Eltek PRS, PRSB, PRSV Quick Start Manual

Quick Start Guide

Installation, Operation, Commissioning and Maintenance

DC Power Supply System

With or without Batteries, Wall-mounted, Modular

Flat

p

ack PS S

y

stem

356803.103

PRS, PRSB PRSV

(with external

batteries)

(w/ without

internal batteries)

MPSU

Miscellaneous

Communication

o Installing WinPower Silver – PC software ( 9)

AC Mains

o External AC Fuses, Recommended Rating (10 )

Earthing

o About AC, DC Earthing Systems ( 11)

Battery Monitoring

o Battery Terminology (12)
o Battery Symmetry – Connections (12 )

Alarms & Monitoring

o Fail-Safe Operation ⎯ Alarm Relays & Digital Inputs (13 )
o Terminals & Pin-out Location, Alarm Card 100350 (13 )
o Terminals & Pin-out Location, Front Access Alarm Card 101825 (14 )

Introduction

o The Flatpack Product Range (2 )
o Brief System Description (2 )

Installation

o Installing Rectifier Modules and MCU Controller ( 3)
o Installation steps; mechanical, electrical (4-5)

Commissioning

o Pre-start check (6 )
o Commissioning steps, Startup (6-7)

Operation

o Front keys and display ( 8)
o Software Menus ( 8)

Check Lists

pullout forms

o Installation Check List
o Circuit Distribution List
o Commissioning Procedure
o Maintenance Procedure

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

2

The Flatpack Product Range

Eltek Energy's Flatpack product range utilizes the Flatpack rectifier and the MCU controller as
building blocks for implementing effective DC power systems, suitable for a wide range of
applications and power ratings.

MPSU systems consist of the power system, which includes rectifiers and controller(s), and the
distribution unit (1U or 4U high). MPSU systems are sold primarily for mounting in existing
cabinets.

In PRS systems, the cabinet contains the power system and the distribution unit. In addition, the
cabinet may also enclose battery banks, additional distribution and other dedicated equipment.

Brief System Description ⎯ Flatpack

The Flatpack PS system is a compact, powerful and cost-effective DC power supply system,
specifically developed for the telecom industry.

Example of a typical Flatpack PS system for DC power supply of telecom equipment. The system is fed
from an external AC mains supply, and consists of rectifiers in power shelves, a control unit and DC
distribution unit. Battery banks, LVD contactors, etc. are typically also a part of the system.

Introduction

Flatpac

k

PRSB

Battery string #1

Flatpack MCU

(Ctrl. Unit)

Flatpack

(rectifiers)

A

C mains
supply
selector

Symmetry

Alarm &

Temp. Senso

r

LVLD

LVBD

AC Suppl y

(Single- or

three-

p

hase

)

Fuse Alarm

DC Supply

(24V, 48V
or 60V

)

AC Fuses,

external

(230VAC or

400VAC

Telecom

equipment

A

larm Outputs NC-C-NO

Digital Inputs

DC

distribution

Batte

r

y

Fuses

Load Fuses
& MCBs

Service

S

witch

+/-

MPSU
Modular Power Supply Unit

PRSV
Power Rack System

Wall-mounted

PRSB
Power Rack System
with or without Batteries

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

3

Installing Rectifier Modules and MCU Controller

Installation

Handel in locked position

Hole to release the

handle’s spring mechanism

Flatpac

k

Handel in
unlocked position

Flatpack

Device
hazard

CAUTION:

- The modules may be warm, but do not hand-carry them by their handles

- Open the handles before inserting them into the power shelves

Mounting Flatpack rectifier modules

1. Open the handles by

inserting a screwdriver into the holes to release the spring
mechanism

2. Insert the module fully into the power shelf, so that it makes

proper contact

3. Lock the handles by

pushing the handles up into their housings (locked position),
so that the module makes proper contact and is secured locked

Removing Flatpack rectifier modules

1. Open the handles by

inserting a screwdriver into the holes to release the spring
mechanism

2. Remove the module

using both handles to pull the module loose; support from
underneath

3. Lock the handles by

pushing the handles up into their housings (locked position). It
is then ready for transport

4. Mount blind panels in

unused module locations

Electric

shock

Mounting and Removing the MCU Controller

Note that cables are plugged to the MCU’s rear panel. When
mounting the controller, you must plug the cables before step 2.
When removing it, unplug the cables during step 2.

1. Unlock the controller by

unscrewing the two fastening screws on the front

2. Insert or remove the module by

sliding it fully into the power shelf
or
using both handles to pull the controller loose. Unplug the
cables, when removing the MCU module

3. Lock the controller by

screwing the two fastening screws on the front. It is then
securely locked in the shelf. Or ensure the screws do not fall
out of the holes, when removing the MCU module

Handle

Fastening

holes

MCU Controller

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

4

Installation Steps

Check off in the Installation Check List, that you find in the pullout section o

f

this folder. Also, refer to the system’s specific drawings.

