Installation Guide MicroBBU 6kW OD Cabinet 15U (B - 356816.033 - 1 - 5) PDF
Installation Guide MicroBBU 6kW OD Cabinet 15U (B - 356816.033 - 1 - 5) PDF
Installation Guide MicroBBU 6kW OD Cabinet 15U (B - 356816.033 - 1 - 5) PDF
Outdoor System
.
356816.033
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.
This product is CE marked and complies with all current requirements for relevant standards and
directives.
This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).
1. Welcome.................................................................................... 6
About this Guide............................................................................................. 7
Definitions ...................................................................................................... 7
Abbreviations ................................................................................................. 7
2. System Description .................................................................. 8
General .......................................................................................................... 8
Applicable standards ...................................................................................... 8
Electrical Safety ....................................................................................................... 8
EMC ........................................................................................................................ 8
Environment ............................................................................................................ 8
System Modules - General Arrangement ....................................................... 9
Cabinet .................................................................................................................... 9
Heat Management System (HMS) ..........................................................................10
Fan Filter / Forced air cooling - FAC ................................................................................ 10
Cable Management ................................................................................................12
Cable glands / entries ....................................................................................................... 12
Cable strain relief .............................................................................................................. 13
Cable support ................................................................................................................... 13
System Options / Kits ................................................................................... 14
Kit: Wall / Pole Mounting.........................................................................................14
Kit: Floor Mounting .................................................................................................16
Kit: 2-Pole AC Breaker............................................................................................16
Kit: Surge Protection Device ...................................................................................16
Kit: Heater ..............................................................................................................17
Kit: MetroSite BTS Breaker 2x16A ..........................................................................17
Kit: 6x10A 1-pole CBI MCB ....................................................................................17
Power System – Brief System Description ................................................... 17
I/O Monitor..............................................................................................................18
Alarm Relays & Digital Inputs .............................................................................................. 21
Changing I/O Monitor setup ................................................................................................. 22
“FP2 6kW 15U OD” is a small outdoor cabinet that comes with a 6kW 48V DC power system
and space for one up to 100Ah 48V battery bank. The outdoor cabinet is a compact cabinet
designed for use in a wide temperature range and with ingress protection IP55. It is referred to as
the “outdoor cabinet” or “system” in the rest of this document. There are two version of the
cabinet based on different heat management systems (HMS):
- Power system with fan cooled cabinet (Eltek PN C20315.001)
- Power system with Aircon cabinet (Eltek PN C20315.013)
The durable construction of the outdoor cabinet secures long lifetime and good protection under
various environmental conditions. The cabinet can be equipped with a plinth for floor mounting,
or with brackets for mounting on a pole or a wall.
Note! The cabinet may be equipped with more/less functions than described in
this document.
Definitions
WARNING: Text highlighted in this way provides the installer with information that
it will be 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 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
CB - Circuit Breaker
FAC - Forced Air cooling
FP2 - Flatpack 2
HMS - Heat Management System
MCB- Magnetic Circuit Breaker
OD - Outdoor
SPD - Surge Protection Device
VRLA- Valve Regulated Lead Acid battery
ACU – Air-conditioning unit
Applicable standards
Electrical Safety
IEC 60950
UL 60950* (depends on version)
CAN CSA-C22.2 No. 60950-1-03 * (depends on version)
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 environments
EN 61000-6-3 (2007-01) Emission for light 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
Pole bracket
Cabinet
Wall
Filter bracket
Plinth
Heat Management system*
Battery Shelf
Cable glands
Figure 1 – Cabinet Overview (example showing the Fan Filter solution in the door)
Cabinet
The cabinet is an aluminum single skinned outdoor enclosure for mounting on wall, pole or base
assembly. 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.
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.
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.
Equipment
Input Filter
Batteries
Fan
Or
Equipment
Equipment
Air Conditioning Unit
Batteries
Or
Equipment
A cabinet equipped with an air conditioning unit (ACU) is a closed loop system that does not
allow outside air inside the cabinet. This type of cabinet accommodates a dust and water
protection rating of IP55.
The air conditioning unit reduces the cabinet temperature below the ambient temperature
(-Δt).
The unit, which is basically made up of a sealed cooling circuit, where the coolant circulates, is
divided into two sections, hermetically separated from each other, where the air in the cabinet
are treated without coming into contact with each other.
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 as standard. However it is possible to use
other cable gland plates with FL21 size like Multigate MC 3 and Roxtec Comseal products. For
details on other optional cable glands/entries refer to their respective data sheets/documentation.
The Multigate MC 25 standard cable gland plate can receive the following cable/conductor
dimensions:
1 x 20-26 mm
12 x 10-14 mm
4 x 05-07 mm
4 x 14-20 mm
4 x 08-12 mm
The Multigate MC 25 is suitable for leading through both low and medium power current cables
as well as various types of tubing.
At the cable entrance (bottom of cabinet) there is placed two cable tie brackets (one on the
outside and one on the inside) for cable strain relief.
Note! Orientation/direction of the cable tie brackets may differ from the picture above.
