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Installation Guide

Flatpack2 -48V 150A

~ 2029242 R2, May 2008

9

Anchor the Cabinet

If the system is delivered installed in a mounting rack, anchor the cabinet before
installing rectifiers and batteries. Refer to the accompanying system installation
guide for rack feet diagrams and floor loading concerns.

Equipment Rack “Frame Ground”

Connections  are  located  at  rear  of  the  rectifier  rack  with  chassis  studs
provided  in  the  AC  input  chamber.  Refer  to  the  NEC  and  any  local  codes
practices  to  determine  the  appropriate  wire  size.  Use  of  paint-penetrating
washers,  abrasive  compounds,  or  other  means  to  achieve  a  reliable  frame
ground is recommended.

Converter Shelf Installation

If

Flatpack

DC-DC converters are to be installed, refer to the manual

accompanying the converters for instructions on mounting and making system
connections.

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Summary of Contents for Flatpack2

Page 1: ...2029242 R2 Installation Guide Flatpack2 48V 150A DC Power Systems Flatpack2 Power System ...

Page 2: ...ocument 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 Valere Copyright 2008 Eltek Valere 1303 E Arapaho Rd Richardson TX 75081 USA Phone 1 469 330 9100 Fax 1 469 330 9101 Technical Support 1 866 240 6614 www eltekvalere com 2029242 R2 May 2008 Published 30 M...

Page 3: ...lectrical Installation 10 Individual Feed 11 Dual Feed 11 5 Module Installation 12 6 Distribution 13 LVD Options 14 Central Office Ground 14 Configurations 15 Two Battery Two Load 2B 2L 15 Two Battery Two Load 12 GMT 2B 2L GMT 16 Two Battery Four Load 2B 4L 16 Four Load 12 GMT 4L GMT 17 Six Load 6L 17 Breakers and Fuses 18 Plug in Breakers 18 Plug in Fuse Holders 18 GMT Fuses 20 Battery Connection...

Page 4: ...tion Guide Flatpack2 48V 150A 2029242 R2 May 2008 8 Controller Access 25 Controller Configurations 25 Smartpack Extended 25 Smartpack Web 25 Local Keypad Access 26 Local Computer Access 28 9 Startup Checklists 29 ...

Page 5: ...le for the compliance could void the user s authority to operate this equipment Protecting personnel against electrical shocks The power system cabling must be done by qualified personnel in conformance with local and national electrical codes Input voltages to rectifiers are at a dangerous level Ensure that circuit breakers are locked in the OFF position at the AC service panel before attempting ...

Page 6: ...ehr vorhanden ist Vergwissern Sie sich das alle Schalter an Ihrem Gereat und in der Vesorgung beim Anschluss abgeschaltet sind Unsachgemaesse Verdrahtung kann koerperliche Verletzung und an der Ausstattung Schaeden verursachen Vor Wartungsarbeiten am Gerät sind alle Netzkabel vom Stromnetz zu trennen um die Gefahr eines elektrischen Schlages oder andere mögliche Gefahren zu reduzieren ...

Page 7: ...ack2 HE rectifiers providing a total power output of 8kW Figure 1 Flatpack2 48V 150A System 2B 2L GMT shown About This Guide This manual provides a comprehensive overview of and installation guidelines for the Flatpack2 48V 150A power system Additional information regarding system components may be found in the following documents o 350002 013 User s Guide Flatpack2 Rectifiers o 350003 013 User s ...

Page 8: ...concrete flooring System Unpacking An individual Flatpack2 48V 150A unit is shipped in a box with protective packing material If pre installed in a cabinet or rack the assembly is wrapped with a shroud of high strength plastic and bolted to a wooden pallet with four anchors Rectifier modules and expansion options are packed in separate cartons Exercise care when unpacking and setting the equipment...