For external AC fuses and AC input cable ratings, refer to your site’s AC
supply specification. Read also our external AC fuse recommendations
in section “Miscellaneous”. In general, a site with better AC supply
quality (stable nominal voltage) may use smaller breakers.

200 mm

600 mm

Flatpack PRS, batteries, Doc.
Chart, Spec. Drawings, CD-ROM

Installation

Preparing the installation site

Begin preparing the following:

1 Organize the installation site

o Min. clearances for cabinet access: 60 cm in front, 20 cm on top
o Levelled surface able to support 600 kg (PRSB),100 kg (PRSV)
o Explosive atmospheres are to be avoided. Ensure suitable

ventilation

o 60V systems are only to be installed in Restricted Access

Locations (RAL)

2 Prepare the installation tools

o Use insulated tools suitable for telecom installations

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

o Correct type AC supply is available
o External AC fuses have correct rating
o AC input cable(s) are sized correctly

EMC

regard

Electric

shock

Mechanical Installation

Power is OFF!

Carry out the following:

4 Remove packaging and check equipment

o Check you have received all the parts, correct cabinet,

documentation, batteries (if applicable), etc.

o Inspect the equipment for physical damage (report any damages)
o Leave rectifier modules in their packaging or in the selves, if

factory installed. To be installed under commissioning

5 Remove top cover and dummy front panels

o Cable entry from the top. Connection terminals are located behind

the upper dummy panels

o Battery shelves (if any) are placed behind the lower panels

6 Position and fasten the cabinet or subassembly

o PRSB cabinets are floor-mounted on levelled surface. Adjust the

legs if necessary. If the cabinet must be fastened, unscrew the legs
and use suitable bolts to fasten it to the floor

o PRSV cabinets are wall-mounted; keyholes facilitate fixing
o MPSU subassemblies are fastened in existing 19” or in ETSI

cabinets, using brackets. Mount the support & heat deflecting
plate under the lower power shelf

7 Mount the batteries on the shelves

o Start (if applicable) placing the batteries on the lower shelf first,

and continue upwards

o Do not terminate the battery cables yet!

Device
hazard

Upper
fastening hole

Ø 7 mm

Ø 13 mm

550 mm

Ø 7.3 mm

10 mm

736.7 mm

Lower
fastening hole

Wall-mounting distances

PRSV cabinets

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

5

Electrical Installation

Power is OFF!

Carry out the following: (Refer to the system’s specific drawings)

8 Make the system completely voltage free

o Switch OFF or remove all load fuses (MCB1, MCBx), battery

fuses (Fb1, Fbx) and the AC supply fuses, in external fuse
boards

9 AC Connections

o Check AC configuration: the AC terminals are correct configured

to the external AC supply, otherwise reconfigure the terminals

o Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
o Connect the AC input cable(s) to the terminals. Cable and

terminal block labeling are to correspond

10 DC Connections ⎯ Load Circuits

o Terminate DC Earth (TE), and check that the common DC

Output Rail is connected to “Telecom Earth” (TE) at only one
place (at the cabinet or at a central distribution point). Se
chapter about AC, DC earthing systems

o For each DC load, connect one of the cables to the common DC

output rail, and the other directly to the MCB or load fuse

11 DC Connections ⎯ Alarm & Signal Circuits

o Refer to your system’s connection drawings and configuration

(Factory Settings), or to the “Miscellaneous, Alarms &
Monitoring” section

o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output

terminals

12 DC Connections ⎯ Battery Cables

Careful! Use correct polarity.

For each battery shelf: (refer to the figure in this page)

(In PRS systems, steps b, d and f are usually performed in factory)

a Mount 3 intercell links to connect in series 4 battery blocks
b-c Connect battery cables to fuses and common DC rail, and to

the shelf’s outer terminals; black (+); blue (-)

d-e Connect battery symmetry cables, if applicable, to the input

terminals, and to the center terminal of the battery string
(+). Deviation from factory settings requires Symmetry
reconfiguration via WinPower Silver

f-g Connect the temperature sensor cable, if applicable, to the

input terminals, and fix the temperature sensor (at the end
of the cable) to a suitable place in the middle of the
installed battery bank

Electric

shock

Installation

Block1

- + + - + - + -

Block4Block3

—

(-48V) Oute

r

Terminal

+

0V Outer

Terminal

Link 2

(DC Earth)

Common
DC Rail

EG

Chassis

Battery

Fuse

Intercell Links

Batter

y

Cable

Symmetry cable

Tem

p

. senso

r

Card Art.100986
CON4:11

…and
CON3:34­35-36

Temp. Sensor cable

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

6

The commissioning of a Flatpack 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

Pre-Start Check

Power is OFF!

