2046916 R1 - Flatpack2 User Manual (300A-1200A)
Contents
1. W ELTEK VALERE alwayson Installat on Guide Flatpack2 Power Systems en Powe t Sys stem S ee Flatpack2 48V 24V 300A 1200A Systems 2046916 R1 Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek Valere 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 Valere Copyright 2008 Eltek Valere W ELTEK VALERE alwayson 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 2046916 R1 June 2008 Published 17 June 2008 2 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Table of Contents 1 Safety and ComplianCe ax rnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnennnnnnnnnnennnnennnnnr 5 FCC COMDPIANCE SLOME ee e Eea en ees 5 2 AEP OGUGCUION ne AEE Ea 7 TE ME 7 About This Revision 2 u eeeecceceseecceceeeeeceecesseneeecesenceeeeesnceeeesseneeeseseaneeesesnaceesesseneeeeerstacers 7 3 Standard SYSTEMS sere Dann aan een ER een 8 TN OR ee ee 8 Flatpack2 48V 600A and 24V 600A eaneesnnsnensnnsnnannnnnnnnnnnennnnsnennensnnannnnnnnnnennnnnnnnnennnnn 8 EE EE EO 9 4 Mechanical Instala eee 10 SETE NE 0800 1 EEE 10 TESS a EE In rer Eee een Ene2. Figure 2 Flatpack2 48V 300A Flatpack2 48V 600A and 24V 600A The 48V and 24V systems output a maximum of 32kW at 48V and 16kW at 24V There is a dedicated 19 alarm and control section with room for up to two Smartpack controllers and alarm cards These systems typically make use of the same 23 wide 4U high distribution unit This distribution features twenty four plug in breaker positions eight bulk battery landings an emergency power off EPO circuit and a service bypass switch Mil mm FLATPACK Power System 2 DIG Ss EDEN Figure 4 Flatpack2 24V 600A Figure 3 Here 48V 600A 3 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Flatpack2 24V 1200A This system outputs a maximum of 32kW It is designed for a 23 rack The 23 wide 6U high distribution unit features twenty four plug in breaker positions eight bulk battery landings room for up to two Smartpack controllers and alarm cards an emergency power off EPO circuit and a service bypass switch ed w VE AA NO ANT I Figure 5 Flatpack2 24V 1200A Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 9 4 Mechanical Installation A A USE OF FULLY INSULATED TOOLS IS REQUIRED WHEN WORKING WITH ANY POWERED AC OR DC CIRCUITS THE SYSTEM IS TO BE MOUNTED OVER A CONCRETE SURFACE ONLY AND INSTALLED IN RESTRICTED ACCESS LOCATIONS RAL ACCESS MUST BE LIMITED BY USE OF TOOL I E LOCK A
3. 2 Use rack screws to connect the system brackets to the desired positions of the rack Anchoring 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 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 1 1 5 Electrical Installation Flatpack2 rectifiers have an operating input voltage range of 85 to 300 VAC rated for 100 250 VAC with a frequency range between 45 and 66 Hz See the User s Guide Flatpack2 Rectifier Modules 350002 013 for further details The AC junction box of each rectifier shelf contains a knockout hole for a standard trade size conduit with a diameter of 0 75 To wire the AC input terminal block CAUTION VERIFY THAT ALL AC CIRCUIT BREAKERS FEEDING THE SYSTEM ARE IN THE O
4. Secondary load breakers LVLD The 1200A system Is very similar except that the top bus Is unused Unused Secondary load breakers Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 1 18 Converter Bus Configuration The top bus can be used to distribute converter output Converters are Is typically fed directly from the main bus on the same side of the LVBD contactor as other loads this arrangement makes converters act as load to the native power of the DC system Thus the converter bus may continue powering dependent devices during an AC supply failure Converter Converter Distribution LVLD gt m Secondary load breakers YA Critical load breakers t DK Rectifier Battery Bus Configurations for Secondary Distributions A second distribution unit can be added atop 23 distributions to double the number of distribution positions from 24 to 48 The configuration of the second distribution panel typically mirrors the primary panel s configuration unless indicated otherwise Always verify the exact configuration prior to landing any connections The following examples illustrate standard configurations and a common variation Standard Secondary Bus Configuration The standard bus configuration for the 600A system uses the bottom bus for critical load termination points in both distribution panels Each of the individual bus bars are rated at 600A ye
5. 4 Make a note for each position on the label provided on the distribution door 2 2 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Load Return Landings Load Output Landings Distribution Device Holders Figure 14 Configurable Protected Load Connections Plug in Breakers Auxiliary contact circuit breakers are the standard over current protection devices used in the distribution section Breakers are connected to system alarming through the holder 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 Straps are available to make use of two pole breakers rated up to 175A and three pole breakers rated up to 250A Plug in Fuse Holders Plug in fuse modules may also be installed The same considerations regarding insertion and removal of breakers should be observed A plug in fuse assembly consists of three main parts A fuse an alarm fuse indicator and a plug in module If the main fuse element opens the alarming fuse also opens giving a visible indication of a fault condition a signal is then sent via the Smartpack alarm board that activates the remote system monitor The alarming fuse must be replaced whenever a new main fuse IS required A fuse holder may be r
