InstallGuide FlatpackPRSB15kW

3514

06.0

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Installation Guide

PRSB 15kW, 48VDC

Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12 2

Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek Energy AS.

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 Energy.

Copyright ©: Eltek Energy AS, Norway 2006 NS-EN ISO 9001:1994 Certificate no: 900005Q NS-EN ISO 14001:1996 Certificate no: 900005E. This product holds a CE mark and satisfies all requirements covering relevant standards and directives.

EMC ▫ EN61000-6-2 Industrial Environment ▫ EN61000-6-3 Residential, Commercial and Light Industry ▫ ETS 300386 v1.3.1 Telecommunication Equipment

LVD ▫ LVD73/23/EEC Low Voltage Directive ▫ EN60950 Safety of Technology Equipment

Head Office: Eltek Energy AS P.O. Box 2340 Strømsø N-3003 Drammen NORWAY Phone: (+47) 32 20 32 00 Fax: (+47) 32 20 32 10 E-Mail [email protected] Internet: http://www.eltekenergy.com Art. No. 351406.033 Issue 4, 2004 December

Published 2004-12-06

Mfm

Flatpack PRSB 15kW, 48VDC (Outdoor Site Power Cabinet, Air Conditioned) has part no. CF1032.002

Certificate no: 900005E Certificate no: 900005Q


Table of Contents

1 DESCRIPTION OF FLATPACK PRSB 15KW, 48VDC 4 OVERVIEW – GENERAL ARRANGEMENT 4 INPUT AND DISTRIBUTION ARRANGEMENT 4 AC INPUT TERMINALS 5 DC DISTRIBUTION AND LVBD DEVICE 6 MONITORING, CONTROL AND SIGNAL INTERFACE 6 SYSTEM MONITORING 6

2 INSTALLATION PROCEDURES 7 SAFETY PRECAUTIONS 7 UNPACKING AND MECHANICAL INSTALLATION 7 ELECTRICAL INSTALLATION 8 RECTIFIER INSTALLATION — MAINS SUPPLY BALANCING EFFECT 10 RECTIFIER INSTALLATION — HANDLES AND LOCKING MECHANISM 10 COMMISSIONING 10

3 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS 11 CONNECTIONS FOR INTERNAL SYSTEM WIRING 12 CONNECTIONS FOR GMT FUSES 13

4 SPECIFICATIONS FLATPACK PRSB 15KW, 48VDC, AIR CONDITIONED 14

5 APPENDIX: SCHEMATICS, DRAWINGS, FIGURES, ETC. 15 GENERAL ARRANGEMENT DRAWING 15 SYSTEM SCHEMATIC — PRSB 15KW, 48VDC, OUTDOOR CABINET, AIR CONDITIONED 16 ON SITE DOOR REMOVAL — OUTDOOR CABINET, AIR CONDITIONED 17 DRILLING TEMPLATE 18 AIR CONDITION UNIT SCHEMATIC DRAWING 19


1 Description of Flatpack PRSB 15kW, 48VDC

This Installation Guide contains information about how to install the Flatpack PRSB 15kW, 48VDC system1, for outdoor site power cabinet, Air Conditioned. Please, refer to the system’s Documentation Set (art. 351406.003) for an overview of related user documentation.

Overview – General Arrangement

The Flatpack PRSB 15kW, 48VDC is a DC power supply system based on the Flatpack 1500 48V rectifier. The system contains AC termination blocks, DC distribution, Flatpack Power Rack, Flatpack 1500 rectifier modules and the Flatpack Monitoring and Control Unit (MCU). The system is designed for cable entry from top and the cabinet size is 770x820x2000mm, (30.3 x 32.3 x 78.7”) (WxDxH).

Figure 1 Flatpack Power Rack System General Arrangement (top of cabinet)

Input and Distribution Arrangement

Figure 2 Location of components

1 PRSB = Power Rack System with Batteries

DC Load Distribution:MCBs, Mains, Alarm and

Signal TerminalsMCU, Monitoring & Control Unit

Flatpack 1500 rectifier modules

Battery strings and MCBs inside, in the lower part of the cabinet

LTE Distribution, MCBs

+ve DC Load Terminals Common positive bus bar, 70 mm2

+ve Battery Terminals Common positive bus bar, 70 mm2

Terminals for GMT 10A LoadFuses, 1.5 mm2

AC Mains Terminals

CON 5, Alarm Terminals1.5 mm2 (Front access)

–ve DC Load Terminals (BTS MCBs) On top of each load breaker, 25 mm2

MCU Ctrl. Unit, and CON 4, Monitoring Terminals(Back MCU)

DC Earth (TE) terminal, M6

AC Earth (PE) terminal, M6

Cabinet main Protective Earth (PE). Connected to powercore PE. Positioned in the ceiling

–ve Battery TerminalsBus bar, 35 mm2


AC Input Terminals

The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase and N.