Cable support
The Kit for Wall / Pole Mounting contains parts for fixing the OD cabinet securely to a wall or a
pole. The kit is designed to support the cabinet with one or two battery banks (MAX 400kg).
Make sure that the wall is able to hold the weight of the cabinet.
The screws/anchors (M8) for fixing the cabinet to the wall are not included in this kit due to
different material of wall (i.e. wood, steel, concrete etc).
By adding 2 crossbars with clamps to the wall mount brackets it is possible to fix the Outdoor
Cabinet securely to a pole. The minimum dimension / size of the pole is 60mmØ and the
maximum size is 115mmØ.
The screws/anchors (M8) for fixing the cabinet to the pole are included with the system.
Figure 7 - Plinth
The Kit for Floor Mounting makes it possible to fix the Outdoor Cabinet securely to the
pad/ground/floor. The kit is designed to support the cabinet with one or two battery banks (MAX
400kg).
The bolts/anchors for fixing the plinth to the pad/ground/floor are not included in this kit because
of the different materials used for pad constructions.
The plinth’s front and right/left side covers are removable for easy access when performing the
installation. These covers may remain withdrawn if cables and conduits are entered here. It is
also possible to open the 4 knock-outs per side and route cables through these holes.
CAN Bus
Flatpack2
rectifiers (BF) Telecom
equipment
LVBD
Load MCBs
DC
AC Fuses, distribution
external
Battery string #1
Example of a typical FP2 system for DC power supply of telecom equipment.
The system is fed from an external AC mains supply, and consists of rectifiers, control unit and
DC distribution unit. External battery banks may be connected to the system.
I/O Monitor
I/O Monitor
Input 6 Relay 1
The I/O monitor is operated and powered via the CAN bus. The 2 CAN ports are electrically
identical. The CAN bus has to be terminated with 120 Ohm resistors (60 Ohm bus impedance) at
each end. This is done to avoid data reflection. In the Power system the end-of-line-resistors are
mounted on the rectifier’s back-wiring card and inside a terminal plug on the I/O monitor.
The DIP switches are used to set the I/O monitor’s address on the CAN bus. The Smartpack
controller registers the I/O Monitor’s ID number which is set by DIP switches. All switches
should be OFF when only one I/O monitor is used. See picture below.
OFF
ON
Switch # 1 Switch # 8
Other systems may have more than one I/O monitor installed. When more than one I/O monitor
is installed their respective addresses are set by individual DIP switch settings (binary
addressing).
I/O monitor number one has all DIP switches OFF. I/O monitor number two has DIP switch 1
ON and the other OFF etc.
C Alarm Circuit 2
Alarm Relay Outputs
Temperature Sense 1 +
2
Fan Control
Standard Relays & Digital Inputs The alarm outputs from the I/O Monitor use the Fail-
Safe Operation Mode (relay coils energized in the
system’s normal operation mode). When the system is
Normal mode NO
Relays X
Com + in alarm mode, the alarm relay coils are de-energized.
NC
(Energized coil) —
Alarm mode NO
The figure shows the position of the relay contacts
Relays X (De- Com + when the relay coils are de-energized (PS system in
energized coil) NC
— alarm mode).
Power System
Correct Use of Alarm Outputs (example)
Normal Mode
Digital Input X + External Relay Y
— In order to implement monitored fail-safe digital inputs
(Normal mode) (Energized coil)
Digital Input X
+ Alarm Mode circuits, the external relay coil must be energized and
—
(Activated)
External Relay Y the contacts closed in the system’s normal mode of
(De-energized coil)
operation.
Power System
Correct Use of Digital Inputs (example)
2x60A Load
1x100A Battery breakers
breaker Fan breaker
Smartpack
controlling
unit
3 positions
for rectifiers
I/O unit
Fan temp
sense
Battery
temp sense
Load
connections Mains input
terminals
Smartpack
controlling 3 positions
unit for rectifiers
I/O unit
Battery
temp sense
Mains input
terminals
DC Load
connections ACU
breaker
Smartpack Control Unit — front keys, display, etc Flatpack2 Rectifier Module — front panel
Display: is in Status Mode (displays the system’s status) Power LED is OFF (mains unavailable), Flashing
or in Menu Mode (displays the menu structure). (controller accessing information) or ON (powered).
Operation: Press on the key to change from Status Warning LED is ON (de-rating or similar minor
Mode to Menu Mode. Press the or keys to scroll warning), Flashing (over-voltage mode) or OFF (OK)
up or down and navigate to find menu options (function
or parameter). Then press the key to select the Alarm LED is ON (shutdown or similar major alarm)
function. or OFF (OK, no alarm)
The ”XvX” references, if any, on the right hand of the option, are not shown in the display. They only
AlarmReset
NomVolt Change Language English 2v0
indicate the firmware version (402073.009 XvX) the option was first implemented.