6. In dialog box Is displayed by selecting Access gt Login from the menu pressing the shortcut key F4 or using the Log In button on the toolbar Security Please enter the password to login For further info on controller operation and adjustment refer to the User s Guide Smartpack SS Monitoring amp Ctrl Unit Es 3 6 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 10 Startup Checklists This section includes basic checklists to assist the user in verifying proper installation and starting system operation Pre Start Check Power is OFF CHECK THE FOLLOWING POINTS OK 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 Breakers fuses are disconnected oO 3 AC input cable s and AC earth wire Ground are terminated 4 Site specific parameters and settings are known oO 5 AC supply and all Breakers fuses are switched OFF oO Start up No Load amp Load Adjustments Power is ON CARRY OUT FOLLOWING OK om JE Ewes sem EG 4 Verify all rectifier modules are working Green power LEDs are ON Verify m OOOO 0 7 Verify DC output voltage Measure and adjust as needed 8 Measure battery voltage confirm level and close disconnect if present Verify correct polarity 9 Verify System Setup is in accordance with desired configuration Enter site sp
7. can be shut down to increase available backup time Each bus bar is rated at 600A for a total distribution capacity of 2400A The top bus of the primary bottom distribution panel is configured to accept battery input the corresponding bus in the secondary panel is unused Load output for the secondary distribution is configured identically to the main section Secondary load breakers Critical load breakers Battery breakers The 1200A system is similar to the 600A except for the top bus of the primary distribution section Batteries can only connect through the rear bulk terminal points Unused Bus Secondary load breakers Critical load breakers Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Breaker and Fuse Installation CAUTION SIGNIFICANT EXTRACTION FORCE IS REQUIRED TO REMOVE DISTRIBUTION AN DEVICES DUE TO THE CONTACT PRESSURE REQUIRED FOR HIGHLY RELIABLE LOW TEMPERATURE RISE CONNECTIONS AN USE INSULATED TOOLS ESPECIALLY WHEN WORKING ON LIVE SYSTEMS NOTE Do not use any type of clamps pliers or similar tools to remove over current protection devices as the housing can be cracked by excessive force Damaged devices represent an operational hazard and should never be used Flatpack2 three bus distributions feature a moveable distribution device holder that accepts a breaker or fuse holder with 5 10 plug in bullets It is designed to align the device to one of the three buses by screw
8. to loosen the bottom bullet receptacle of the holder See Figure 11 4 Select the appropriate bus based on system configuration Buses are numbered 1 to 3 from top to bottom and are labeled by function on the right and left walls e g Primary Battery etc See the sections on bus configurations beginning on page 16 for details Hook the device holder into the position that lines up with the bus selected in the above step The holder s hooks Figure 11 correspond to each bus NOTE Holders set to higher buses sit higher than those at lower buses See Figure 10 on page 15 6 Lower the holder into position against the bus 7 Screw the receptacle into the bus using an insulated 7 16 or 11 mm nut driver Torque between 20 25 in lbs TEE a EG gt elie ce amp 4 ce KEREI RET HA m sd EEE ae tm A EE ss mb CC EI 0 2 040 M name En eee G ti ds ma A PA lag 9 Figure 12 Distribution Device Holder Installation To make load connections 1 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 Do not connect batteries until system turn up 2 Torque connections to 51 58 in Ibs 3 Land each return lug to the corresponding position on the return bus directly behind the load buses Return landings are closer together than the output landings and are offset to the right
9. 6916 R1 June 2008 5 dass die Cirquite Breaker in der aus position sind Benutzen Sie ein Spannungsmesser um sicher zu sein das keine Netzspannung mehr 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 Ger t s nd alle Netzkabel vom Stromnetz zu trennen um die Gefahr eines elektrischen Schlages oder andere m gliche Gefahren zu reduzieren 6 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 2 Introduction The Flatpack2 power system consists of 19 rectifier shelves one or more Smartpack controllers and a distribution section It can be mounted in a standard 19 or 23 telecommunications equipment rack Systems are available in 48VDC and 24VDC versions with maximum outputs of 8kW to 32kW Distribution Section Controller Expansion Slot J 1 ON INNS NSNSNS NNN NNN Smartpack f p f f N V aT 4 f f i El g i Controller ae i pY r Sg i T PT FP Ae RF la Dp De I A ahaha I fi EEE ii F f f A f f 4 4 4 f 4 4 r A y A r 4 4 ree WU UYVU WU WU a a g kr Ar bred Alarm Connections Flatpack2 Power Shelves hide ln ae Figure 1 Flatpack2 24V 600A System About This Guide This manu