Figure 3 AC input terminals, L1, L2, L3 & N, with internal terminal connection bars

You may reconfigure the AC terminal block for connection of 230VAC, 3 phase supply. To do so, rewire the internal (blue) wires as described in the table below, and connect the AC mains supply cable to terminals L1, L2 and L3.

AC Terminal Block400VAC, 3ph+N

Internal Wire Connections Internal Wire

(Labeled) Wire Color Connected to

Terminal Bar L1,1 Black L1-bar N1(L2) Blue N-bar L2,1 Black L2-bar N1(L3) Blue N-bar L3,1 Black L3-bar N1(L1) Blue N-bar L1,2 Black L1-bar N2(L2) Blue N-bar L2,2 Black L2-bar N2(L3) Blue N-bar

Factory configuration

AC Terminal Block 230VAC, 3ph

Internal Wire Connections Internal Wire

(Labeled) Wire Color Connected to

Terminal Bar L1,1 Black L1-bar N1(L2) Blue L2-bar L2,1 Black L2-bar N1(L3) Blue L3-bar L3,1 Black L3-bar N1(L1) Blue L1-bar L1,2 Black L1-bar N2(L2) Blue L2-bar L2,2 Black L2-bar N2(L3) Blue L3-bar

Customized configuration

L1(Terminal for

incoming wire)

L3(Terminal for

incoming wire)

N (neutral) (Terminal for incoming wire)

L2(Terminal for incoming wire)

Labels on internal wires(Wires may be reconnected to match the site’s type of AC mains supply)

L3-bar

L2-bar

N-bar

L1-bar

AC Input Feed Sizing (Recommended AC Breaker Rating and Min. Wire Size)

VAC Input 18kW

400VAC +N, 3 ph 40A – C 4x6 mm2 Cu – max. 30m

230VAC, 3 ph 63A – C 3x10 mm2 Cu – max. 45m

An external breaker is required on all sights. This should be turned OFF under all installation.


To connect your system to 1 phase from a 230 VAC-system or a 400 VAC + N-system connect the input cables as illustrated in the table to the right. With one phase the maximum amount of rectifiers is 4. These have to be placed in position 1,4,7 and 9 in Figure 4, page 10. The other positions will not be usable.

DC Distribution and LVBD device

The system is configured for negative distribution. The common positive bus bar is located inside the distribution section; see Figure 2, on page 4. The system is equipped with LVBD device.

Monitoring, Control and Signal Interface

The Flatpack PRSB 15kW, 48VDC is available with basic functionality for monitoring and control of the system, and is equipped with:

Relay outputs, 6 pcs Digital inputs, 4 pcs Symmetry input signals, 2 pcs

(battery string midpoint measurements) Digital input for external symmetry circuitry

One of the interface boards (104649) is located behind the MCU (with rear access to the terminals), while the other board (104648) is mounted on top of the MCU (with front access to the terminals). Se “Figure 7 Customer connections interface”, page 11.

System Monitoring

The Flatpack MCU Monitoring & Control Unit monitors and controls the entire rectifier system including distribution and batteries, as well as other equipment on site. The unit also incorporates a communication port for connecting computers via the RS232C interface.

The Flatpack system can be operated and configured locally via the keypad on the MCU unit, by selecting commands from set-up menus in a hierarchical menu system.

Please refer to the Flatpack MCU Operation Guide for detailed information about system monitoring.

Remote system monitoring and configuration may also be performed using WinPower Silver — a Windows-based program that runs on a connected PC.

Following configuration tasks require the use of a PC:

Installation settings System calibration Battery configuration Alarm setup Alarm log retrieval Site information Site specific configuration

AC Input Connection1-phase

External Wire Connections AC configuration in

Terminal Block 400 VAC + N 230 VAC

L1 L1-terminal L1-terminal 400VAC + N N N-terminal L2-terminal

L1 L1-terminal L1-terminal

Input (230 VAC, 3ph or

400 VAC, 3ph + N)

230VAC L2 N-terminal L2-terminal

1 phase configurations


2 Installation Procedures

This section describes how to install the Flatpack PRSB 15kW, 48VDC. Step-by-step procedures will guide you through the installation.

For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and control unit, please refer to the Operation Guides for the respective parts.

Safety Precautions

The equipment described in this manual must only be installed by authorized personnel, and only operated by persons who have attended a suitable Eltek Energy training course.

The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty.

There are hazardous voltages inside the rectifier system. As the rectifier units incorporate large charged capacitors, it is dangerous to work inside the system even if the mains supply is disconnected.

Products into which our components are incorporated have to comply with a number of requirements. Installation is to be in accordance with the recommendations herein.

Please read the manual carefully before using the equipment.

