and the ampmmeter reading do not differ more than ± 1A.   Turn the AC mains back ON. Note that at very low currents curr ents (especially below approx. 5A), the accuracy of Smartpack may be slightly lower than expected. The same rule applies to accuracy of a ampmeter which may also be not good enough for measuring very low currents. This combined combined may indicate low calibration accuracy but should not justify a re-calibration. r e-calibration. If reading is out of limits perform battery current calibration, point 3 3. Battery current calibration HighCalibration Point. 

This action is performed during battery discharging di scharging (while the rectifiers/AC Mains are turned off, or have reduced output voltage and the battery current is at least 30% of the current shunt rating. Carry out the following:   Turn OFF AC mains and ensure that the batteries are delivering a stable current to the load. The current should be at least 60A (30% of battery shunt size)   Measure the discharge current with an ammeter   Enter the measured current, as a value (e.g “ -60” in the High Calibration Point   date field in PowerSuite, in the BatteryCurrent dialog box, under the Calibration  tab. See figure 1 below. NOTE: Remember to put negative mark ” -” before the value i.e -103A   Verify the calibration by repeating step 2 for different currents.   Turn the AC mains back ON.

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

45 

 

  Low Calibration Point.

This action shall be performed when the battery is disconnected e.g. by tripping the battery MCB`s. (Note that if the AC input fails while batteries are disconnected, the load equipment will be shut down)

This action should only be performed if setting of High Calibration Point hasn’t resolved calibration issue. In order to set Low Calibration Point carry out the following:  

Disconnect the batteries from the load, using the batteries MCB’s.  

 

Measure with an ammeter and confirm that the discharge current is 0A. Enter the value: “0A” , as a Low Calibration Point  in PowerSuite, in the BatteryCurrentX  dialog  dialog box, under the Calibration tab. See figure 1 below. Click “Apply”, then “OK”.  Reconnect the batteries by switching the battery breaker(s) back ON. Check the calibration as in step 2.

       

Figure 22. Powersuite Battery current calibration

46 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

 

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   5

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   6    4  ,    0    4

   6    8  ,    0    5

   7    9  ,    3    6

   6    0  ,    2    8

     5    3   -

   7    2  .    1

   4    5  ,    2

   1    8  ,    3

   8    0  ,    5

   7  ,    7

   9    8  ,    3    1

   8    7  ,    0    2

   7    6  ,    5    2

   1    2  ,    2    3

   4    0  .    1    4

   3    6  .    1    5

   2    9  ,      4    6

   8    4  ,    3    8

   0    1

   6    1

   0    2

   5    2

   2    3

   0    4

   0    5

   3    6

  y   t    f    i   n    d   e   r    1   o   r   u    M  c  

2

3

4

 

6

Rated current

 

   0    3   s    i   s    B    C    M    f   o   e   r   u    t   a   r   e   p   m   e    t   g   n    i    t   a   r   e   p   o    d   e    t   s   e   g   g   u   s   e    h    T  .    d   e    l    l   a    t   s   n  ,    i   s    B   i    C    B    M    C   s   e   M    i   r   e   e   s    h    t

   6    3    h   c   -    i    2   h    B  w    D  n    N   i  ,    t   e   n    B   i    C   b    M  a   c   s   e   h   c    i    t   r    i   e   s   w   s    3   f    6   -   o    1   y    t    i    M   n    D   i   c    N   i   r   v   e   o    f    h   e   t    l   n    b   i   a    t    i   g   n    i   u   s    t   s   s    i    i   x   e   a    t    t   a   a    d   h    t   g   s   n   i    i    t   e   a   r   r   e   u    d   t   a   r   e   r   e   p   u    t   m   a   e   r   e   t   p   g   n    i   m   t    t   e   a   s   r   e   :    i    h   p   e    t    T    O   o  .  .    N   1   2

Figure 23. Breakers derating table. Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

47 

 

 

34U

 