10. AU distribution does not contain alarm boards rather a 1U alarm and controller section installed between the distribution and power shelves houses up to two front access boards depending on the number of Smartpack controllers used just to the left of the controller slots The 23 6U distribution contains front access boards just to the left of the integrated controller slots The alarm interface board provides an equal number of configurable input alarms and form C output relays The Smartpack Extended version has six input alarms and six output relays the Smartpack Web has two inputs and outputs 2 ACMainAlarm High Voltage Alarm Low Voltage Alarm 6 Rectifier Fail Alarm Closure to Alarm put 2B e Common Open to Alarm MOI Conf in To install an alarm wire to the board 1 Strip the alarm wire end 3 8 2 Press the white terminal clamp above the desired wire location 3 Insert the alarm wire and release the terminal clamp Alarm terminals are 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 amp Ctrl Unit for further details of alarm relay designations and assignment procedures Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 2 9 Configurable Inputs The configurable alarm inputs of the Smartpack alarm board ca
11. Device _ Open the handles before inserting modules into shelves Flatpack2 rectifiers incorporate an AC mains fuse In each line Double Pole Neutral Fusing M Both the Smartpack controller and the Flatpack2 rectifier utilize the same locking mechanism to keep the module fixed in place when installed into a system shelf Typically the Smartpack controller is delivered installed in the system If it is not pre installed make required connection to the back of the controller before installing see Section 8 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 Handle Release To remove modules 1 Release the handles by inserting a small flat blade screwdriver into the release slots and pressing up 2 Use the handles to pull the module out just far enough to where the body can be held 3 Slide the module out the rest of the way Do not carry it by the handles Flatpack2 rectifiers weigh just over 4 lbs 1 9 kg each 1 4 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 7 Distribution Flatpack2 system distributions range in size from 19 to 23 in width and AU to 6U in height Although each distribution design is intended for a specific system configuration distributions have inherent flexibili
12. FF POSITION KEEP ALL AC BREAKERS OFF UNTIL ALL APPROPRIATE SYSTEM CONNECTIONS HAVE BEEN MADE AND VERIFIED REFER TO SECTION 9 FOR STARTUP CHECKLISTS WARNING FoR SAFETY REASONS HIGH LEAKAGE CURRENT AND HIGH TOUCH CURRENT ALWAYS CONNECT THE AC EARTH WIRE PE TO THE TERMINALS BEFORE CONNECTING AC INPUT CABLE S 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 either a Phillips or flat blade screwdriver 3 Use a small flat blade screwdriver to er open each terminal and install AC Mana wiring See the sections Individual Ru Feed on page 13 and Dual Feed on Al lin page 13 for wiring details p S iaia 4 Pull a green safety wire in the AC mains conduit and terminate it to Figure 6 AC Input Cover the ground terminal of the connector It should be longer in length than the black and white AC wires 5 Double check that each connection is secure and replace the connector 6 If necessary terminate additional safety wires to the shelf ground termination stud located to the right of the connector see Figure 8 and Figure 9 7 Replace the cover after AC terminations are complete Make sure to line up the bottom plate between the guides on the bottom of the shelf Figure 7 AC Terminal Block 1 2 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Indivi
13. ND KEY The following tools are required for the installation O O O Standard wrench and or socket set 1 4 to 1 Torque wrench 10 40 Ft lb range Torque screwdriver 5 10 in lb range Small flat blade screwdriver 3 32 wide Standard blade screwdriver and Phillips tip screwdriver Wire cutters strippers Fork lift truck or similar heavy equipment handling transport Hoist with lifting straps Electric drill and appropriate bits a hammer drill may be required for concrete flooring System Unpacking An individual Flatpack2 unit is typically pre installed in a cabinet or rack 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 in place Rack Mounting Flatpack2 systems can be installed in a rack or an enclosure The mounting brackets are pre installed at the factory and designed to be mounted within a standard EIA 19 or 23 rack depending on the width of the distribution box Systems are designed to be mid mounted Other mounting configurations may require additional support brackets Rack Installation 1 Use proper lifting equipment to position the Flatpack2 system so that the holes in the support bracket are aligned with the correct mounting holes in the rack 1 O Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008
14. Rete 10 ROCK AS eel Vee IO ee ee en Re 10 PMWM MN INS ANN EE een 11 Equipment Rack Frame Ground nee 11 Converter Shelf He alla One 11 5 Electrical INS AWE Ol ncesannsewesanccsesmacevauseneeserseowsccscuazacansnasenaneeasccene 12 fy 6 175100 19 Fee ee ee 13 DUIE T EEE ee 13 6 Module Installation asernnnnnnnonnnnnnnnnnnnnennnnennnnnnnnennnnennnnnnnnennnnennnne 14 PET DUNN xe ae ae meer een 15 ACEBO DIE FH DEE OM Se ee 15 BES eo ee ee 15 Bus Configurations for Single Distributions uucuusursunnennennnnnnennennennennennonennennennnnnnn 16 Bus Configurations for Secondary Distributions uneesessnsenesnesnesensennennennennennenennennn 18 Breaker and Fuse se ON een 21 PUB IN BES OS ee 23 PIUS USE OL CTS nennen 23 Device Installation and Extraction sornennonnrennrnnvennvennvennvennvrnnennvennvennrsnnennvennvenvennnennnenne 24 BUK DIS NN 24 Bulk Battery CONNEL LION et ea ee ee 24 Fh ALOE SL IM VG OE een een 27 Other Features and ODUONS een ei een 27 DISTNOULON COVER re ea 27 Emergency Power Off EPO and Service Bypass Switch rrnnrnnrnnvnnvnnvnnvrnvrnververnennenn 28 LYD ODON JE er 28 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 3 8 Alarm and Control Terminations aravannnvavavannnnnvannvnnnnnavavnvnnnnvaneve 29 AE da CORE IC ee ee 29 CF ONEIgUrODIEINPURS zei inter neers meant ete 30 Temperature Probe Terminations ccscsscsssssessscsessessessesseessesseeseesee