Unpacking and Mechanical Installation

Installation Step Comments OK

1 TAKE THE FLATPACK POWER

SYSTEM OUT OF THE PACKAGING

Inspect the unit for any physical or transit damage, and tighten the screws that connect conductors. Report any transit damage to Eltek Energy immediately

2 DRILL HOLES IN THE GROUND

ACCORDING TO DRILLING

TEMPLATE

The Drilling Template with instructions is located in section 5, page 18.

3 POSITION THE CABINET IN THE

REQUIRED LOCATION The floor construction must be capable of supporting the equipment.

4 BOLT THE CABINET TO THE

GROUND/PLINTH

Bolts are not included in the cabinet. If a plinth is used, refer to ‘Installation Guide, Kit for Plinth’, Doc. No. 351416.033.


Warning!

The cabinet has to stand upright (vertical position) for at least 2 hours before the Air-Condition devise is started.

Electrical Installation

For location of components, see “Figure 2”, page 4, Figure 3, page 5, and Figure 9, page 15.

Installation Step Comments OK

1. EARTH CONNECTIONS

Connect the AC Earth (PE) and DC Earth (TE) to the copper terminal positioned in the cabinet ceiling. The Common Positive Bus bar is internally cabled to DC Earth (TE); thus the positive output of the rectifiers is connected to ground (TE), and the negative output represents the –48Vdc supply voltage. • If required, you can remove the internal cable that

connects the positive bus bar to local PE.

2. AC CONNECTIONS

• Switch OFF the AC input power (external MCBs), before connecting the cable.

• Open the clamps that fasten the cable entry rubber gland.

• Shape the cable entry rubber gland with a knife to fit the mains cables, and draw the cables into the top of the cabinet. It is recommended to do the same with the load cables at this time. Fasten the cables with strips to the brackets inside the cabinet. Do not make the cable slot too wide! Use silicon to make the input hole watertight.

• Connect the AC cables, max. 35sq mm(AWG 2), to the terminal block in the top of the cabinet as the labels indicate. Replace the cable entry clamps. Do not power up the system until the whole installation is complete.

• Connect the external AC ground wire to the cabinets main Protective Earth (PE) terminal. See Figure 2.- page 4.


3. LOAD CONNECTIONS • Turn OFF the Load/BTS MCBs. • Turn OFF the PRS battery MCBs on the left side of the

cabinet. • Loosen the screws and pull the black cable gland back to

draw the load cables down to the powercore. • The kit includes two copper bridges. One for 100 A (two

pins) and one for 150 A. If the load current is larger than 50 A use the two pin copper bridge. Then the 3rd hole in the breaker cannot be used. If the load current is larger than 100 A, use the three pin copper bridge. Insert the chosen copper bridge on to the top of the MCB.

• Connect the orange alarm cable to the copper bridges with a screw if the bridges are used.

• Connect the positive cable(s), max 70 mm sq (AWG 2/0), to the common positive bus bar on the top of the power core.2

• Connect the negative (-48V) cables, max 25 mm sq each (AWG 3), to the top of the MCBs or the copper bridges. Connect the negative (-48V) cables to the MCBs.

4. GMT FUSE CONNECTION Connect the adequate cables, 1,5 mm sq (AWG 15), to the GMT fuse card according to the table in section 3 – page 13

5. BATTERY CONNECTIONS The positive and negative (-48V) battery cables are connected from factory to the common positive bus bar and to the battery MCBs. (Excluding additional battery string kits) The battery temperature sense cable is also pre-wired to CON4, and temporally fixed to the cabinet’s wall. • Connect the loose end of the battery cables to the

battery terminals; blue cable to the negative terminal and black cable to the positive terminal.

• Connect all battery intercell links • Place the temperature sensor, located at the end of the

battery temperature sense cable, on top of the topmost battery string.

• Connect and fasten the ventilation hose kit (follows the batteries) to every battery block, guiding the exhaust end of the hose out of the cabinet through the upper whole on the side of the cabinet. Fasten the exhaust host to the cabinet with strips. Make sure that the fixings do not limit the airflow in the hose.

6. POWER UP

Please follow chapters “Pre Start Check” and “Start Up Procedure” in manual “Commissioning Guide Flatpack 1500 DC Rectifier Plant”, Doc. No. 360006.163.

2 The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.

100A 150A

Alarm connection

Battery ventilation hole with gland removed

Battery ventilation hole with gland

Right Corner

Cable gland


Rectifier Installation — Mains Supply Balancing Effect

The Flatpack PRSB system may be expanded to a maximum of 10 Flatpack 1500 rectifiers. In order to load the supply net evenly — similar current load from the 3 phases of the mains supply — it is advisable to mount the required number of rectifiers in the following order:

Figure 4 Rectifier mounting order to load the mains supply evenly.

When possible, mount an equal number of rectifiers on each phase, L1, L2 and L3.