T2

32U

30U

28U

26U

24U

  22U

T1

20U

330 mm

18U

16U

 

14U

326 mm

12U

10U

8U

 

6U

4U

329 mm

2U

HxDxW: 1800x820x700mm

Figure 24. General Arrangement Flatpack2 PS System, 9kW, 48VDC, Fan OD 1.8m  

48 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

 

  s   n   o  i t  c   e   n   n   o   c   r  e    m   o  t  s  u    C

  s  n   o  i t  c  e   n   n   o   c  r  e    m   o  t  s   u    C

 

 

  c   d    V  8   4     s   r  e   k   a   e   r  b  d   a   o   L

  c   d    V   8   4   -  s  t i  u   c   r i   C   s   g   n  i   r t    S  y   r  e  t t  a    B

   1    2    3    4    B    B    B    B    F    F    F    F   -   -   -   -

   )   n   a    F   r   o   o    D    (    3    1    F   -

   1   2   6    F   F   F   -   -   -

  s  n   o  i t  c  e   n   n   o   c   r  e    m   o  t  s   u    C    5

 

   7    8    F    F   -   -

  s   n   o    i    t   c   e   n   n   o   c    t   n   o   r    F

   2    1    F   -

   t   r   o   p    B   )   n   o   e   t    i   p  c   y   e    t   n    0  .   n    2   o    d    t    B  c    i    k   n    C   c   a   n    S   P   a   g   u    U   (

   +   n   o   m   m   o   c   r   a    b      U    C

  p   i   n   l    t   r   r   o   r   o   t   a   t   m   i   n   o    S  n   o   c   s   n   m    i   o   s   n   o    i    t   c   e   n   n   o   c   r   a   e    R

   )    E    T    (    h    t   r   a    E    C    D

  x   8    i   r   2    t    0   a   0    M    0   e   0    6    d   2   o   6    i    D   8

  s   n   o    i    t    t   c   c   e   e   n   n   n   o   o   n    C   c   y   m    5   t   e    4   r   e    N  s    N   t    t    O  y    O  a    C   S    C   B

   5    1

   D    L    V    L

   X    Y

   ”   s   n   o    i    t    k   c   c    f   e   n  a   p  .   o  n   t   r   n   e  o  a   o   i    C    i    t    d   m   c   s    S   r   y   r   f   e   a   e   o   n    t   n   e    t   o   r   a   e   c   n   B   i    d    2   o  .   s   r   t   r    3   o    2   x   a    E  e    S   t   r   n   ”

   B    S    U

   5    1

  n   o    i    t   p    O

   )    P    M    N    S    /    B    E    (    W    t   e   n   r   e    h    t    E

   )    T   s   E   n   N   o   E    i    t   (   s   c   P   e   M   n   o   n   N    i   n   S    t   c   o   /   e    C   b   n   e   n    O    /    I    W   o   m    l   :   a    C   r   n    O    /   a    I   o    l    i    2   A   t    1   m   p  .    N   t    N  r   a    O  x   O   :    O   l    C   E   2    C   A

   6    2    /    8

   5    1    /    9

   0    1

   t   r   o   p    N    A    C

   8

   t   r   o   p    N    A    C

   R  o   r   s   e    b   f   e   h   u   i   c   t   s   n   l   a   n     p   o    D   d   e   e   d   n   t   e   n   R   t    i   p   u  .   n   o   k   o   c   a   u    9    l   a   m   m   p   e   n   b   t   o   r   n    i    t   n   a   e   p   a   m   h    O   C   S  w   :    1