15. al provides a comprehensive overview of and installation guidelines for Flatpack2 power systems with 300A to 1200A DC output Additional information regarding system components is found in the following documents o 350002 013 User s Guide Flatpack2 Rectifiers o 350003 013 User s Guide Smartpack Monitoring amp Control Unit Information for the Flatpack2 48V 150A system and distribution configurations is contained in the following document o 2029242 Installation Guide Flatpack2 150A DC System About This Revision 2 A new document format was adopted for this revision to reflect the transition to the Eltek Valere brand In addition information from individual Flatpack2 system manuals was incorporated into this manual Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 3 Standard Systems Standard Flatpack2 systems are defined by voltage and output current Asa general guideline each larger system outputs about two times the current of the preceding system The smallest system Flatpack2 48V 150A is discussed in detail in another manual 2029242 because of Its unique and highly configurable 1U distribution section Flatpack2 48V 300A This system outputs a maximum of 14kW It is designed for a 19 rack There is room for a single Smartpack controller and up to seven Flatpack2 rectifiers The typical 19 distribution unit features twenty plug in breaker positions and four bulk battery landings
16. cts Smartpack with Controller Blank SmMARTPACK Because the 600A and 1200A Flatpack2 systems can accommodate up to two Smartpack controllers a blank faceplate may be installed if the expansion slot is not populated Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 3 3 Local Keypad Access The Smartpack controller is typically pre configured at the factory according to customer requirements If operational adjustments are required refer to the PowerSuite Help menu or Smartpack manual for further details The Smartpack digital controller is located in the distribution section and provides system control and monitoring functions Features include e Local user interface via a three button keypad on the front panel e 2line x 16 character high contrast backlit LCD display e Digital Communication over CAN bus with each Flatpack2 rectifier e Storage of setup parameters alarm configuration and system history in non volatile memory e Realtime clock with battery backup e Advanced battery monitoring and protection SMARTPACK Display Modes Status Mode displays the system s status or Menu Mode displays the menu structure Operation Press the 4 key to change from Status Mode to Menu Mode Press thel I orl I keys to scroll up or down and navigate to find menu options Function or parameter Press the key to select functions Graphical Display Alarm 16 character x 2 lines LCD dis
17. dual Feed An individual feed shelf is fed by four 4 AC feeds each feed supplies one rectifier Systems operating at 48VDC and should have 15A breakers on each AC feed 24VDC systems should have 20A breakers on each AC fat a AWG wire Is recommended but Pin Description up to 10 AWG may be used for each feed termination position The figure below illustrates 2 LineZ Rectifier1 the 9 pin AC input connector Termination points for Line 1 Line 2 and Ground are listed in the table 4 Line 2 Rectifier 2 at right 6 Line 2 Rectifier3 8 line2 Rectifiera o feron e d 2 e ms g Figure 8 Individual Feed Connector Cover Removed Dual Feed A dual feed shelf is fed by two 2 AC feeds each feed supplies two rectifiers Systems operating at 48VDC and should have 30A breakers on each AC feed with 10 AWG wire 24VDC systems should have 40A breakers on each AC feed with 8 AWG wire 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 in Description a Line 2 Rectifier 1 amp 2 2 Line 2 Rectifier 3 amp 4 Line 1 Rectifier 1 amp 2 Ft _ Line 1 Rectifier 3 amp 4 Figure 9 Dual Feed Connector Cover Removed Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 1 3 6 Module Installation CAUTION AN Do not carry modules by the handles even if they are warm
18. ead only To make changes to the settings enter the Service Options menu and enter the password Default password 0003 When the front keys are not in operation the display Is in Status Mode The upper line continuously displays the battery voltage The lower line scrolls the following Information o Battery Current o Load Current o Active alarms o Other messages 35 Local Computer Access PowerSuite software must be installed on the PC to be used before connecting to the Smartpack controller Do not connect USB prior to installation process In most cases FrameNet also provided must be installed prior to Powersuite Z Eikhaugen Eltek PowerSuite Access Tools Windows View Help el m configuration EventLog Alarm su mmary 23 240 En Battery Voltage 57 52 vorne Power System amp Refresh S Cancel AY Apply Close eneral Security Summary Company Eltek Site Eikhaugen Model SmartPack Controler Date time Serial 123456789 Message 1 Module 3 has been changed Message 2 Battery test OK Vi 04 11 2005 16 19 5 VS Interface with a PC requires a standard A B USB cable To make changes to the settings enter the Service Options menu Default password lt 0003 gt The Log
19. ec info in PowerSuite 11 Verify the rectifiers output current and load function 12 Verify System Alarm Setup is in accordance with desired configuration Configure alarm mapping in PowerSuite 13 Use PowerSuite to simulate Alarm Relay conditions Verify all alarm relays are working correctly 10 Connect all load Breakers fuses and verify no alarms are displayed m 14 This completes the basic system start up and configuration Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 3 W ELTEK VALERE alwayson www eltekvalere com Headquarters Eltek Valere Eltek Valere 1303 E Arapaho Rd Richardson TX 75081 USA Gr terudv 8 Pb 2340 Stramsg 3003 Drammen Norway Phone 1 469 330 9100 Fax 1 469 330 9101 Phone 47 32 20 32 00 Fax 47 32 20 32 10