BoostVolt NomVolt
LoBattMaj BoostVolt
Firmware 402073.009 2v00 Smartpack, Distributed
VoltageInfo LoBattMin
Firmware 402073.009 2v00 Smartpack,
LoBattMaj
HiBattMaj VoltAdjustment LoBattMin
HiBattMin HiBattMaj
LVBD HiBattMin
LVLD 1.1 LVBD
DisplayMessages Message
Distributed
LVLD 1.1
SoftwareInfo
Software Menus
VoltCalibration VoltCal
SerialNumber ChangePassword Password
NoOfRects. nn SetManBoostTime
…
RectCurrent Start/StopBoost
Rectifier Info RectSerialNumber Auto Boost Config. Enable/Disable & Threshold
Rect.PrimaryVolt
Rectifier Status
DateTime Date Time
Nxt Test
Volt
End
Rectifier Temp Batt Test Setup MaxTestDur
Rect. OutputVolt Test Int
Rectifier SW Ver Guard Time
Start/Stop Test
NoOfPhases nn NoOfRects. ; nn Reset
Mains Info Mains Status Charge Curr Lim. Enable/Disable & Max C.Curr
Mains Voltage
Level
Temp Level Info Battery Setup NumOfString
NoOfString Nn CellCap Ah nn
BattStringCurr Output Control VoltageCtrl / TempComp
Battery Info BattStringTemp Change Date/Time Date Time
BattBlockVolt Alarm Output 1
NOTE: For functionality description refer to the “User Guide RelayTest Alarm Output 2
Smartpack Controller”, doc 350003.013 and to the PowerSuite Batt Contactor
Help file. Load Contactor
Alarm Output nn
BlockOutputs Enter OutpBlocked/Exit OutpBlocked 2v0
BattLifeTime Rst
1. Install PowerSuite
1 Insert the CD in your PC drive, start the PowerSuite installation
and follow & accept the wizard default steps
2. Switch Smartpack ON and plug USB cable (Part 202073)
2 to Smartpack and to any available USB port in the PC
3. Wait for Windows to install USB drivers
Follow & accept the wizard default steps to automatically install
3 New hardware the USB drivers; the wizard runs twice
is ready to use
4. Start PowerSuite and establish connection
Select “Start > All Programs > Eltek> PowerSuite”. On the
4 toolbar, click “Connect” button. On the Connection dialogue
box, click the “Connect” button
If PowerSuite fails communicating via the standard COM port, find the COMx assigned to
Smartpack (My Computer/ Properties/ Hardware/ Device Manager) and configure PowerSuite to
communicate via this COMx (read the instructions in the installation CD).
PowerSuite’s newest version is always available on our FTP server. Call your Eltek’s contact
person.
For first time installations of rectifiers in power system, follow the scheme below:
1. Insert & hot-plug the rectifiers in the indicated positions (refer to the figures below)
one module at a time, allowing 2 seconds delay between them
and starting with ID number 1, 2 and 3.
PE (Protective Earth)
TE (Telecom Earth)
Earth connections are in particular important Link 2 EG (Exchange Ground)
AC Mains Input
(L1,L2,L3,N)
. DC Load
PE (AC Earth)
Cabinet Circuit
Chassis
Common DC Rail +
DC Load
—
wires
—
AC Earth (PE) is connected to chassis. DC Earth (TE) is also
—
—
connected to chassis via “Link 2”. Remove the link (“floating
Negative DC
earth”) for compliance with other local earthing systems. Refer
Distribution to your system’s specific drawings to identify how these links
are implemented in your DC power system.
Common Positive DC Output Rail is usual in 48 and 60V DC supply systems: Negative DC
Distribution.
PE N L1 L2 L3 PE N L
1 1 2 3 4 5 6 7 1 1 2 3 4 5 6 7
Distribution
All breakers in the distribution are protecting the -48Vdc feeds.
The 60A load breakers “F1” and “F2”, which serve for negative (-)DC external
connection, are connected to the (-)DC load connection terminals located at the bottom
of cabinet.
Maximum cable diameter is 25 mm2 (AWG 2)
(+)DC load connection terminals, located at the bottom of the cabinet, serve for positive
(0Vdc) load connections.
Maximum cable diameter is 25 mm2 (AWG 2)
The battery breaker is labeled “FB1”. The screw terminal for this breaker can fit cables
up to 50mm² (AWG 0).The battery breaker is rated at 100A and has a slower
characteristic than the load breakers.
DC Load terminals
Battery breaker Load breakers (-) and (+) for F1
(-) and (+) for F2
Battery compartment
The battery shelf is designed to accommodate standard 19” batteries. Standard 19” batteries are
approximately 105mm wide. The total width of the battery shelf is 445mm but do not mount
batteries wider than 105mm due to cooling reasons. There should always be a small gap of air
between the batteries for fan / Heater air to circulate.
Maximum depth is 400mm. Batteries deeper than 375mm will stick out in the front of the 19”
side rails. The battery Arrestor has to be removed before lifting the batteries onto the shelf. After
the batteries are placed on the battery shelf the battery arrestor can be mounted in 5 different
positions on the battery shelf and be slid into the front of the batteries. This will prevent the
batteries from moving. If 400mm deep batteries are used the Battery Arrestor is redundant.
Minimum battery depth for using the battery Arrestor is 232mm.
The battery compartment can accommodate maximum to 8U / 356mm high batteries..
Note! Installation of optional kits is described in manuals that are supplied with the kits.
Safety Precautions
Follow these precautions during installation, commissioning and general handling of Outdoor
Cabinet.
