Professional Documents
Culture Documents
EMC LVD
EN61000-6-2 Industrial Environment LVD73/23/EEC Low Voltage Directive
EN61000-6-3 Residential, Commercial and Light Industry EN60950 Safety of Technology Equipment
ETS 300386 v1.3.1 Telecommunication Equipment UL60950,UL1801
Head Office:
Eltek Energy AS
P.O. Box 2340 Strms
N-3003 Drammen
NORWAY
Phone: (+47) 32 20 32 00
Fax: (+47) 32 20 32 10 POWER
E-Mail: eltek@eltekenergy.com DISTRIBUTION
Internet: http://www.eltekenergy.com
CENTER FOR
COMMUNICATIONS
EQUIPMENT
This product is made according to EU directive 2002/95/EC (RoHS) 9N73
and 2002/96/EC (WEEE).
Flatpack PRSB 9kW, 48VDC (Outdoor Site Power Cabinet, Fan Cooled) has part no. CF1017.001
2 Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Table of Contents
2 INSTALLATION PRODECURES 12
SAFETY PRECAUTIONS 12
UNPACKING AND MECHANICAL INSTALLATION 12
ELECTRICAL INSTALLATION 13
COMMISSIONING 16
MAINTENANCE 16
REPLACEMENT OF FILTER, INTERVAL 16
REPLACEMENT OF DOOR FILTER 17
REPLACEMENT OF FAN FILTER 17
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 3
1 DESCRIPTION OF Flatpack PRSB 9kW, 48VDC
This Installation Guide contains information about how to install the Flatpack PRSB 9kW, 48VDC system 1 ,
for the outdoor site power cabinet, fan cooled. Please, refer to the systems Documentation Set (art. no
351405.003) for an overview of related user documentation.
IMPORTANT NOTICE
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 75C (167F).
Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.
Use copper conductors only.
DC Load Distribution:
MCBs, Mains, Alarm
and Signal Terminal Heater MCB (AC)
Air filter
Figure 1: Flatpack Power Rack system General Arrangement. The system consists of 1 battery shelf.
1
PRSB = Power Rack System with Batteries
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
4
INPUT AND DISTRIBUTION ARRANGEMENT
AC Mains Terminals
Figure 2: Location of components in The Powercore; contains Distribution and Power Racks
AC INPUT TERMINALS
The AC terminal blocks are factory configured for mains supply type: 400VAC, 3 phase and N.
L2-bar L3-bar
L1-bar N-bar
L2
(Terminal for
L3
incoming wire)
(Terminal for incoming
wire)
L3 (neutral)
(Terminal for incoming
wire)
Labels on internal wires
(Wires may be reconnected to
match the sites type of AC
mains supply)
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
5
AC Input Feed Sizing
(Recommended AC Breaker Rating)
An external breaker VAC Input 9 kW Th/Mag 9 kW Hy/Mag
is required on all 400 VAC +N 25A C-char. 20A C2-char.
sites. This should be 3 ph
turned OFF during 230 VAC 3 32A C-char. 32A C2-char.
installation. ph
230 VAC 1 25A C-char. 20A C2-char.
ph
It is possible to reconfigure the AC terminal block for connection of 230VAC, 3 phase supply. To do so,
rewire the internal (blue) wires as described in the table below and connect the AC mains supply cable to
terminals L1, L2 and L3.
One of the interface boards (Eltek p/n: 200920) is located behind the MCU (with rear access to the
terminals), while the other board (Eltek p/n: 200958) is mounted on top of the MCU (with front access to the
terminals).
See Figure 8 Customer connections interface, page 10.
SYSTEM MONITORING
The Flatpack MCU (Monitoring & Control Unit) monitors and controls the entire rectifier system including
distribution and batteries, as well as other equipment on site. The unit also incorporates a communication
port for connecting computers via the RS232C interface.
The Flatpack system can be operated and configured locally via the keypad on the MCU unit by selecting
commands from set-up menus in a hierarchical menu system.
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
6
Please refer to the Flatpack MCU Operation Guide for detailed information about system monitoring.
Remote system monitoring and configuration may also be performed using WinPower Silver a Windows-
based program that runs on a connected PC.
The following configuration tasks require the use of a PC:
Installation settings
System calibration
Battery configuration
Alarm setup
Alarm log retrieval
Site information
Site specific configuration
Open both handles, insert and plug the module into power shelf. Then lock
it into position by rotating the handles upwards and pushing them firmly
home. Failure to do so will prevent the module from making proper contact.