Check off in the Commissioning Procedure, that you find in the pullout 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 Flatpack 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 in)

o All cabling and copper bars are securely terminated and supported
o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled

2. Battery and load fuses are disconnected

o Verify that all battery and load MCBs/ fuses are switched OFF or removed

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
o Verify that the AC input cable(s) and external AC fuses are sized and rated as specified
o Check that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)

4. Site specific parameters and settings are known

o Read the system specific drawings and documentation

5. AC supply and all MCBs, fuses are switched OFF

o Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF

Commissioning Steps, Startup

Check off in the Commissioning Procedure, that you find in the pullout section of this folder.

After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you
will switch ON the Flatpack PSS — while the batteries and load are disconnected ⎯ then
measure the output voltage, and adjust it if required. Carry out the following:

Startup and No-Load Adjustments

Power is ON!

1. Disconnect all rectifier modules, without removing them

o Read how to install modules, on page 3 in this guide. and then
o If Flatpack rectifier modules are installed, unlock the handles and pull the modules

partially out (fan housing visible), but do NOT physically remove them from the
power shelves

o If Flatpack rectifier modules are not yet mounted, release their handles and insert

them partially into the shelves

2. Switch ON the system

o Switch ON the AC input supply (external AC fuses) to the PS cabinet

3. Measure and verify that the AC input voltage is correct

o Measure the AC input voltage at the cabinet’s mains connection box
o Verify the AC voltage is within range

Commissioning

Device
hazard

Device
hazard

I

II

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

7

4. Mount all Flatpack rectifier modules in the power shelves

o Push all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯

to plug them in the shelf. Lock their handles. Refer also to page 3 in this guide

o Mount blanking panels over unused positions

5. Ensure that the MCU controller 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 MCU controller displays fuse alarms

6. Connect a PC to the PS system (to facilitate operation)

o Plug the correct serial cable between the PC and the MCU controller
o Start WinPower Silver on the PC (click on Start>All Programs>Eltek>WinPower Silver)
o Configure equal communication parameters on the MCU and the PC.

Refer to chapter “

Installing WinPower Silver ⎯ PC Application

”, page 9, if required

7. Measure and adjust DC output 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 WinPower Silver

8. Verify the alarm relays are working correctly (alarm relay test)

o Run the alarm relay test using the controller’s front keys (refer to page 8) or via

WinPower Silver (click the “General Information” button; then the “Relay Test” tab)

9. Make sure the System Setup is in accordance with configuration

o Verify system settings using the controller’s front keys or via WinPower Silver
o Use the opportunity to enter site related information, type of batteries, etc. (Click

the “General Information” button; then the “Site Information” tab)

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:

10. Adjust DC output voltage to equal measured battery voltage

o Measure the battery voltage is within range (check connections have correct polarity)
o Adjust DC output voltage — using the controller’s front keys (refer to page 8) or via

WinPower Silver— to equal the measured battery voltage.
(Important adjustment to avoid arcing when connecting the batteries)

11. Unplug all rectifiers but one, and connect the battery fuses /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

12. Adjust DC output voltage again to equal the nominal battery voltage

o Adjust DC output voltage — using the MCU’s front keys or via WinPower Silver — to

equal the nominal battery voltage (or the nominal load voltage, when not using batteries)

13. Plug in again all rectifiers, and verify the rectifiers’ current sharing

o Connect all rectifiers again by pushing them firmly inwards ⎯ Repeat step 4, in stage II
o Wait for about 2 min., and check — reading the LED bar graph on the rectifiers’ font

panel — that each of the rectifiers delivers the same output current. A ±5 % deviation is
acceptable. (Each LED represents 3A approx.)

14. 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

Commissioning

Device
hazard

Device
hazard

III

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

8

Firmware 402080.009 5v1

Service menu <ServiceOption>

Password= 0003

English
German
Norwegian
Language Polish
French
Spanish

p

Comm

Protocol Trace *
Comli

9600
Set baud 1200
2400
4800

MODEM sense MODEM sense: ON
MODEM sense: OFF

* “Trace” is for internal factory use

Level 2 Level 3

Front Keys and display, menus, etc.

Flatpack rectifier module — front panel, left side

Power LED is OFF (mains unavailable) or ON
(powered). Alarm LED is ON (shutdown or similar
major alarm) or OFF (OK, no alarm)
Output voltage is factory adjusted on delivery. In
stand-alone operation (MCU ctrl. unit is not used),
you can use the potentiometer to adjust the output
voltage.

MCU Control Unit — front keys, display, etc

Display: is in Status Mode (displays the system’s
status) or in Menu Mode (displays the menu structure).

Operation: Press on the

key to change from

Status Mode to Menu Mode. Press the

or
keys to scroll up or down and navigate to find menu
options (function or parameter). Press then the
key to select the function.

Menus: When you “enter” Menu Mode, you access
the User Options. You may also scroll down to
password protected Service Options. Default password
<0000> and <0003> should be changed.