Page 9: ...Rack Frame Ground Connections are located at rear of the rectifier rack with chassis studs provided in the AC input chamber Refer to the NEC and any local codes practices to determine the appropriate wire size Use of paint penetrating washers abrasive compounds or other means to achieve a reliable frame ground is recommended Converter Shelf Installation If Flatpack DC DC converters are to be insta...

Page 10: ... 75 To wire the AC input terminal block 1 Remove the cover located at the rear of each rectifier shelf using a Phillips screwdriver two screws 2 Unscrew and remove the green AC connector using a Phillips or flat blade screwdriver 3 Use a small flat blade screwdriver to open each terminal and install AC wiring See the sections Individual Feed on page 11 and Dual Feed on page 11 for wiring details 4...

Page 11: ...Feed A dual feed shelf is fed by two 2 AC feeds each feed supplies two rectifiers and should have 30A breakers The figure below illustrates the 5 pin AC input connector Termination points for Line 1 Line 2 and Ground are listed in the table at right 10 AWG wire is recommended for each 30A circuit Figure 5 Dual Feed Connector Cover Removed Pin Description 1 Line 2 Rectifier 1 2 2 Line 2 Rectifier 3...

Page 12: ... If it is not pre installed make required connection to the back of the controller before installing see Section 7 To install modules 1 Release the handles by inserting a small flat blade screwdriver into the release slots and pressing the tip upward extend each handle 2 Slide the module firmly into the shelf 3 Latch the handles to lock the rectifier in place To remove modules 1 Release the handle...

Page 13: ...for load landings To make cable connections 1 Remove the two screws securing the cover using a Phillips screwdriver 2 Make careful note of the labels for each landing before making connections Do not connect batteries until system turn up 3 Make connections with a maximum 1 AWG cable with two hole lugs having 1 4 diameter holes on 5 8 centers 1 4 20 fastening hardware is provided 4 Torque connecti...

Page 14: ...nnect LVD contactor can be installed for either battery or load equipment The Configuration label in front of the return bus to the right of the RETURN label describes which of the three LVD configuration options the distribution section contains LVBD battery disconnect LVLD load disconnect or NO LVD Central Office Ground A dedicated central office CO grounding conductor connection is recommended ...

Page 15: ...s provided for batteries and load equipment The following are common configurations Two Battery Two Load 2B 2L The two leftmost breaker position sets are populated and the rightmost bus set is not installed in the 2B 2L configuration Figure 8 Recommended Return Bus Organization Battery Returns Load Returns CO Ground Battery A Battery B Load 1 Load 2 Returns Battery Load ...

Page 16: ... block in the rightmost section Two Battery Four Load 2B 4L The 2B 4L configuration populates all six plug in positions As usual the leftmost positions are dedicated to batteries the rest are for load output NOTE Battery breakers turn ON to the left load breakers turn ON to the right Figure 9 Connections to GMT Block Rear View Battery A Battery B Load 1 Load 2 Load 3 Load 4 Batteries Loads 1 2 Loa...

Page 17: ...turn ON to the right Four Load 12 GMT 4L GMT The 4L GMT configuration changes the two 100A battery breaker positions into 60A load positions by tying them to the internal load bus Two bulk unprotected battery landings are available in the rear of the system see Figure 10 The rightmost position is populated by a GMT fuse block Figure 10 Bulk Battery and Protected Load Landings Six Load 6L This conf...

Page 18: ...are connected to system alarming so that an open breaker whether tripped or manually placed in the OFF position triggers a Load Distribution Alarm in the Smartpack controller Breakers should be removed from any unused positions to prevent nuisance alarms Single pole circuit breakers rated up to 100A can be installed Each set of positions also accepts a two pole breaker rated up to 175A Plug in Fus...

Page 19: ...N to the left The other positions have LINE to the left and LOAD to the right the actuator turns ON to the right To install plug in breakers or fuse holders for BATTERY if used 1 Connect the battery alarm wire to the device s normally closed NC alarm pin 2 Orient the LINE and LOAD bullets to the correct bus The battery breaker set next to the Smartpack controller has LINE bus to the right and its ...