   ”

  s    W    l   a   e   n   c   a   o   l    i    t   p   p   e    O   R   :    2

   8

   1    T

  y    b    d   e   c   a

   7    9    4    6    8  

 .    f   o   0    2   e   -    N   c  .   a    l   w   p   a   r   e    R    D

   1    f   o    1

  e   g   a    P

  m    8  .    1   m    D   a   r   O   g   a   n    i   a    d   F   c    i    8    V    t   a   4    /   m   e    h   W   c   k    S   9    2    P    F  

   t    3   a    A   m   r   o    F

  -

   t   n   a    t    l   u   s   n   o    C

   /    1   N    1    0   C    2  .    E    5   H    0  .    E    3   G    1

   A    C    3    1    5    0    1    1

   V    V    0    8    4      d    k   e   w   e   c   o   u    l   a    l    R    l    B    B   e    Y

 

 .   v   5   e

  -    R

   l  .    d   e   p    k   v   e   r   e    t    l   e    E   s    R    t   e    h   r   s   g   t    i   r    h   g   y   i   p   r   o   l    l   r    C   A   o

  a    D

   N    A    F   r   o   o    D

  n   g    i    S    /   e    t   a    D

  n   o    i    t   a   r   e    t    l    A  .   m   y    S

   5

   X

   D    B    V    L

   1    H    S

 .   n   ”   o   s    i    t   n   o   c   i   e   t   n   c   n   e   o   n   c   n    )   o    T   C    E      N   O    /    I    E    (   r    P  m   a    M   l    N   A  .    S    /   t    b   x   e   E

  s   e   f    t    h   o   u    t   p   e   t    f    d  .   o   o   u    )   s   n   m  o   g   o   y    i   a    t   n    l    i    i   m   e   t   s   r   r   a    t   o   l   e   p   a   e   S    h   y   e   t   s   T    h    i    t    )  .   r   o   n   d   t   s   i   c    i  n   o   e   w   i   a    t   c   e   z   F   o   s   i    j   o   r    h   m  g   (    P   s   e   r   y   e   r   g   t   o   n   s   n   y   e   t    i   c   w   S    a    l  e   e   f   a   c   a   r    d    S   r   m   n    D  e   w  e   o   r    d   S   n   o   h   f   v   o    t    d   e   o    i   r    F    I    t    P   p   p   e   e    A   c   e   r   e   h    t   a   m    K    l   s   m   n   e   i   a    S   o   n    N    h   o   r   a   w   O    C   r    A    /   w  c   g    J    D   o   c   y   r    i   s   l    t    t   p    K   a   c   a   e   e    S   r   a   r   p   n   m    N   g    O    i   e   t    (   s   e    A   n   e    D    J    h   n   o   o   r   c   c   i   a    S  y   t   a    0   r    1   e   l   a    0    2    h   e  .     6   r   p    T  e  .   o    t  e    0    5    2

   Y    C    T    N

   +

  r    h   c   o   t   o   i    D  w   s

  -

   2    T

  s  n   o  i t  c  e   n   n   o   c  r  e    m   o  t  s   u    C    1 2 3 4 5 6 7 8 9   0    1 2 3 4 5 6 7 8    1   2    1    1   1   1    *    *    3   s    1   s    0   n    0   n   o   -    +   -    +   -    +   -    +   -    +    o    +   -    +    3   i    +  -    +    3   i    N   t    N   t   c   c    O  e    O  e    1    2    C  n    l    l   n    C  n    1    2    1    2    3    4    5    6   n    t   o   o   r   r   e    2   t    t    t    t    t    t   o   u    t   o   e   s   s    1   u   u   u   u   u   n   n   n    h   h   p   p   p   p   p    C   p   c   o   o    C   n   e   e   c   n    I   n    I   n    I   n    I   n   n    I   a   a   C   C    I    S    S    T    l    l    l    l    l    O    T   d    d    O    /    l   a   a   p   a    /   p   a   a   a    I    t    t   e   e    t    t    t    t    I   m   m    i    i    i    i    i    i   e   e   g    i   g    i   g    i   g    i   g   g    i    i   p   e   p   e   m    D    D    D    D    D    D   m   r    S   S   r    T    T    4   r   a   a    l   o    0   i    l    t    A    3    A  .  .  .    t    0   n    *   s    t   o   x   x    2   n    E    0   M   0    E    1   o    2   t    i    2   O    N   c    4   /    O  e    2   I   n    C  n   y    1    2    3    4    5    6    l   o   p   y   y   y   y   y   y   p   a   a   a   a   a   a    C    l    l    l    l    l    l    t   u   e   e   e   e   e   e   r    t   r    S    O    R    R    R    R    R    R    /   o   o    I    D   p   p    V    L   m    N    N   r   a    A    A    M    M    M    M    M    M    l    C    C    C    C    C    C    C    C    O    O    O    O    O    O    O    O    O    O    O    O    A    N   C   N   N   C   N   N   C   N   N   C   N   N   C   N   N   C   N   -    +  .    t   x    1   2   3   4   5   6   7   8   9   0    E    1 2 3 4 5 6 7 8 9   0    1   1   1   1   1   1   1   1   1   1   2