Software Menus

LED bar graph

Output current scale, 10 green LEDs (3A each)

0A scale mark

Alarm

LED Lamp (red)

Power

LED Lamp (green)

30A scale mark

Potentiomete

r

Output voltage adjustment

Flatpack rectifie

r

RS232C

D-Sub 9 pins

female

LCD displa

y

Alarm

LED Lamp (red)

”Up” arrow key

”Down” arrow key

”Enter” key

MCU control unit

Service menu <ServiceOption>

Password= 0000

NomVolt
BoostVolt
LowBatt1
LowBatt2

V

oltAdjustment HighBatt1

HighBatt2
LVD 1

LVD 2
LVD 3

Calibration VoltCal

SetDefaultCalib.

ChangePassword Æ Password
SetBoostTime Æ BoostTime
Start/StopBoost Æ StartBoost/StopBoost

Auto Boost Cfg. Enable/Disable
Threshold

IntervalTest Date Time
Test End Volt

Batt Test Setup Max Test Duration

Test Interval
Test Delay Period

Start/Stop Test Æ Start Test/Stop Test
Charge Curr Lim Enable/Disable

Max Charge Curr

Battery Setup Æ Number of banks
Number of rectifiers
Capacity Al.Cfg. Current pr rectifier
Alarm limit

Temp.Comp
OutputControl Voltage Control

Presat Rect.Volt

Change Date/Time Date

Time

Relay1
Relays 2…10

Relay Test Relay 11

LVD1 relay
LVD2 relay
LVD3 relay

Level 2

Level 3

Firmware 402080.009 5v1

User menu <UserOption>

System ON/OFF Æ Turn system ON/OFF *
Alarm Reset Æ Alarm Reset
NomVolt
BoostVolt
LowBatt1
LowBatt2
VoltageInfo HighBatt1
HighBatt2
LVD 1
LVD 2
LVD 3
DisplayMessages Æ Display messages
Sw Info Æ SwInfo

* The ON/OFF function may be disabled in some

systems

Level 2 Level 3

Firmware 402080.009 5v1

Operation

Keys & Menus

PULLOUT

Check Lists Pullout

Pull out the pages with the gray outer band,

and use them as check lists

INSTALLATION CHECK LIST

System Data

Flatpack PS System

Flatpack Power Supply System, type: Article No.:

Site, name:

Serial No.: Software, version No.: Rectifiers, type & number of:

AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:

Site Preparations

CARRY OUT FOLLOWING

:

OK

1. Organize the installation site

o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm

o Check that the levelled surface is able to support 600 kg (PRSB systems), 100 kg (PRSV systems)

o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas



2. Prepare the installation tools

o Check that insulated tools suitable for telecom installations are used



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

o Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated



Mechanical Installation

Power is OFF!

CARRY OUT FOLLOWING

:

OK

4. Remove packaging and check equipment

o Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc

o Inspect the equipment for physical damage (report any damages)

o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)



5. Remove top cover and dummy front panels

o Check that cable entry from the top is possible



6. Position and fasten the cabinet or subassembly

o PRSB cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor

o PRSV cabinets are wall-mounted. Keyholes facilitate fixing

o MPSU subassemblies in existing 19” or in ETSI cabinets, using brackets. Mount support & heat deflecting plate



7. Mount the batteries on the shelves

o Start (if applicable) on the lower shelf first, and continue upwards

o Do not terminate the battery cables yet!



Electrical Installation

Power is OFF!

CARRY OUT FOLLOWING

:

OK

8. Make the system completely voltage free

o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses



9. AC Connections

o Check AC configuration: The AC terminals are correct configured to the external AC supply

o Connect the AC Earth wire (PE) to the terminals AC Earth (PE)

o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond



10. DC Connections ⎯ Load Circuits

o Terminate DC Earth (TE):

Common DC Output Rail is connected to TE at only one place

o For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB



11. DC Connections ⎯ Alarm & Signal Circuits

o Refer to your system’s connection drawings and configuration, or to the Factory Settings in the Quick Start Guide

o Terminate Alarm Circuit cables to the relay output terminals

o Terminate Signal Circuit cables to the digital input/output terminals



12. DC Connections ⎯ Battery Cables Careful! Use correct polarity.

For each battery shelf,

o Mount 3 intercell links to connect in series 4 battery blocks

o Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-)

o Connect battery symmetry cables, if applicable, to the input terminals, and to the battery string

o Connect the temperature sensor cable, if applicable, to the input terminal, and fix the sensor (at the end of the

cable) to a suitable place in the middle of the installed battery bank



Approval

Responsible of installation, sign.: Date: Approved by customer, sign.:

EMC

regard

Electric

shock

Device

hazard

Electric

shock

Form XXX-gb-v1-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11

Eltek Energy AS

Tel. [phone]

Internet: www.eltekenergy.com E-Mail: [email protected]

Form 165-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11

Eltek Energy AS

Tel. [phone]

Internet: www.eltekenergy.com E-Mail: [email protected]

CIRCUIT DISTRIBUTION LIST

System Data

Flatpack Power Supply System, type: Article No.:

Site, name:

CIRC

.