Page 20: ...ttery termination points When viewed from the rear the battery bus landings take up the one of the rightmost positions of the distribution section just to the left of the Smartpack alarm board A label reading BATT appears directly in front of the landings There are two possible configurations for battery connections With breaker positions or without breaker positions If breaker positions are utili...

Page 21: ...put in the Flatpack2 48V 150A system features a variety of configurations If configured for load output the system can have two four or six load busses The two parallel buses farthest to the left when viewed from the rear of the system can be substituted for a 12 position 65A GMT fuse block ...

Page 22: ...e end 3 8 2 Press the white terminal clamp above the desired wire location 3 Insert the alarm wire and release the terminal clamp The alarm connector is designed to accept a wire range of 26 AWG solid or stranded to 18 AWG The Form C contacts provided in the system have a rating of 1A at 60 VDC Please refer to the User s Guide Smartpack Monitoring Ctrl Unit for further details of alarm relay desig...

Page 23: ... and advanced battery discharge monitoring Temperature probes can be provided alone or integrated into the symmetry monitoring cables Rear access to the system controller is required in order to connect a single temperature probe Unlock the Smartpack controller using the same process used for the rectifiers see page 12 Feed the cable through the system as desired through the wiring ports The 15 pi...

Page 24: ...tions Symmetry capability is facilitated by a symmetry monitoring kit A battery connection board is mounted near the batteries using a bracket The serial port connector DE15 connects the board to either CON3 or CON4 on the rear of the Smartpack controller Up to two battery boards may be installed for each controller In this case temperature probes must connect to the battery connection board one p...

Page 25: ...ackup Advanced battery monitoring and full symmetry for 2 battery strings Recording of rectifier serial numbers and other information Load shedding control 6 digital inputs for site equipment alarms 6 user defined form C output contacts Smartpack Web Local user interface via a three button keypad on the front panel 2 line x 16 character high contrast backlit LCD display Digital communication with ...

Page 26: ...ocal user interface via a three button keypad on the front panel 2 line x 16 character high contrast backlit LCD display Digital Communication over CAN bus with each Flatpack2 rectifier Storage of setup parameters alarm configuration and system history in non volatile memory Real time clock with battery backup Advanced battery monitoring and protection Display Modes Status Mode displays the system...

Page 27: ...ing information o Battery Current o Load Current o Active alarms o Other messages NomVolt BoostVolt LoBattMaj Volt Adjustment LoBattMin HiBattMaj HiBattMin LVBD LVLD 1 1 Volt Calibration VoltCal Change Password Password Set Boost Time Start Stop Boost Auto Boost Conf Enable Disable Threshold Nxt Test Date Time Date Time End Volt Batt Test Setup MaxTestDur Test Int Guard Time Start Stop Test Of Rec...

Page 28: ... provided must be installed prior to Powersuite Example screen shots Interface with a PC requires a standard A B USB cable To make changes to the settings enter the Service Options menu Default password 0003 The Log In dialog box is displayed by selecting Access Login from the menu pressing the shortcut key F4 or using the Log In button on the toolbar For further info on controller operation and a...

Page 29: ...Verify AC input voltage is correct Measure and verify 3 Switch ON the external AC feeds 4 Verify all rectifier modules are working Green power LEDs are ON Verify 5 Verify The Smartpack is functioning Green power LED is ON Verify 6 Connect a PC to the PS system Install the PowerSuite software if required 7 Verify DC output voltage Measure and adjust as needed 8 Measure battery voltage confirm level...

Page 30: ...re com Headquarters Eltek Valere 1303 E Arapaho Rd Richardson TX 75081 USA Phone 1 469 330 9100 Fax 1 469 330 9101 Eltek Valere Gråterudv 8 Pb 2340 Strømsø 3003 Drammen Norway Phone 47 32 20 32 00 Fax 47 32 20 32 10 ...

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