     0

   1    2    5   n   1 2 3 4 5 6 7 8 9   0    1   1    1    X   i   o    *    t    +   -    +   -    +     c         e  .    l    1   A   n   A   n    f    t    i   n    t   n   a    l    1   o   2   o   e   n   u   p   e   r    F    i   a   n   m   R   o    I   r    d    F   D   m   D   u   e   r   m   m   r   s   e   V   m   o   V    C   u   e    L   o    t   a    C   e   s   L   C    C   s   w   y   u   o   m   r    F   o   y   y    F    D    D   e   r   e    P    t    B    t    t   e    d    V    V   S   a    t   a    L    L   n   s    B    t   y   a   o    S

  o    i    t   c   5    2   e   6   n   0   n   0   o   2    C   m   e    t   s   y    S

   3    3    P    J

   B    L

   2    P    J  .    T    S  I   D  .   G    E    N  .    T    S  I   D .   S    O    P    1    P    J  .    T    S  I   D  .   G    E    N

   1    N    O    C

   5    1

   d   n   a   s   s   t   u   4    t   u   p   n   5   p   I    t    9   u   l   a   5    O   t    i    0    1    i   m  g   r    D   a    l    A

   2    1

 .    T    S  I   D .   S    O    P

  s   n   o    i    t   c   e   n   n   o    *   C    A  m    5   t   e   n  s   o  y    C   S

   1   s    1   2 3 4 5 6 7 8 9   1   n    X    *   i   o   +   -    +     -    O   M   C   O   M   C    t      N   O   N   N   O   N   c    C    C   e   n    1    2   n    t    t    2    1   o   u   u   y   y   p   p    C    I   a   a   n    I   n    l    l   e   e    l    l    O    R    R   a   a    /    t    t    I    i    i   g    i   g    i   m    D    D   r   a    l    A

   3    2    1    3    2    1

   1   2   3   4   5   6   7   8   9   0    2   s    1 2 3 4 5 6 7 8 9   0    1   1   1   1   1   1   1   1   1   1   2   n    X    *   i   o   -    +   -    +   -    +   -    O   M   C   O   M   C   O   M   C   O   M   C            t    +    N   O   N   N   O   N   N   O   N   N   O   N   c    C    C    C    C   e   n    4    5    6   n    3    t    t    t    6    5    4    3   o    t   u   u   u   u   y   y   y   y   p   p   p    C   p   a   a   a   a   n    I   n    I   n    I   n    l    l    l    l    I   e   e   e   e    l    l    l    l    O    /    R    R    R    R   a   a   a   a    I    i    t    t    t    t    i    i    i   g    i   g    i   g    i   g    i   m    D    D    D    D   r   a    l    A  .    t   x    E   s   n   o    i    t   s   c   n   e   o   n    i    t   n   c   o   e    C   n   n    O    /   o    I    C   m   r    *   O    *    /   a    A   I    A   l    1   m    2   A   r   n   t  .   n  a   o   l   o  x    C   A    C   E