NO

.

FUSE

KNIFE

TYPE

MCB

LVLD

CONTROLLED

DESCRIPTION

FUSE

AMPERE

CABLE

mm

2

Fb1

Fb2

Fb3

Fb4

Fb5

Fb6

F1

F2

F3

F4

F5

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

Continue

LOAD

BATT.

CIRCUIT DISTRIBUTION LIST

CIRC

.

NO

.

FUSE

KNIFE

TYPE

MCB

LVLD

CONTROLLED

DESCRIPTION

FUSE

AMPERE

CABLE

mm

2

31.

32.

33.

34.

35.

36.

37.

38.

39.

40.

41.

42.

43.

44.

45.

46.

47.

48.

49.

50.

51.

52.

53.

54.

55.

56.

57.

58.

59.

60.

61.

62.

63.

64.

65.

66.

LOAD

Form 165-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11

Eltek Energy AS

Tel. [phone]

Internet: www.eltekenergy.com E-Mail: [email protected]

MAINTENANCE PROCEDURE

System Data

Flatpack PS System

Flatpack Power Supply System, type: Article No.:

Site, name:

Serial No.: Software, version No.: Rectifiers, type & number of:

AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:

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.

At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration



3. The equipment is free from damage, dust or dirt; verify.

Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.



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

Correct any loose connections, excessive cable temperature, defective insulation, etc.



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

Otherwise, correct and put the PS system in normal mode of operation.



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

Correct possible abnormalities before continuing.



7. Connect the PS system to a PC (install the WinPower Silver application if required)

The WinPower Silver program in the PC enables system configuration from the PC.



8. Rectifiers’ load current sharing; verify.

The number of LEDs illuminated on every rectifier's bar graph should be equal (±1 LED).



9. Display the stored log of Alarm Messages.

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



System Adjustment

Activate the Service Switch, if installed

CARRY OUT FOLLOWING

:

OK

1. DC Output Voltage Calibration; ensure correct display readings.

If measured DC output voltage at the load terminals deviates more than ±1% from the display reading, calibrate the

output voltage from the MCU’s keypad or the PC.



2. Load & Battery Current Calibration; verify correct display readings.

Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery

current. If the calculated total values deviate more than ±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 manufacturer.

(Voltage measurements to be done at the DC rail, with little load current)



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

From the MCU’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.:

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.

Electric

shock

Form 166-gb-v2-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11

Eltek Energy AS

Tel. [phone]

Internet: www.eltekenergy.com E-Mail: [email protected]

PULLOUT

Form 164-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11

Eltek Energy AS

Tel. [phone]

Internet: www.eltekenergy.com E-Mail: [email protected]

COMMISSIONING PROCEDURE

System Data

Flatpack PS System

Supplier’s Order No.: Flatpack Power Supply System, type: Article No.:

Site, name:

Serial No.: Software, version No.: Rectifiers, type & number of:

AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:

Pre-Start Check

Power is OFF!

CHECK FOLLOWING

:

OK

1.

Flatpack system installation is completed;

The Flatpack Installation Check List is filled in.

All cabling is securely terminated with correct polarity



2. All battery and load MCBs/ fuses are disconnected



3. AC input cable(s) and AC earth wire (PE) are terminated



4. Site specific parameters and settings are known



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



2. Switch ON the system (external AC fuses ON)



3. AC input voltage is correct;

Measure and verify



4. Insert all Flatpack rectifiers in their locations in the power shelves



5. The MCU and all rectifier modules are working, LEDs are ON;

Verify



6. Connect a PC to the PS system

Install the WinPower Silver program, if required



7. DC output voltage;

Measure and adjust



8. Alarm relay test;

Verify all alarm relays are working correctly



9. System Setup is in accordance with configuration

Enter site spec. info in WinPower Silver



10. Adjust DC output voltage to equal measured battery voltage

Check correct polarity!



11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs



12. Adjust DC output voltage to equal nominal battery or load voltage



13. Plug in again all rectifiers, and verify the rectifiers’ current sharing



14. Connect all load MCBs/ fuses, and verify no alarms are displayed



Approval

Responsible of commissioning, sign.: Date: Approved by customer, sign.:

Device

hazard

I

II

Device

hazard

III

Device

hazard

PULLOUT

Check Lists Pullout

Pull out the pages with the gray outer band,

and use them as check lists

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

9

Installing WinPower Silver ⎯ PC Application

WinPower Silver software enables you to configure and operate the Flatpack PSS from a
personal computer.