20. emoved and inserted into the plug in module at any time it is not necessary to remove the plug in module to replace the fuse 0 305 Dia Bullet Terminal SF Alarm pin 0 02 x 0 11 a Biown Fuse Indicator Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 23 Device Installation and Extraction To install plug in breakers or fuse holders in device holder 1 Remove fuses and turn breaker actuators OFF until system turn up 2 Orient the device correctly to the device holder line is the bottom receptacle load is the top securely insert device into the receptacles A distribution device extraction tool is installed on the distribution door It is shaped like a handle and has two Phillips head screws This item is provided for convenience and should not be necessary for all extractions To remove plug in breakers or fuse holders 1 Align the extraction tool to the device to be removed 2 Use a Phillips screwdriver to secure the device 3 Firmly pull the device out from the holder Avoid using excessive force or motion to extract an over current protection device Bulk Distributions CAUTION IT IS STRONGLY RECOMMENDED THAT EXTERNAL BREAKERS OR FUSES BE INSTALLED BETWEEN BULK SYSTEM TERMINALS AND EQUIPMENT AND OR BATTERIES A bulk distribution unit Is usually a 23 section that features large front access copper buses Each polarity has two landings that accept up to 535MCM cable wi
21. ilding a total distribution capacity of 1200A The critical buses are fed through the low voltage battery disconnect contactor The LVBD contactor disconnects the battery from the system when it reaches a user defined setpoint during discharge The top bus of the bottom distribution section is configured to accept battery input the top bus of the secondary distribution panel is not used Load output for the secondary distribution panel is configured identically to the primary distribution panel Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Critical load breakers Battery breakers Critical load breakers Rectifier The 1200A system uses both the bottom bus and middle bus of each distribution section for critical load termination points yielding a total distribution capacity of 2400A The top buses are unused Batteries may only connect to the rear bulk termination points Critical load breakers i Critical load breakers Battery Rectifier Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 1 9 Load shedding with Secondary Distribution The load shedding bus configuration for the 600A system with secondary distribution uses the bottom buses for critical loads that need the longest available backup time Both critical buses are fed through the LVBD contactor The middle busses are fed through an LVLD contactor and used for peripheral or redundant loads that
22. ing the bottom bullet receptacle directly into the desired bus A single cable landing on top accepts up to 1 AWG cable with a two hole 1 4 lug on 5 8 centers The holder also connects the distribution device to the system alarm circuit a Cable Landing Top Bullet Receptacle Alarm Contact Bottom Bullet Receptacle Hooks for Bus 3 Hooks for Bus 2 Hooks for Bus 1 Bus Screw tand Figure 11 Distribution Device Holder il NOTE The distribution device holders must be installed in the desired bus before plugging over current protection devices Into the holders NOTE Breakers and other over current protection devices must be modified in order to alarm correctly If using breakers other than those provided by Eltek Valere contact technical support for more Information about the modifications necessary for using the breaker fuse alarming of the three bus distribution Distribution device holders are pre installed to Bus 3 the lowest bus at the factory To properly access and reassign the distribution device holders refer to Figure 11 and Figure 12 when following these instructions 1 Open the distribution cover using the two thumbscrews Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 2 1 2 Use a Phillips screwdriver to remove the two screws on the front that hold the Lexan cover at the top of the distribution box 3 Toremove a device holder use an insulated 7 16 or 11 mm nut driver
23. irectly at the battery post s Ron The best termination point may vary depending on the type of battery kLoekWasher Used The probe itself is not polarity Flat Washer Sensitive so it can be installed at SensingLug either a or battery post The voltageortemp hardware configuration at left is Power Cable Lugor fecommended This allows the probe _ Inter module Strap tO monitor the temperature accurately without interfering with Battery Post the current carrying terminations on the battery 3 O Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 NOTE IF USING EXTERNAL BATTERY CONNECTIONS BOARDS SUCH AS THOSE PROVIDED WITH A SYMMETRY MONITORING KIT DO NOT CONNECT MORE THAN ONE TEMPERATURE PROBE TO EACH OF THE BOARDS CONNECT A SINGLE PROBE EITHER TO THE 15 PIN SERIAL PORT CON6 CON7 or TO THE SENSE INPUTS TO TERMINALS 9 AND LO OF THE TERMINAL BLOCK Symmetry Terminations 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 per board Battery symmetry harness connections will vary depending on the desired configuration Refer to the symmetry kit manua