General Precautions
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.
CAUTION: The installer is responsible for ensuring that the EMC properties of this
product/ system do not deteriorate during installation, and that it is performed in
accordance with applying regulations.
Installations in USA and Canada must comply with NEC/CEC requirements.
WARNING: Opening the equipment may cause terminal injury — even if the mains
AC supply is disconnected. Hazardous voltages may be present inside, as large
capacitors may still be charged.
To be installed only in restricted access areas or the like, 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
Installation in USA/Canada must comply with NEC/CEC. For other countries, local or
national requirements may apply.
The equipment represents an energy hazard and failure to observe this could cause
terminal injury and invalidate our warranty
Products into which our components are incorporated have to comply with a number of
requirements. Installation is to be in accordance with the recommendations herein
The enclosure must remain locked at all times, except when authorized service
personnel are present
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
WARNING: For safety reasons (high leakage current and high touch current) you
must always connect the AC earth wire (PE) to the terminals, before you connect
the AC input cable(s).
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
The supply neutral conductor must be bonded to earth ground at the disconnect panel
Hazardous electrically live parts inside the enclosure are energized by batteries even
when the AC input power is disconnected. Make sure the power is removed via the
battery disconnect breaker before servicing any of the equipment
The internal equipment may be powered by AC circuits. Make sure power is removed
via the appropriate breaker before servicing any of the equipment
Prior to installation, verify that the AC input voltage to the enclosure and its equipment
with respect to voltage and frequency
Prior to installation, 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 installation, contact local utilities, local building maintenance departments, and
cable/piping 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 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 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
Do not drill new holes or use other methods for cable entry than what is described in the
product documentation
Mechanical Safety
Keep hands, hardware and tools clear of the fans. Fans are thermostatically controlled
and will turn on automatically as a function of temperature
Rectifiers can reach extreme temperatures under load and normal operation
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
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, 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
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 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 with a special solution contained in an approved
spill kit or 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
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 to set all battery related parameters
accordingly
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.
Note! Do not install the batteries until the cabinet has been properly fastened
Note! Make sure that the lifting lugs has shrink tubes as shown in Figure 11 to
prevent scratching the cabinet paint.
Shrink Tubing
Figure 9 – Plinth dimensions (see cabinet details for dimensions that match the cabinet that has been ordered)
The wall bracket needs to be fastened to the wall before lifting the cabinet into position.
Enter the four M8 bolts in the available holes on rear side of the cabinet. See Figure 12. Let the
bolts stick out approximately 4-6mm. The wall bracket material is 3mm thick and the bolt heads
have to go into the key holes in the wall bracket and slide into position.
Wall Bracket
Pole Anchor
Mount the two wall brackets together with the two pole anchors by the use of 4 M8 screws,
washers and nuts. Torque 24 Nm.
The pole bracket needs to be fastened to the pole before lifting the cabinet into position.
Enter the four M8 bolts in the available holes on rear side of the cabinet. See Figure 11. Let the 4
bolts stick out about 4-6mm from the rear insert nuts.
Mount the bracket to the pole using M8 bolts and pole bracket that are included with the bracket.
Tighten the screws evenly on both sides. Torque 8 Nm.
Fix the four M8 bolts on the rear side of the cabinet with Torque 24 Nm.
Do not install the batteries until the cabinet has been properly fastened.
Start with removing the front by open the cabinet door and pull the front plate towards you.
Remove the desired side plate(s) by unfixing the 2 self locking M5 nuts from the inside of the
plinth. Push the side plate away from the cabinet and then pull the side plate towards you.
8. Battery Connections
Note! Improper handling of batteries can result in the batteries short-circuiting, which
can result in serious injury due to high energy levels. Excersise care when
working with batteries. This is also because of the batteries weight.
Note! Ensure that the battery circuit breakers are off.
Normally it is not necessary to fit venting tubes to VRLA batteries in a fan cooled cabinet since
any battery gas will be evacuated with the hot air through the cabinet door. However some
battery manufacturers always recommend installing venting tubs. Follow your battery supplier’s
recommendation.
If venting tubes are recommended please ensure battery manufacturer instructions with regard to
connection of the venting tubes are followed. Pull the tube out through the cabinet cable entry
from the inside and ensure that the tune is not bent or blocked in any way.
Figure 15 – Insert nuts on the 19” side rails for cabinet grounding.
Connect the grounding cable with a cable lug and M6 screw to one of the grounding points in the
cabinet. There are 4 insert nuts for grounding on both sides of the cabinet. Make sure that the
cables are secured tightly.
CAUTION:
- The modules may be warm, but do not hand-carry them by their handles
Device - Open the handles before inserting them into the power shelves (hot-pluggable)
hazard The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing
Hole to release the Note that cables are plugged to the Smartpack’s rear panel.
Smartpack handle’s spring
controller mechanism When mounting the controller, you must plug the cables before
step 2. When removing it, unplug the cables during step 2.
FGFG Warning:
- Only mount rectifiers, part 241115.120, with the fan rotation symbol on the front!
- The modules are mounted vertically (see picture on front page)!