Installation

1. Connect the MCU’s D-Sub to one of the PC’s COM port using an RS232C serial cable

2. Install WinPower Silver in the PC

3. Verify that MCU and PC have equal communication parameters,

e.g.: 9600 baud, 8b, P=N, Sb=1

MCU

Control Unit

Control Room

Technical Room

RS232C serial cable, 9—9 pins

Max. 15m, RS232 driver protocol

D-SubD-Sub

9 pins (female)

9 pins (male)

1

2

3
4
5
6
7
8

9

1

2

3
4
5
6
7
8

9

COM1, D-Sub

9 pins (female)

COMx, D-Sub

9

p

ins

(

male

)

RxD
TxD

GND

RxD

TxD

GND

CTS

DTR

Flatpack PRS

D-Sub

WinPower
Silver

PC

Communication

Miscellaneous

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

10

External AC Fuses ⎯ Recommended Rating

The site’s AC supply quality is of great importance. In general, a site with better AC supply
quality (stable nominal voltage) may use smaller breakers.

Miscellaneous

AC Mains

* The calculation for single sub-rack configuration requires separate AC feed to each module position

Note: The above recommendations apply for use of Thermal magnetic circuit breaker, type Siemens 5SX or 5SY series, MG C60H
series or similar. For more information regarding External AC fuses and other types of fuses, please read the article 2014385 for
Flatpack 1500 systems or the article 2014386 for Flatpack 1800 systems on the CD, 356802.CD3.

AC Mains No of Power Current Ext. Fuse

Type Shelves Max. (A) Type (Th/Mag)

1

16.2

25A-C

2

32.4

40A-C

230VAC

1-phase

3

48.6

50A-C

1*

8.1

25A-C

2 or 3

16.2

25A-C

230/400VAC

3-phase, TN network

(5 wire system)

4,5 or 6

32.4

40A-C

1*

14.0

25A-C

2 or 3

28.1

32A-C

4

42.9

50A-C

230VAC

3-phase, IT network
(4 wire system)

5 or 6

56.1

63A-C

AC Mains No of Power Current Ext. Fuse

Type Shelves Max. (A) Type (Th/Mag)

1

18.1

25A-C

2

36.1

40A-C

230VAC

1-phase

3

54.2

63A-C

1*

9.0

25A-C

2 or 3

18.1

25A-C

230/400VAC

3-phase, TN network

(5 wire system)

4,5 or 6

36.1

40A-C

1*

15.6

25A-C

2 or 3

31.3

32A-C

4

47.8

50A-C

230VAC

3-phase, IT network
(4 wire system)

5 or 6

62.6

63A-C

205VAC Inputs 185VAC Inputs

Flatpack 1500

For Flatpack 1500 sys­tems use the recom­mendations in the
205VAC table, if you
are sure the available
AC mains voltage will
not drop below
205VAC.

OR

If you are unsure ⎯ or
know that the voltage
may drop below
205VAC ⎯ use the
185VAC table recom­mendations.

Doc 2014385, v2

AC Mains No of Power Current Ext. Fuse

Type Shelves Max. (A) Type (Th/Mag)

1

19.5

25A-D

2

39.0

40A-C

230VAC

1-phase

3

58.5

63A-C

1*

9.8

25A-D

2 or 3

19.5

25A-D

230/400VAC

3-phase, TN network

(5 wire system)

4,5 or 6

39.0

40A-C

1*

16.9

25A-D

2 or 3

33.8

40A-C

4

51.6

63A-C

230VAC

3-phase, IT network

(4 wire system)

5 or 6

67.6

80A-C

For Flatpack 1800 sys­tems use the recom­mendations in the
205VAC table, if you
are sure the available
AC mains voltage will
not drop below
205VAC.

OR

If you are unsure ⎯ or
know that the voltage
may drop below
205VAC ⎯ use the
185VAC table recom­mendations.

Doc 2014386, v2

AC Mains No of Power Current Ext. Fuse

Type Shelves Max. (A) Type (Th/Mag)

1

21.7

25A-D

2

43.5

50A-C

230VAC

1-phase

3

65.2

80A-C

1*

10.9

25A-D

2 or 3

21.7

25A-D

230/400VAC

3-phase, TN network

(5 wire system)

4,5 or 6

43.5

50A-C

1*

18.8

25A-D

2 or 3

37.7

40A-C

4

57.5

63A-C

230VAC

3-phase, IT network
(4 wire system)

5 or 6

75.3

80A-C

205VAC Inputs 185VAC Inputs

Flatpack 1800

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

11

About AC, DC Earthing Systems

To prevent the risk of electric shock, all cabinet’s chassis are to be electrically connected to AC
Earth (PE). Also, it is a common practice for telecom equipment to have its common DC output
rail (+ or -) connected to a separate “Telecom Earth” (TE) or DC Earth.

Earth connections are in particular important where frequent lightning might induce high
voltage levels in AC supply and in battery and load cables.

AC Earth (PE) and DC Earth (TE) are usually connected to chassis via “Link 1” and “Link 2”.
Remove the links (“floating earth”) for compliance with other local earthing systems. Refer 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. Common Negative DC Output Rail is usual in 24V systems: Positive DC
Distribution.