24. l 251491 033 for more details and installation instructions Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 3 1 9 Controller Access Controller Configurations The Flatpack2 power system can be delivered in several configurations The following examples are basic configurations The 300A power systems use a single Smartpack controller the 600A and 1200A systems permit the use of a master slave configuration for up to two controllers 32 Smartpack Extended SMARTPACK 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 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 full symmetry for 2 battery strings Recording of rectifier serial numbers and other information Load shedding control 6 digital inputsfor site equipment alarms 6 user definedform C output contacts Smartpack Extended with Slave SMARTPACK 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 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 fullsymmetry for 4 bat
25. n be used to connect external site alarms or input devices such as door sensors fire alarms and generator activation alarms Each relay circuit can be set to normally closed or normally open This can be selected through either the menu or the PowerSuite interface Some inputs can be used by auxiliary system components like external or tray mounted battery disconnects and DC DC converter alarms Use solid or stranded wire of size 28 16 AWG Temperature Probe Terminations put 2B Re O Relay 1 CTA Relay 2 OTA gt Relay 2 COM Relay 2 CTA inpu inpu miConf inpu ZIConf inpu 1 i Mia ele aia Qa a cc Gi G 00 OO ay 1 COM OlConf input 2A OlConf in gt The standard Smartpack controller is capable of temperature compensated battery charging symmetry monitoring and advanced battery discharge monitoring Temperature probes can be connected directly to the controller or integrated into 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 14 Feed the cable through the system as desired through the wiring ports The 15 pin serial connector DE15 of the N3 CO temperature probe connects to either CON3 OL JOD Q or CON4 on the rear of the Smartpack F controller SD sg The probe end is designed to be installed d
26. o determine which hardware on the return bus fastens it to the internal system return bus take care not to disconnect the return bus To make connections to battery landings 1 After successful system turn up remove the four screws holding the rear cover in place 2 Make connections using two hole 3 8 16 lugs on 1 centers Fastening hardware is provided 3 Torque connections from 15 to 23 ft lbs Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 2 5 Do NOT Remove HHHH TE HEHHEHE Figure 16 Bulk Battery Landings 23 4U Distribution Battery Returns Do NOT Remove Battery Hot 2 CO Ground Figure 17 Bulk Battery Landings 23 6U Distribution 2 6 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Central Office Ground A dedicated central office CO grounding conductor connection is recommended This conductor should be of the same or larger gauge than the largest system conductor so that It can discharge total system current in a fault condition A THHN style cable is recommended Install this cable between the DC system point and the critical site ground bar See the figures on page 26 for the recommended organization of return connections Other Features and Options Distribution Covers Internal Cover There are two protective covers supplied with the power system The lower internal cover is positioned just behind the primary return bus bar and s in
27. oad termination point During battery discharge the critical bus is fed from battery input through the low voltage battery disconnect LVBD contactor The contactor is designed to disconnect the battery from the system when it reaches a user defined setpoint during discharge The top bus is configured to accept battery input Both the top bus and the rear bulk battery terminals are connected to the LVBD Battery breakers Critical load breakers u 1 6 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 io The 1200A system has a different configuration since each bus is rated at 600A therefore rectifier output must be divided between at least two buses The top bus is unused in this configuration Unused Bus Critical load breakers Critical load breakers LVBD RE gj t WAR gt Rectifier Battery Load Shedding Bus Configuration The load shedding bus configuration is connected as shown The bottom bus is used for critical load termination points The critical bus is intended for loads that need to have power for the longest available backup time The critical bus is fed from the batteries through the low voltage battery disconnect contactor The secondary bus powers peripheral or redundant loads that can be shut down to increase available backup time The secondary bus is fed through a low voltage load disconnect contactor The top bus is configured to accept battery input Battery breakers
28. play LED Lamp red i per line z rn Warning utput voltage or lm oo Prac LED Lamp yellow menu options ee 1 E Piy Cutualt 1 54 1500 BH Power Lower line BattCunp 00587A f LED Lamp green Battery or load current alarms or keys to press 4 Down arrow key T Up arrow key CAN port 2 4 Enter key Battery Connections Alarm K0 Connections Rear View Battery Connections Alarm 0 Connections system Connections 3 4 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Adjustment Menu Example NomVolt Jt J Boostvot V J todattmaj UV Volt Adjustment gt LoBattMin JT HiBattMaj UT HiBattMin 1 gt fivBD 4 gt S Change Password gt Password JT Set Boost Time gt HE Start Stop Boost gt 0000000 Enable Disable JT amp Auto Boost Conf gt Threshold Nxt Test Date Time Date LT Time JT Pend ott YP Test Int JT Guard Timel Start Stop Test gt Enable Disable JT amp Max Charge Curr Lim gt C Curr LT Battery Setup gt NumofString LT Cellcap A nT Output Control gt Voltage Ctrl u Comp Change Date Time gt Date JT Time LT fAlamOutputl gt BattContactorl gt pf toad Contactor TO Alarm Output 7 gt Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Menus When entering Menu Mode Level 1 access User Options By default it is set to r