Screwdriver to
release the locking
tabs Removing Blind Panels
1. Release the panel’s upper and lower right corners by
inserting a small screwdriver into the panel’s upper right gap
and carefully press down and out to release the locking tabs.
Repeat on the lower right gap
2. Remove the blind panel by
using you hand to pull the panel loose
Blind panel’s
locking tabs
General Torque
Recommended tightening torque Carry out following steps sequentially:
Application, Torque 1. Make the system completely voltage free
Type & Size (Nm) o Switch OFF all load fuses, battery fuses (Fb1, Fbx), and
Circuit Breakers the external AC supply fuses
CBI 13 mm, QY, QF, QA 3.0 o Unscrew the Cable Entry Plate and route all cables
Siemens 18mm 5SY 3.5 through their suitable holes. Then, loosen fastening screw
AC and DC Rail Terminals
WDU 16 4.0
and extract the “AC Terminals plate” to Maintenance
Screws position.
2. AC Connections
M6 5.0 o Connect the AC Earth wire (PE) to the terminal for AC
M5 4.0 Earth (PE).
M4 2.0
M3 1.0
o Connect the AC input cable(s) to the terminals marked L
and N. Cable and terminal block labeling are to
Mains ”PE” terminal block correspond.
WPE 10 2.0 / 0.6*
shock
to the battery MCB
c Connect the other end of the (-) battery cable to the
battery string’s negative outer terminal (-)
d Verify that one end of the (+) battery cable is connected
Temp. sensor
Battery
to the common positive DC rail
Cable
e Connect the other end of the (+) battery cable to the
battery string’s positive outer terminal (+)
g Fix the temperature sensor (at the end of the cable) to
— - + - + - + - + the warmest area of the installed battery bank
(-48V) Outer (to the center (width & depth) of the battery string)
Terminal
Block Block Block
1 3 + 4
0V Outer
Intercell links Terminal
2. Electrical:
The commissioning of the FP2 system consists of following stages:
I. Perform a pre-start check before the system is switched ON
II. Switch ON the system with disconnected load; adjust output voltage
III. Adjust the nominal output voltage with connected batteries and load
Pre-Start Check
Check off in the Commissioning Procedure, that you find in chapter 6 in this document.
If you have just finished the system installation successfully and the Installation Check List is
completed, jump over the Pre-Start Check and continue with stage II.
M6x12mm screw
11. Mount all Flatpack2 rectifier modules in the power shelves (keep original location)
o Push all rectifiers firmly inwards one module at a time, allowing a 2s delay to plug them in
the same shelf location. Lock their handles.
o Mount blanking panels over unused positions.
System Failures
Symptom Possible Error How to Find and Eliminate the Problem
1. All LED’s OFF No AC supply or Both input and output are disconnected from
(rectifiers and batteries present power sources.
Smartpack)
Inspect connections and verify input voltage
and battery circuit breaker states
2. Excessive System fan error Locate the noise source.
audible noise
Rectifier fan error If a rectifier module is creating the noise,
replace the rectifier with a new one
Gasket
Figure 17 - Gasket
Check and make sure that the gasket on the door is complete. Contact your local Eltek Company
for ordering a new gasket replacement kit.
If the gasket is not complete please replace the gasket by performing the following procedure;
Damage less
than 20mm
Damage >20mm
Replace complete gasket. See the door gasket installation guide.
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. Contact your local representative for stock.
Eltek recommends bi-monthly site checks during the first year of operation, to establish actual
filter replacement intervals for each individual site.
6. Connect the fan Turn on the breaker for See GA for actual position.
the fan, and verify that
the fan is running.
WARNING: Before servicing the ACU make sure no voltage is being supplied to the
latter.
See Appendix – Instruction Manuals for information about performing ACU maintenance.
Gore Vents
Gore Vents
Maintenance
Locate Gore vents on left side of door. Unscrew cover and do a visual check on the membranes.
WARNING: Do not touch!
If to be replaced contact your local Eltek Company for ordering a replacement kit.
Part number 257464.
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:
Approval
Responsible of installation, sign.: Date: Approved by customer, sign.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:
1. Flatpack2 system installation is completed; The Flatpack2 Installation Check List is filled in.
All cabling is securely terminated with correct polarity
2. All battery and load MCBs/ fuses are disconnected
I 3. AC input cable(s) and AC earth wire (PE) are terminated
Device
4. Site specific parameters and settings are known
hazard 5. AC supply and all MCBs/ fuses are switched OFF
Start-up, No-Load & Load Adjustments Power is ON!