   0    1

  s    i   s   s   a    h    C

     8

   6    2

   9

     8

  s   n    2   C   o    i    P   A   i    t    F   4    t   s   9   g   n   o   5   n   e   p   0    i   r   r   r   r    2    i   u   e   w    i    f    2    2    k   C   i    t   c   h   c   a   i   g   r    B   H  e    4

   +

     1    R    P

   2   1   0   5   4   3   8   7   6   1   0   9    1   1   1   1   1   1   1   1   1   2   2   1    N   N   N   N   N   N   N   N   N   N   N   N    O   O   O   O   O   O   O   O   O   O   O   O    C   C   C   C   C   C   C   C   C   C   C   C    E   1   2   E   1   2   E   1   2   E   1   2    P   L   L   P   L   L   P   L   L   P   L   L

 

   8      1   n    i   p  ,    8   n   o    C

8

   6    1      9   n    i   p  ,    8   n   o    C

  r   e   s   w   n   o   o    t    P    i   s   c    k   u   e   c   b   n   a   n   p   o    t   r   N   r   a   A  c   e    C   m    /    t   n    S  -   i

  r  e  t  a   e    H    C    A   r  o   f  d   e   r  a   p   e   r    P

     E    P

   L

   N

   4    1    F

8

Not in use

   1    1    C    2    O    1    N    4    C    1    N

SP

   E    P

   N        ϑ

   3    L        ϑ

   2    L        ϑ

   V    0    0    4    h   p    3   r    D   f    P  o    S   d   e   r    i   w   e   r   p

   1    L

   E   E   1 2 3 4    5 6 7 8 9    P   P

 t  u   p   n  i  s   n  i  a    M

  m   e    t   s   s   y   e   s    i   r   r   e   e    t    t   w   a   o    b    P   r   r   o   o    f    f   e   e   s   s   n   n   e   e   s   s   p   p   m   m   e   e    T        T    –    –    1    2        T    T

   )    d   e   s   u   e    b   o    t   s   n    i   a   m    C    A    f   o   e   p   y    t   e    h    t   o    t   g   n    i    d   r   o   c   c   a   s    k   n    i    l   r   o    t   c   e   n   n   o   c   s   n    i   a   m   e   r   u   g    i    f   n   o   c   e    R    (

  s

   E    P    +

   k   c   o    l    b    l   a   n    i   m   r   e    t    t   u   p   n    i   s   n    i   a   m   e    l    b   a   r   u   g    i    f   n   o    C

   W    3  ,   c   a    V    0    5    2      0    0    1

   8    3    L

  s   r   n   e   m    t   o   c   o   i    t   e   s   n   u   n    C  o   c

   2    L    1    L

   7    6    5    4    3    2    1

   E    P

   9

     E    P    +    W    2  ,   c   a    V    0    5    2      0    0    1

  s   r   n   e   i   o    t   m   c   o   e    t   s   u   n   n    C  o   c

   8    7    1    L

   6    5    4    3

   N

   2    1

   E    P

   E    P    +    N    +    )    t    W    3   l  ,   u   a    V   f    0   e    3   d    4   r   -   y   o    0   t    7   c    1    /   a    V   F    (    0    5    2      0    0    1

 

  s   r   n   e   i   o    t   m   c   o    t   e   s   n   u   n    C  o   c

   9    3    L

   8

   2    L

   6

   1    L

   4

   N

   2

   7    5    3

   1    E    P

Figure 25. System Schematic Flatpack2 PS System, 9kW, 48VDC, Fan OD 1.8m

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

49 

 

 

Figure 26. Smartpack configuration page 1/2

50 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

 

Figure 27. Smartpack configuration page 2/2

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

51 

 

 

Figure 28. Outdoor cabinet Fan 1.8m drawing

52 

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

 

 

Figure 29. Plinth drilling pattern

Installation Guide Flatpack2 PS System, 9kW/ 48V,Fan OD 1.8m doc.n 351677.033 

53 

 

 

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