29. sly approved by the party responsible 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 to work on the power system Dangerous voltages may still be present at the terminals even if the rectifiers are OFF Use a voltmeter to verify the presence of such voltages Do not Switch circuit breakers to ON until the entire system has been assembled and you have been instructed to do so according to the appropriate procedure Improper wiring can cause bodily harm and equipment damage Turn off all power sources before servicing units WARNUNG Schuetzen von Personal gegen elektrische Schocks Die Spannungsversorgungs Leitungen darf nur durch qualifiziertes Personal in Anpassung mit Oertlichen und nationalen elektrischen Codes ausgefuehrt werden Unsachgemaesse Verdrahtung kann koerperliche Verletzung und Schaeden verursachen Eingangsspannungen von der Netzspannungs Versorgung Ihrer Hausanlage koennen unter Spannung stehen beim Anschluss derLeitungen Vesorgungsspannungen koennen bei unsachgemaessen Gebrauch gefeahrliche Schaeden verursachen Sorgen Sie daf r Installation Guide Flatpack2 Power Systems 204
30. sseeseessesseeeaess 30 SMET TE MINE NON een ee 31 FEMTE ACCESS eee 32 FE PN 32 SMALLDACK EXTENdEU EE 32 Smartpack Extended with Slave ea 32 MANN 33 SMAA NET 33 SMarLDack VIN EO OLE BEAN 33 Local ICY PA ER 34 Local Computer NES 36 10 Startup Checklists csicssansennnanennane nennen 37 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 1 Safety and Compliance WARNING For safety the power supply Is required to be reliably connected to PROTECTIVE GROUND The equipment is to be connected to supply mains by qualified personnel in accordance with local and national codes e g NEC CEC etc Do not disconnect and reconnect I O power connectors during lightning storms The output of the power supply is not intended to be accessible due to energy hazards Rack mounting must be performed in accordance with instructions provided by the manufacturer to avoid potential hazards A readily accessible disconnect device shall be incorporated in the building installation wiring for all AC connections Select wall breakers according to section AC input requirements page 13 FCC Compliance Statement This device complies with Part 15 of FCC Rules Operation Is subject to the following two conditions 1 This device may not cause harmful interference and 2 This device must accept any interference received including interference that may cause undesired operation WARNING Changes or modifications to this unit not expres
31. tended to protect the internal bus structure amp contactors This cover can be removed by loosening the four screws securing It in position with two on either side Permanent removal of this cover is not recommended and may impact the safety ratings of the device Top Cover The second cover IS positioned above the main distribution section and is intended to protect the DC load termination points The cover should be removed during the installation of load wiring Once wiring is complete it is recommended to replace the cover during long term use This cover is removed by opening the front door of the system and loosening the two screws securing the cover one on either side Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 2 Emergency Power Off EPO and Service Bypass Switch The emergency power off circuit and service bypass switch are situated on a front access circuit board inside the 23 distribution units In the 23 AU distribution the board is located on the far left in the 23 6U the board is near the center of the distribution unit just to the left of the controller slots EPO and service bypass are not available in 19 distributions The emergency power off circuit is a normally closed circuit that stops system operation when opened This feature is useful for fires or other emergencies requiring the immediate shut off of a power system A jumper wire Is provided to keep
32. tery strings Recording of rectifier serial numbers and other information Load shedding control 12 digital inputsfor site equipment alarms 12 user definedform C output contacts Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Smartpack Web SmMARTPACK r USR Local user interface via a three bu 2 line x 16 character high contrast backlit LCD display Digital communication with each Flatpack2 rectifier TCP IP or SNMP user interface Storage of setup parameters alarm configuration and system history in non volatile memory Real time clock with battery backup Advanced battery monitoring and full symmetry for 2 battery strings Recording of rectifier serial numbers and other information Load shedding control 2 digital inputs for site equipment alarms 2 user defined form C output contacts Smartpack Web with Slave SmMARTPACK 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 each Flatpack2 rectifier TCP IP or SNMP user interface Storage of setup parameters alarm configuration and system history in non volatile memory Real time clock with battery backup Advanced battery monitoring and full symmetry for 4 battery strings Recording of rectifier serial numbers and other information Load shedding control 8 digital inputs for site equipment alarms 8 user definedform C output conta