CARRY OUT FOLLOWING: OK
1. Disconnect all rectifier modules, without removing them (keep original location)
2. Remove the Condensation Stopper
3. Switch ON the system (external AC fuses ON)
II 4. AC input voltage is correct; Measure and verify
5. Insert all Flatpack2 rectifiers in their original locations in the power shelves
Device
hazard
6. The Smartpack and all rectifier modules are working, LEDs are ON; Verify
7. Connect a PC to the PS system Install the PowerSuite software, if required
8. DC output voltage; Measure and adjust
9. Alarm relay test; Verify all alarm relays are working correctly
10. System Setup is in accordance with configuration Enter site spec. info in PowerSuite
11. Adjust DC output voltage to equal measured battery voltage Check correct polarity!
12. Unplug all rectifiers but one, and connect all battery fuses/ MCBs
13. Adjust DC output voltage to equal nominal battery or load voltage
14. Plug in again all rectifiers, and verify the rectifiers’ current sharing
15. Connect all load MCBs/ fuses, and verify no alarms are displayed
Approval
Responsible of commissioning, sign.: Date: Approved by customer, sign.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:
4. Alarm Relay Test; verify all alarm relays are working correctly.
From the Smartpack’s keypad or PC use the Relay Test function; verify activation of external equipment
5. Battery bank control; measure and verify battery specifications.
Follow the recommendations of the actual battery manufacturer.
Approval
Responsible of maintenance control, sign.: Date: Approved by customer, sign.:
6U
HxDxW: 736x581x585mm
Load
Terminals Configurable to 400Vac 3
phase,TN
0V
LVBD
SH1
PE CON12 Backwiring FP2
dc
L1 CON11 - FB1
strings
Mains L2 CON10 - +
circuit -48V
PE CON15
4 rectifier positions Y X
MCB kit L1 CON14 105833
Mains input L2 CON13
PE CON18 +
L1 CON17
L2 CON16
OPTION 1 PE CON21
L1 CON20 -
PE 1
Mains Input L2 CON19
MCB 2 PR 1
3 8
Smartpack Power Con8, pin 1-8
N 4 - /CAN bus 8
interconnections Con8, pin 9-16
L 5
6
7
OPTION - 2
Load circuits
+ 3
Battery Current
- 4
CON1 Battery Fuse Fail + 5
- 6
Load Fuse Fail 1 7
LVD 1A 8 Diode
LVD Common 9 Matrix
L PE LVD 2A 10
11
Chassis 100323
LVD Common 11
1
System Ref. 12 5
2
14
4
NEG. DIST.
POS. DIST.
NEG. DIST.
POS. DIST.
N N JP1 JP2 JP3
1 2 3 1 2 3 1 2 3 - F3 (Door Fan)
HEATER KIT 4
OPTION
PE
Thermostat Rear connections Front connections
L N Smartpack
<ϑ monitoring and
15 control unit
CON5
System Connections USB 2.0 type B port USB
Heater 15 (PC connection)
Heater MCB CON4 9
Battery connections
1: Optional: RS232
Customer
connections
* 9/15 CON3
T1 Ext. Battery connections
1: Optional: RS 232
8/26 CON2
Ext. Alarm I/O Connections
2: Optional: Web/SNMP (ENET)
10
CON1
Alarm I/O Connections
Configurable mains input terminal blocks 8
Reconfigure mains connector links according to the type of AC mains to be used CAN port
242100.304
8
400 Vac3- phase, TN 230 Vac1 x single phase,TN I/O Monitor
CAN port
CON202*
Ext. Alarm I/O Connections
CON303* 1: Optional 9 pin D-sub RS232 connection.
Customer connections
1 NO Ext. Alarm I/O Connections
Door
Customer connections Can be mounted in front or on rear side of
2 COM Relay 1 - 1 switch
3 NC Digital Input 1 Smartpack. Replaces ”Ext. Battery Connections”
+ 2 11 14
4 NO when mounted on the rear side of Smartpack
- 3
PE N L1 L2 L3 PE N L 5 Digital Input 2
COM Relay 2 + 4
6 NC - 5 2: Optional Web/SNMP (ENET) connection.
7 NO Digital Input 3 + 6
8
Schematic Diagram FP2 6kW 15U OD Fan
COM Relay 3 - 7
Replaces ”Ext. Alarm I/O Connections”
9 NC Digital Input 4
1 1 2 3 4 5 6 7 1 1 2 3 4 5 6 7 + 8
10 NO Door FAN
- 9 The Schematic/Connection Drawing shows the position of the
11 COM Relay 4 Digital Input 5
+ 10
12 NC - 11 Black relay contacts when the Power System is in its alarm mode of
13 NO Digital Input 6
+ 12 -48V
14 COM Relay 5
15
Red 0V operation (relay coils are then de-energized). The relay outputs
NC
16 CON301*
NO Tacho Blue
17 COM Relay 6
Ext. Alarm I/O Connections are preprogrammed from factory (Factory Settings).