Earthing

Miscellaneous

Cabinet

PE

A

C Mains

Common
DC Rail

EG

.

A

C Mains Input

(L1,L2,L3,N)

DC Load
Circuit

Link 2

(DC Earth)

Link 1
(AC Earth)

TE

Chassis

Chassis

PE (Protective Earth)
TE (Telecom Earth)
EG (Exchange Ground)

Common DC Rail —

DC Load

wires

+

+

+

+

Positive DC
Distribution

—

—

—

Negative DC
Distribution

Common DC Rail +

DC Load

wires

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

12

Battery Terminology

Refer to your system’s specific drawings for the exact connection points.

Symmetry measurement is a battery monitoring method of automatically detecting

unbalanced battery blocks. Symmetry monitoring of a battery string may be performed by
measuring each battery block (block measurement method), or by only measuring the mid­point of the battery string (mid-point measurement method).

The mid-point measurement method requires one symmetry cable per battery string, while the
block measurement method requires 3 symmetry cables per battery string.

Flatpack PRSB systems are delivered with the symmetry measurement method and the
number measurement points already preprogrammed in the MCU module. Any deviation from
factory settings requires Symmetry reconfiguration via PC and WinPower Silver.

Battery Symmetry Connections

The examples below show battery symmetry connections for 48V DC supply systems.

Battery Terminology

Battery Block, Battery String and Battery Bank

48V Battery Bank

Batter

y

String #1
(48V)

Batter

y

Block (12V)

Batter

y

String #2
(48V)

Battery Symmetry

Mid-point Measurement

One measurement per string

—

(-48V) Oute

r

Terminal

+

0V Oute

r

Terminal

Intercell Links

11

CON4

+

Front access
circuit card
100986

Symmetry
cable 1

Battery Symmetry

Block Measurement

Three measurements per string

—

(-48V) Oute

r

Terminal

+

0V Outer

Terminal

Intercell Links

CON4

+

Front access
circuit card
100986

+ +

11

12

13

Symmetry
cable 1

Symmetry

cable 3

Example of a 48V battery bank implemented
with two 48V battery strings; each string
consists of four 12V battery blocks.

Normally, battery banks are implemented
by connecting in parallel several battery

strings; each string is formed by battery
blocks connected in series.

Miscellaneous

Battery Monitoring

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

13

Fail-Safe Operation ⎯ Alarm Relays & Digital Inputs

The alarm outputs in Flatpack systems use the Fail­Safe 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)

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.

Terminals & Pin-out Location, Alarm Card 100350

DC power systems using the Alarm & Signal Interface Card ⎯ Art. 100350, basic version ⎯
have following alarm outputs and monitoring inputs available: 6 alarm relay outputs, 4 digital
inputs, 3 symmetry alarm inputs and 1 temperature sense input.

For detailed information about the card’s pin-out location and terminal block connections,
refer to the figure in this section.

Standard Relays & Digital Inputs

Correct Use of Digital Inputs (example)

Normal Mode

External Relay Y

(Energized coil)

+

—

Digital Input X
(Normal mode)

A

larm Mode

External Relay Y

(De-energized coil)

+

—

Digital Input X
(Activated)

Flatpack PS System

Correct Use of Alarm Outputs (example)

Flatpack PS System

—

+

NC

NO

Com

Normal Mode

Relay X

(Energized coil)

+

—

A

larm Mode

Relay X

(De-energized coil)

NC

NO

Com

The figure shows the position of the relay
contacts when the PS system is in its alarm
mode of operation. The relay coils are then
de-energized (fail-safe mode). The relay
outputs are preprogrammed from factory
(Factory Settings).

Terminals & Pin-out Location

Alarm & Signal Card, Art. 100350

CON2*

CON3*

CON2*

1 10

11 20

1 18

CON5

CON4

1

12

CON5

6

5

4

3

2

1

9

7

12

11

10

15

14

13

18

17

16

8

NC

NO

Com

NC

NO

Com

NC

NO

Com

NC

NO

Com

NC

NO

Com

NC

NO

Com

Relay 6

Common Alarm

Relay 5

Module Alarm

Relay 4

Fuse Alarm,

Load & Battery

Relay 3

Low Battery Alarm

Relay 2

High Battery Alarm

Relay 1

Mains Alarm

Alarm Relay Outputs

Voltage free (circuit card 100350)

A

larm Circuit 1

A

larm Circuit 2

A

larm Circuit 3

A

larm Circuit 4

A

larm Circuit 5

A

larm Circuit 6

FUNCTION SIGNAL PIN-OUT

1.