Figure 5: Module with released handles
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
7
FAN & HEATER OPERATION
The fan runs as soon as the temperature in the cabinet passes 25oC (77F). Hysteresis is 1C (1.8F).
The heater is controlled through a thermostat and the heater starts up at 5C (41F).
The digital inputs are configured as fail-safe, i.e. if the input is enabled,
Input 1
it will trigger an alarm when the input is open. If several external AGND
devices are to be connected to the same digital input, they must be
connected in series.
The alarm relays are also operated in fail-safe, i.e. the relays are
energized when there is no alarm. The description below describes the CON4
pin out in normal state, i.e. the REL output is closed to COM in normal External device
operation and the REL output is open to COM in an alarm-state. alarm state
Figure 7: Backwiring interface and internal terminals (max. 1.5 mm2, AWG 15). Art no. 200920
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
8
CON 41 Pin Assignment
for basic PCB version, art. No. 200920
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
9
Customer Connections
Figure 8: Customer connection, relay output (max. 1.5 mm2, AWG 15). PCB art.no: 200958
WARNING:
Do not connect external cables to relay 1 as this is used for fan control.
Pin 16 Pin 1
GMT fuses
Max. 10A each
2
Figure 9: GMT fuse board (max. cable size 1.5mm )
10Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
The table below shows the pin assignment for the GMT load fuse board:
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
11
2 INSTALLATION PRODECURES
This section describes how to install the Flatpack PRSB 9kW, 48VDC. Step-by-step procedures will guide
you through the installation.
For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and control unit, please refer
to the Operation Guides for the respective modules.
SAFETY PRECAUTIONS
The equipment described in this manual must only be installed by authorized
personnel and only operated by persons who have attended a suitable Eltek Energy
training course.
The equipment represents an energy hazard and failure to observe this could cause
terminal injury and invalidate our warranty.
There are hazardous voltages inside the rectifier system. As the rectifier units
incorporate large charged capacitors, you should show precaution when working
inside the system even if the mains supply is disconnected.
Products into which our components are incorporated have to comply with a number
of requirements. Installation is to be in accordance with the recommendations herein.
5. REMOVE
CONDENSATION STOPPER
12Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
WARNING:
Live bus bars underneath opening inner roof. You are operating in a live
Electric
system. Precaution must be taken when working in this area. shock
ELECTRICAL INSTALLATION
For location of components see Figure 2 - page 5, Figure 3 - page 5 and Figure 10 - page 20.
Step Comments OK
The cabinet roof is locked with 2 triangle locks with access from inside the
1. OPEN THE ROOF
system. Open these locks and lift up the roof. The key is located on the left
hand side of the cabinet. Secure the roof during installation with the rod on
the left side under the roof.
Avoid placing cables on top of cable entry as this will block the filter
2. CABLE ENTRY
entry
Filter entry
Marcon 25 multigate
The picture below show how to cut the grommets. The cut must be
smaller than the cable diameter:
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
13
Step Comments OK
Go back to the grommet and pull the cable back approx. 10mm. This
will lock the cable in the grommet and ensure full IP protection.
Secure cables with cable tie to the cable bracket
Cable bracket
AC-connections
Switch OFF the AC input power (external MCBs), before connecting the
cable
There are two pre-installed MC 25 Cable entries in the cabinet. These
can be mounted on rear, left and right side of the cabinet.
To change position, remove MC 25 from existing position. Remove Blind
Panel from the position were you want the cable entry. Store all fixings in
a safe place.
Then remount MC 25 in the preferable position and remount blind panel
in the empty space
Connect the external AC ground wire to the protective earth (PE
terminals)
If you are using double lug PE cable connect to the cabinets main PE
terminal. See page 5.
Connect cables to L1-L2-L3-(N)
The system is prepared for an AC socket located to the right side of the
5. AC SOCKET
cabinet. This AC outlet is intended for optional equipment. Due to the
many different socket types all over the world, no socket is delivered with
14Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Step Comments OK
the system.
Turn off the AC breaker. Connect the cables L, N and PE to the preferred
socket type and mount the socket to the bracket.
6. LOAD / BTS
CONNECTIONS
2-pole
link for CBI MCB
Connect the adequate cables, 1.5mm2 (AWG 16), to the GMT fuse board
7. GMT FUSE
according to the table on page 11
CONNECTION
The positive and negative (-48V) battery cables are connected from the
8. BATTERY
factory to the common positive bus bar and to the battery MCBs (excluding
CONNECTIONS
additional battery string kits). The battery temperature sense cable is also
pre-wired to CON4, and temporally fixed to the cabinets back wall.