18 NC + 1
* Control Yellow
19 Temp Sense 1 T2 Date Design Draw Approved Scale Projection
- - 2
20 LVD Supply FAMONO
+ + 3 21.12.2007 HAHANO ERBRNO
Temp Sense 2
- 4
8 Tach 1 5
CAN port Tach 2 6 Schematic Diagram
8 Speed Control 1 7 Copyright Eltek Valere.
CAN port Speed Control 2 8 All rights reserved
* T1 – Temp sense for batteries 4 110909KB
05.10.2011 FP2 6kW 15U OD Fan Replace for Replaced by
ROBHRISK - -
T2 – Temp sense for door fan Format
0V
LVBD
SH1
PE CON12 Backwiring FP2
dc
L1 CON11 - FB1
strings
Mains L2 CON10 - +
circuit -48V
PE CON15
4 rectifier positions Y X
MCB kit L1 CON14 105833
Mains input L2 CON13
PE CON18 +
L1 CON17
L2 CON16
OPTION 1 PE CON21
L1 CON20 -
PE 1
Mains Input L2 CON19
MCB 2 PR 1
3 8
Smartpack Power Con8, pin 1-8
N 4 - /CAN bus 8
interconnections Con8, pin 9-16
L 5
6
7
OPTION - 2
Load circuits
+ 3
Battery Current
- 4
CON1 Battery Fuse Fail + 5
- 6
Load Fuse Fail 1 7
LVD 1A 8 Diode
LVD Common 9 Matrix
L PE LVD 2A 10
11
Chassis 100323
LVD Common 11
1
System Ref. 12 5
2
14
4
NEG. DIST.
POS. DIST.
NEG. DIST.
POS. DIST.
N N JP1 JP2 JP3
1 2 3 1 2 3 1 2 3
Airconditioning unit
PE
F3
L
RED
BLUE
* 9/15 CON3
T1 Ext. Battery connections
1: Optional: RS 232
8/26 CON2
Ext. Alarm I/O Connections
2: Optional: Web/SNMP (ENET)
10
CON1
Alarm I/O Connections
Configurable mains input terminal blocks 8
Reconfigure mains connector links according to the type of AC mains to be used CAN port
242100.304
8
400 Vac3- phase, TN 230 Vac1 x single phase,TN I/O Monitor
CAN port
CON202*
Ext. Alarm I/O Connections
CON303* 1: Optional 9 pin D-sub RS232 connection.
Customer connections
1 NO Ext. Alarm I/O Connections
Door
Customer connections Can be mounted in front or on rear side of
2 COM Relay 1 - 1 switch
3 NC Digital Input 1 Smartpack. Replaces ”Ext. Battery Connections”
+ 2 11 14
4 NO when mounted on the rear side of Smartpack
- 3
PE N L1 L2 L3 PE N L 5 Digital Input 2
COM Relay 2 + 4
6 NC - 5 2: Optional Web/SNMP (ENET) connection.
7 NO Digital Input 3 + 6
8 COM Relay 3 Replaces ”Ext. Alarm I/O Connections”
- 7
9 NC Digital Input 4
1 1 2 3 4 5 6 7 1 1 2 3 4 5 6 7 + 8
Schematic Diagram FP2 6kW 15U OD ACU
10 NO
- 9 The Schematic/Connection Drawing shows the position of the
11 COM Relay 4 Digital Input 5
+ 10
12 NC - 11 relay contacts when the Power System is in its alarm mode of
13 NO Digital Input 6
+ 12
14 COM Relay 5
15 NC
operation (relay coils are then de-energized). The relay outputs
16 CON301*
NO
17 COM Relay 6
Ext. Alarm I/O Connections are preprogrammed from factory (Factory Settings).
18 NC + 1
19 Temp Sense 1 Date Design Draw Approved Scale
- - 2
20 LVD Supply 05.03.2013 JARPORSK JARPORSK IFS -
+ + 3
Temp Sense 2
- 4
8 Tach 1 5
CAN port Tach 2 6
8 Speed Control 1 7 FP2 48V 6kW 15U ACU ODT2 Copyright Eltek.
Speed Control 2 8 All rights reserved
CAN port
Part no.
* T1 – Temp sense for batteries
Sym. Alternation Date/Sign Format Page Drawing no. Rev.
A3 1 of 1 2148756 1
71
Smartpack Set-Up for FP2 6kW 15U OD FAN
Prepared by: JAONSK System Part no.: C20315.001 Smartpack part no.: 242100.110 SW Rev: 3.05 Doc no.: 2054036 Doc rev: 2
Approved by: IFS CTO: Mains input: 1PH 230Vac System type: 48V 24V
Note! If any customer changes are made in this document, they will overwrite the default values in the Smartpack.