5

mm

2

, max. wire section

Symmetry Alarm 2

(digital input)

Symmetry Alarm 3

(

Not used)

+21V Auxiliary Supply

200mA (for external equipment)

6

5

4

3

2

CON4

1

+

9

8

7

12

11

10

15

14

13

18

17

16

20

19

—

screen

Monitoring Input Signals

Digital & Analogue Inputs (circuit card 100350)

Analogue

Inputs

Temperature Sense

(for internal battery bank)

+

—

(To Modem)

+

—

Symmetry Alarm 1

+

—

+

AGND

(From external Symmetry

A

larm circuit card, art. 26851)

Digital Input 4

+

AGND

Digital Input 3

+

AGND

Digital Input 2

+

+

AGND

(From external equipment)

**

FUNCTION SIGNAL PIN-OUT

(From area with

internal batteries)

Temperature

senso

r

(F

r

om

internal

batteries)

1.5 mm2, max.
wire section

* CON2 & CON3 are used for internal connections (connected from factory)
** For correct use of digital inputs, see the Fail-Safe Operation chapter

A

larms & Monitorin

g

Miscellaneous

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

14

Terminals & Pin-out Location, Alarm Card 101825

DC power systems using the front access Alarm & Signal Interface Card (Art. 101825) have
following alarm outputs and monitoring inputs available: 11 alarm relay outputs, 5 digital
inputs, 5 symmetry alarm inputs and 1 temperature sense input.

For detailed information about the card’s pin-out location and terminal block connections,
refer to the figure in this section.

Miscellaneous

Alarms & Monitoring

Terminals & Pin-out Location

Alarm & Signal Front Access Kit, Art. 101825

Circuit Card 100985

Internal System

Connections,

CON1

1

CON3

Customer Connections (front access, circuit card 100986)

1

1

2

10

1120

118

1936

CON4

CON5

The figure shows the position of the
relay contacts when the PS system
is in its alarm mode of operation.
The relay coils are then de­energized (fail-safe mode). The
relay outputs are preprogrammed
from factory (Factory Settings).

6

5

4

3

2

CON3

1

9

8

7

12

11

10

15

14

13

18

17

16

24

23

22

21

20

19

27

25

30

29

28

33

32

31

36

35

34

26

NO

Com

NC

Relay 7

(not programmed)

A

larm Circuit 11

Alarm Relay Outputs

Voltage free (Front access circuit card 100986)

FUNCTION SIGNAL PIN-OUT

+

—

screen

Temperature Sense

(for external battery bank)

(From area
with external
batteries)

Temperatu

r

e

senso

r

NO

Com

NC

NO

Com

NC

NO

Com

NC

NO

Com

NC

NO

Com

NC

A

larm Circuit 1

A

larm Circuit 2

A

larm Circuit 3

A

larm Circuit 4

A

larm Circuit 5

A

larm Circuit 6

Relay 6

Common Alarm

Relay 5

Module Alarm

Relay 4

Fuse Alarm,

Load & Battery

Relay 3

Low Battery Alarm

Relay 2

High Battery Alarm

Relay 1

Mains Alarm

NO

Com

NC

Relay 8

(not programmed)

NO

Com

NC

Relay 9

(not programmed)

NO

Com

NC

Relay 10

(not programmed)

NO

Com

NC

Relay 11

(not programmed)

NO

Com

NC

A

larm Circuit 10

A

larm Circuit 9

A

larm Circuit 8

A

larm Circuit 7

1.

5

mm

2

, max. wire section

2

CON5

1

+

—Auxiliary Supply

System output voltage

(for external equipment)

(To external
equipment)

1.5mm2, max.
wire section

FUNCTION SIGNAL PIN-OUT

Symmetry Alarm 5

(digital input)

(

Not used

)

6

5

4

3

2

CON4

1

+

9

8

7

12

11

10

15

14

13

18

17

16

20

19

—

Monitoring Input Signals

Digital & Analogue Inputs

(Front access circuit card 100986)

Analogue

Inputs

(To Modem)

+

Symmetry Alarm 1

+

+

AGND

(From external
Symmetry Alarm circuit
card, art. 26851

)

Digital Input 4

+

AGND

Digital Input 3

+

AGND

Digital Input 2

+

AGND

Digital Input 1

+

AGND

(From external equipment)

**

(From

external

batteries)

+21V Auxiliary Suppl

y

200mA (for external equipment)

(

Not used

)

+

+

Symmetry Alarm 2
Symmetry Alarm 3
Symmetry Alarm 4

Digital Input 5

+

AGND

1.5 mm2, max. wire section

* CON1 is used for internal connections (connected from factory)
** For correct use of digital inputs, see the Fail-Safe Operation chapter

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

15

Head Office

Eltek Energy AS

PO Box 2340 Strømsø; N-3003 Drammen; Norway

Tel:[phone] — Fax:[phone]
E-mail: [email protected]

Internet: www.eltekenergy.com

Copyright © Eltek Energy AS, Norway 2006

This document may be changed without notice

Doc. No. 356803.103, Issue 4, 2006 Oct

Published 2006-10-11

This product is CE marked and
complies with all current requirements
for relevant standards and directives.