33. th two hole 3 8 lugs on 1 centers The recommended torque range is 15 to 23 ft lbs When facing the front of the system the bulk hot output is the left bus the bulk return is the right bus The rear bulk battery terminal specifications are identical to those of the three bus distributions See the discussion of bulk battery connections on page 21 for details Bulk Battery Connections AN CAUTION Do NOT CONNECT BATTERIES UNTIL SYSTEM TURN UP FOLLOW THE CHECKLIST PROVIDED FOR THE PROPER PROCEDURE CAUTION T IS STRONGLY RECOMMENDED THAT EXTERNAL BREAKERS OR FUSES BE AN INSTALLED BETWEEN BULK SYSTEM TERMINALS AND BATTERIES NOTE UNFASTENING THE HARDWARE MARKED Do NOT REMOVE IN THE FIGURES WILL DISCONNECT THE RETURN BUS FROM THE INTERNAL SYSTEM BUS WORK 2 4 Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 Flatpack2 distributions feature multiple battery termination points at the rear Landings accept two hole 3 8 16 lugs on 1 centers Each distribution unit has different specifications for cable landings as follows o 19 AU Four landings per polarity maximum wire size of 250 MCM o 23 AU Eight landings per polarity maximum wire size of 250 MCM o 23 6U Eight landings per polarity maximum wire size of 750 MCM Bulk battery return buses contain an extra landing as a central office CO ground see the section on CO Ground on page 25 Carefully examine the figures on page 26 t
34. the circuit closed If desired an external emergency device such as a switch or lever may be wired to this connection val FF Fu TT x iA ves 1G 7 x x wS Figure 19 EPO and Service Bypass Switch in 23 6U Distribution The service bypass switch forces the LVD contactor to remain closed preventing service disruption during maintenance In the Normal position DOWN in the 23 AU UP in the 23 6U the contactor operates according to the settings defined in the Smartpack controller To activate the bypass change the switch to Bypass UP in the 23 4U DOWN in the 23 6U this forces the LVD contactor to close and prevents controller signals from opening it A label is provided on the inside of the distribution door to illustrate proper switch operation Additionally the LED on the board illuminates Figure 18 EPO and Service when the bypass Is active Switch in 23 6U Distribution LVD Options Up to two low voltage disconnect LVD contactors can be installed Contactor settings are configured through the Smartpack controller Installation Guide Flatpack2 Power Systems 2046916 R1 June 2008 8 Alarm and Control Terminations Alarm Contacts Alarm interface boards differ in location depending on the distribution unit used The 19 AU distribution has a single rear access board located to the far right when viewed from the rear next to the bulk battery hot bus The 23
35. tpack2 Power Systems 2046916 R1 June 2008 1 5 23 AU The 23 wide AU high distribution section is designed for 600A systems Load buses have twenty four positions and holders for over current protection devices The rear of the distribution has eight bulk battery landings on each polarity accepting a maximum wire size of 250 MCM An additional AU distribution section can be added to double the number of cable landings for a total of forty eight 23 6U The 23 wide 6U distribution section Is designed for 1200A systems Load buses have twenty four positions and holders for over current protection devices Because each load bus is rated for 600A two buses are strapped together to share the output current The internal return bus Is rated for the full 1200A The rear of the distribution offers eight bulk battery landings on each polarity with each landing accepting a maximum wire size of 750 MCM An additional 4U distribution section can be added to double the number of cable landings for a total of forty eight Bus Configurations for Single Distributions Three bus distributions can be configured in many ways The following examples illustrate standard arrangements and some common variations Notice that each diagram indicates the presence of a customer supplied disconnect device between the system and batteries Standard Bus Configuration The standard bus configuration is connected as shown The bottom bus is the critical l
36. ty that permits them to work with all configurations There are three primary designs defined by dimensions o 19 wide 4U 7 0 high unit o 23 wide 4U 7 0 high unit o 23 wide 6U 10 5 high unit Front views of these distributions and typical system configurations are found beginning on page 8 Rear views of the distributions are on page 26 Three Bus Distributions The three bus distribution features a unique configurable design that allows load breakers and or fuses to be aligned to any one of the three parallel front access buses see Figure 10 Load landings accept up to 1 AWG cable with two hole 1 4 lugs on 5 8 centers Rear access battery landings accept two hole 3 8 16 lugs on 1 centers maximum wire gauge depends on the size of the distribution section Jo UV VEVIVPVVBUBHIPBVPBRE BRD A I 2 2 2 20 he au N p i nA 3 BE Sho oy LN b X 3 Vee ar Lo 108808 w o Dumme ee x as IAAI E O bi A a aj gd 123 TAR yt aos es eer eet Figure 10 Three bus Distribution with En Distribution Device Holders Designations 19 4U The 19 wide 4U high distribution section Is designed for 300A systems The parallel load buses have twenty positions and holders for over current protection devices The rear of the distribution offers four bulk battery landings on each polarity with each landing accepting a maximum wire size of 250 MCM Installation Guide Fla
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