Para Site Info DEFAULT VALUE CUSTOMER DEFINE TEXT
1.1 Company <Blank> Nokia Siemens Networks
1.2 Model Flatpack 2 Power System FP2 6kW 15U OD Fan
CUSTOMER DEFINE
Para System Voltage Levels DEFAULT VALUE
Value Function
2.1 Nominal Voltage (float) 53,52V 54.40
2.2 Boost Voltage 54,50V 56.40
2.3 Battery Contactor LVBD Enabled
2.4 Battery Disconnect Voltage - LVBD 43,0V 42
2.5 Battery Reconnect Voltage - LVBD 47,0V
2.6 LVBD Disconnect Delay Timer Disabled (30min) 0
2.7 Load Contactor LVLD 1 Disabled
2.8 Load Disconnect Voltage - LVLD 1 44,0V
2.9 Load Reconnect Voltage - LVLD 1 48,0V
2.10 LVLD1 Disconnect Delay Timer Disabled
2.11 Load Contactor LVLD 2 Not configured
2.12 Load Disconnect Voltage - LVLD 2 Not configured
2.13 Load Reconnect Voltage - LVLD 2 Not configured
2.14 LVLD2 Disconnect Delay Timer Not configured
2.15 Rectifier Current limit Disabled ( 1000Amp )
2.16 Rectifier standby voltage 1,85V/cell 44,40V
2.17 Battery Charge current limit Disabled
2.18 Battery Charge current limit (Mains) 100Amp 18 Enabled
2.19 Battery Charge current limit (Generator) 100Amp
2.20 Battery test end voltage 1,9V/cell (45,60V) 1.85
Para Programmable Inputs DEFAULT VALUE CUSTOMER DEFINE
New Description Funtion Alarm Group Event
3.1 PROG INPUT 1.1 Disabled Over Voltage Device Disabled Normally closed Over Voltage Device Major Alarm
3.2 PROG INPUT 1.2 Disabled Door Open Enabled Normally closed Door Alarm Major Alarm
3.3 PROG INPUT 1.3 Disabled
3.4 PROG INPUT 1.4 Disabled
3.5 PROG INPUT 1.5 Disabled
3.6 PROG INPUT 1.6 Disabled
ALARM GROUP NAME CUSTOMER DEFINE
Para Set Alarm Levels DEFAULT VALUE
DEFAULT Value Alarm Group Funtion
4.1 Mains Low Alarm Enabled
4.2 Mains Low Major alarm 2 Phase Mains Alarm
4.3 Mains Low Minor alarm 1 Phase Mains Alarm
4.4 MainsVolt 1 Alarm Enabled
4.5 MainsVolt 1 Major High 280V Mains Alarm
4.6 MainsVolt 1 Minor High 260V Mains Alarm
4.7 MainsVolt 1 Minor Low 100V Mains Alarm
4.8 MainsVolt 1 Major Low 80V Mains Alarm
4.9 MainsVolt 2 Alarm Enabled
4.10 MainsVolt 2 Major High 280V Mains Alarm
4.11 MainsVolt 2 Minor High 260V Mains Alarm
4.12 MainsVolt 2 Minor Low 100V Mains Alarm
4.13 MainsVolt 2 Major Low 80V Mains Alarm
4.14 MainsVolt 3 Alarm Enabled
4.15 MainsVolt 3 Major High 280V Mains Alarm
4.16 MainsVolt 3 Minor High 260V Mains Alarm
4.17 MainsVolt 3 Minor Low 100V Mains Alarm
4.18 MainsVolt 3 Major Low 80V Mains Alarm
4.19 Rectifier Current Alarm Disabled
4.20 Rectifier Current Major alarm 5000Amp Major alarm
4.21 Rectifier Current Minor alarm 4000Amp Minor alarm
4.22 Rectifier Error Alarm Enabled
4.23 Rectifier Error Major alarm 2 Units Rectifier Alarm
4.24 Rectifier Error Minor alarm 1 Unit Rectifier Alarm
4.25 Rectifier CommError Alarm Enabled
4.26 Rectifier CommError Major alarm 2 Units Rectifier Alarm
4.27 Rectifier CommError Minor alarm 1 Unit Rectifier Alarm
4.28 Rectifier Capasity Alarm Disabled
4.29 Rectifier Capasity Major alarm 95% Major alarm
4.30 Rectifier Capasity Minor alarm 90% Minor alarm
4.31 Recitifer CurrentShare Alarm Disabled
4.32 Rectifier CurrentShare Major al 10% Major alarm
4.33 Rectifier CurrentShare Minor al 5% Minor alarm
4.34 Load Current Alarm Disabled
4.35 Load Current Major alarm 30000Amp Major alarm
4.36 Load Current Minor alarm 20000Amp Minor alarm
4.37 LoadFuse 1 Major Alarm Enabled Fuse alarm
4.38 BatteryVoltage Alarm Enabled
4.39 BatteryVoltage Major High 57,0V Battery High 59
4.40 BatteryVoltage Minor High 56,8V Minor Alarm 58
4.41 BatteryVoltage Minor Low 47,0V Minor Alarm 45
4.42 BatteryVoltage Major Low 46,3V Battery Low 43
4.43 BatteryCurrent Alarm Disabled
4.44 BatteryCurrent Major High 500Amp Major Alarm
4.45 BatteryCurrent Minor High 300Amp Minor Alarm
4.46 BatteryCurrent Minor Low -300Amp Minor Alarm
4.47 BatteryCurrent Major Low -500Amp Major Alarm
4.48 Battery Tempsense 1.1 Enabled
4.49 Battery Tempsense 1.2 Disabled
4.50 BatteryTemp Alarm Disabled
4.51 BatteryTemp Major High 40°C Major Alarm 50
4.52 BatteryTemp Minor High 30°C Minor Alarm Enabled
4.53 BatteryTemp Minor Low -5°C Minor Alarm 0
4.54 BatteryTemp Major Low -10°C Major Alarm
4.55 BatteryLifeTime Alarm Disabled
4.56 BatteryLifeTime Major Alarm 100 days Major Alarm
4.57 BatteryLifeTime Minor Alarm 100 days Minor Alarm
4.58 BatteryQuality Alarm Enabled
4.59 BatteryQuality Major Alarm 75% Major Alarm
4.60 BatteryQuality Minor Alarm 80% Minor Alarm