Connect the battery cables to the battery terminals; blue cable to the
negative terminal and black cable to the positive terminal
Connect all battery inter-cell links
Place the temperature sensor, located at the end of the battery
temperature sense cable, on top of the topmost battery string
9. CONNECT ALARM You can now connect all external alarm wires to the front relay access card
WIRES located above the MCU. See figure 2 page 5 for location.
10. PLUG IN Plug in the rectifiers and make sure you balance the rectifiers over the faces
RECTIFIERS
Please follow the chapters Pre-Start Check and Start-Up Procedure in the
11. POWER UP
manual Commissioning Guide Flatpack 1500 DC Rectifier Plant, doc.no.
2
The bus bar is prepared for connection of stripped cables (app. 30mm) or with ferrules. Clamps are fitted at delivery.
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
15
Step Comments OK
360006.163
Remove the condensation stopper placed in front of both filters; inside door
12. REMOVE
and in front of fan:
CONDENSATION
STOPPER
COMMISSIONING
For information regarding system commissioning, please read manual Commissioning Guide Flatpack 1500
DC Rectifier Plant, art. no. 360006.163.
MAINTENANCE
WARNING:
You are operating in a live system. Precaution must be taken when changing
filter in front of the fan. Electric
shock
16Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Replacement of Door filter
Step Comments OK
Remove the filter grid by pushing it slightly up and then pulling it towards you
1. REMOVE FILTER
Exchange the old filter with a new. Make sure that the smooth side of the
2. EXCHANGE FILTER
filter faces the inside of the cabinet (the rough side of filter should not be
visible).
Fasten the frame to the door again and push it slightly down when the hinges
3. FASTEN FRAME
are in place.
2. OPEN TOP OF
CABINET
The fan filter is located behind the power equipment and should be removed
from the top of the cabinet
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
17
Step Comments OK
3. REMOVE FILTER
GRID
Remove the filter grid by pushing it slightly up and then pulling it out and up
towards you
4. EXCHANGE FILTER
Exchange the old filter with a new. Make sure that the smooth side of the
filter faces the inside of the cabinet
5. FASTEN GRID
Fasten the filter grid by pushing it slightly down when the hinges are in place
Replace the fuse for fan and verify that the system is operating normally
6. CONNECT FAN
Close the top of the cabinet and lock it with the key found on the left side
7. CLOSE TOP
18Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
3 SPECIFICATIONS Flatpack PRSB 9kW, 48VDC, Fan Cooled
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
19
APPENDIX: SCHEMATICS, DRAWINGS, FIGURES etc.
Door switch
Main Protective
Earth (PE)
DC Distribution,
Alarm, AC
Terminals, etc.
Heater MCB
(AC)
Rectifiers
AC socket
Battery MCB
FB2
Battery MCB
FB1
Figure 10: General Arrangement drawing, PRSB 9kW, 48VDC Outdoor Cabinet, Fan Cooled
20Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
A2 - System Schematic PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled
LTE Distribution
Load
L3 L2 L1 N PE *OPTIONS F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 *
OVP kit F1
*
F2
204144 204144
F3*
First p.shelf
2xFlatpack 1500
A
PE + CU-bar common + F4*
N
SH1 Fan
B
L -
- +
Load Alarm
- 16
PE + F12 15
N
SH2 REL1 COM1
14
F11
AC Detection
+ 13
L - CON 5
12
F10 11
Third p.shelf 10
-
203929
2xFlatpack 1500 F9 9
LVBD NO
PE + 8
+ F8 7
N
6
- F7
Load Alarm
L
5
4
F6 3
2
10
11
12
1
2
3
4
5
6
7
8
9
F5 1
CU-bar Battery -
MCU
Monitoring / Interface Board
Controller Unit Con41
Con3
10
12
13
6
8
Batt.string 1 Batt.string 2*
AC socket Battery Heater*
PE
N Date Design Draw Approved Scale Projection
13,02.2006 OLHUNO OLHUNO N/A
L
AC MCB
Heater
Door Switch
Schematic PRSB 9 kW OD
Eltek
Co pyright A/S Eltek. All rig hts reserved
Replace for Replaced by
- -
Consultant Format Page Draw. No. Rev.
Sym. Alteration Date/Sign
- A4 1 of 1 2011671 1
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
21
A3 - Drilling Template
Figure 12: Top view of the cabinets bottom plate. 700x700mm external dimensions
The cabinet overhangs by 35 mm outside the plinth in the rear, on the left hand and on the right hand
side. The Fan box builds an extra 80mm in the front.
22Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
MCU Default Settings PRSB 9 kW, 48 VDC
CF1032.001
SITE INFO Default System Setup
Customer
Location
Max. Current Rectifier 33
Rectifier Installed 0
Battery Type Marathon M12V 155FT
SET LEVELS Setup
High Battery Alarm 1 58 V
Low Battery Alarm 1 45 V
High Battery Alarm 2 59 V
Low Battery Alarm 2 43 V
Battery Voltage 54,5 V (at 25 C)
Boost Voltage 56,4 V
Alarm Delay 0s
High Temperature Alarm Level 1 25
High Temperature Alarm Level 2 (LVBD
disconnects) 50
Disconnect Voltage LVD1 40 V
Reconnect Voltage LVD1 47 V
Disconnect Delay Time LVD1 0
Disconnect Voltage LVD2 NA
Reconnect Voltage LVD2 NA
Disconnect Delay Time LVD2 NA
Disconnect Voltage LVD3 NA
Reconnect Voltage LVD3 NA
Disconnect Delay Time LVD3 NA
ALARM SETUP (which relay output is wanted
on each alarm) Setup
High Battery 1 No alarm relay
Low Battery 1 No alarm relay
High Battery 2 Relay 2
Low Battery 2 Relay 3
LVD1 No alarm relay
LVD2 No alarm relay
Battery Fuse Relay 4
Rectifier Relay 5
Critical Rectifier Relay 5
Mains No alarm relay
Battery Test No alarm relay
Battery Pre No alarm relay
Battery Fault No alarm relay
Common Relay 5
Load Fuse Relay 4
Symmetry1 No alarm relay
Symmetry2 No alarm relay
High Temperature 1 Relay 1
High Temperature 2 No alarm relay
Conf. Input 1 / Heat management No alarm relay
Conf. Input 2 Relay 6
Conf. Input 3 Relay 7
Conf. Input 4 Relay 8
Conf. Input 5 No alarm relay
LVD3 NA
SYSTEM CONFIGURATION Setup
Nom. Voltage 48V
Enable Function:
ON/OFF OFF
Battery Fuse ON
Symmetry 1 (SW) OFF
Symmetry 2 (HW) OFF
Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
23
Auto Boost OFF
Setup LVD1 Battery contactor
Type LVD1 Normally Open
Setup LVD2 No contactor
Type LVD2 NA
Setup LVD3 No contactor
Type LVD3 NA
OUTPUT CONTROL Setup
Temp. Comp.
BATTERY CONFIGURATION Setup
Battery Test Setup
End Voltage* 1.85 V/cell
Max test duration 300 min
Test interval 270 days
Test delay period 3 days
Battery Type
Battery Type User defined, type:
Marathon M12V 155FT
Number of battery modules (strings) 1
Battery cable resistance 0
Charge Current Limit
Charge Current Limitaion Active
Max. Charge Current 0.2C10 (18.4A)
Battery Setup User Def.
Battery Name
Battery test end voltage 1.85 V/cell (44.4 V)
Temp. Compensation (voltage at 20) 2.29 V/cell
Slope of temperature comp. equation 5,5 (mV/cell)/deg
Battery table (see next sheet for table) Marathon M12V 155FT
CONFIGURABLE INPUTS Setup
Conf.Inp. 1 Disable
Conf.Inp. 2 Phase 1
Conf.Inp. 3 Phase 2
Conf.Inp. 4 Phase 3
Conf.Inp. 5 Door Open
TEMPERATURE COMP. CHARGING Setup
Voltage at 20 C 2.29 V/cell
Slope 5,5 (mV/cell)/deg
Max. Compensation Voltage 2.4 V/cell
Min. Compensation Voltage 2.21 V/cell (53 V)
MODEM
Modem Callback NA
Baud Rate NA
RELAY SETTINGS(Jumper settings) Setup
Relay 1 NO
Relay 2 NO
Relay 3 NO
Relay 4 NO
Relay 5 NO
Relay 6 NO
Relay 7 NO
Relay 8 NO
24Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Head Office:
Eltek Energy AS
P.O. Box 2340 Strms
N-3003 DRAMMEN
Norway
Phone: 47 32 20 32 00
Fax: 47 32 20 32 10
E-Mail: eltek@eltek.no Art. No. 351434.033
Issue 3, 2006-July
Internet: www.eltekenergy.com
Published 2006-07-18