Rectifier Installation — Handles and Locking Mechanism

The Flatpack 1500 rectifier module is equipped with handles that serve two purposes:

Locking the module into position

Open both handles, insert and plug the module into power shelf. Then lock it into position by rotating the handles upwards and pushing them firmly home; failure to do so will prevent the module from making proper contact.

Figure 5 Module with released handles

Pulling the module out

Unlock and release the handles by inserting a small screwdriver into the upper holes, thus releasing the spring mechanisms. Do not use excessive force. The handles will release and pop out. When both handles are released, use them to pull the module out.

Do not hold or carry the rectifier by its handles.

Figure 6 Releasing the module’s handles

Commissioning

For information regarding system commissioning, please read manual “Commissioning Guide Flatpack 1500 Dc Rectifier Plant”, art. No. 360006.163.

1st Pos(on L1)

2nd Pos (on L2)

3rd Pos (on L3)

4th Pos (on L1)

5th Pos (on L2)

6th Pos (on L3)

7th Pos (on L1)8th Pos (on L2)

9th Pos (on L1)

10th Pos (on L2)

MCU Rectifiers

Handle in locked position

Upper hole to release the spring

mechanism


3 Alarm Relay Outputs and Signal Connections

The digital inputs are configured as fail-safe, i.e. if the input is enabled, it will trig an alarm if the input is open. If several external devices are going to the same digital input, they must be connected in series.

The alarm relays are also operated in fail-safe, i.e. the relays are energized when there is no alarm. The description below describes the pin out in normal state, i.e. the NO output is open in normal operation and shorts to the COM output in the alarm-state.

Alarm relay specification

Nominal switching capacity 2A/30V DC

Maximum switching power 60W (resistive load)

Maximum switching voltage 220V DC

Maximum switching current 2A DC

Interface Customer Connection Pin Out

Figure 7 Customer connections interface and internal terminals. (Max. 1,5 mm2, AWG 15)

Terminal Description Terminal Description CON 2 Internal system connections CON 4 Customer connections (digital inputs, symmetry, etc.)CON 3 Internal communication CON 5 Customer connections (alarm relay outputs)

Interface Card 104649Located back the MCU

Ctrl. Unit (plug for MCU)

Interface Card 104648Located on top of the MCU Ctrl. Unit

CON2

CON4 CON5

Pin 1 Pin 10

Pin 11 Pin 20

Pin 1 Pin 20

CON3

Pin 1

Pin 12

CON4 External device alarm state

Input 1AGND


Connections for Internal system wiring

CON3 is used for rectifier and power shelf communication. CON2 is used for internal system wiring, which has been done at the factory. These connectors are not involved in the system installation and commissioning process. The table below shows the pin assignment for CON2.

CON 5 Pin Assignmentfor basic PCB version, art. No. 104648

Pin Signal Function Pin Signal Function 1 2 3

NC NO Com

Relay 6: Common Alarm

10 11 12

NC NO Com

Relay 3: Low Battery Alarm

4 5 6

NC NO Com

Relay 5: Module Alarm

13 14 15

NC NO Com

Relay 2: Heat Management Alarm

7 8 9

NC NO Com

Relay 4: Load / Battery Fuse Alarm

16 17 18

NC NO Com

Relay 1: High Temp. (Fan regulation)

19 20

(not used) (not used)

Factory Settings


Pin Signal Function Pin Signal Function 1 2

+ AGND

Digital Input 1 (Heat Management)

11 12

+ —

Battery Symmetry 1 (analogue input)

3 4

+ AGND

Digital Input 2 (programmable)

13 14

+ —

Battery Symmetry 3 (analogue input)

5 6

+ AGND


15 16 17

+ —

+21V Auxiliary Supply (for modem or ext.equipment) (not used)

7 8

+ AGND


18 19 20

+ — screen

Battery Temperature Sense Analogue ground (system ref.)

9 10

+ AGND

Battery Symmetry 2(digital input)



+ —

Shunt 2: Battery current measurement

9 + Battery Fuse State (digital input)

3 4

+ —

Shunt 1: Battery current measurement

10 + Load Fuse State (digital input)

5 6

+ —

Auxiliary Supply (for Flatpack MCU)

11 — LVBD control (Battery Disconnect contactor)

7 8

VDC+ VDC—

Voltage Sense (system signal reference)

12 — LVLD control (Load Disconnect contactor)


Connections for GMT fuses

Figure 8 GMT fuse card (Max. cable size 1,5 mm sq)

The table below shows the pin assignment for the GMT load fuse card.

Pin Assignment for GMT Fuse


+ —

GMT fuse 1 (F4) 9 10

+ —

GMT fuse 5 (F8)

3 4

+ —

GMT fuse 2 (F5) 11 12

+ —

GMT fuse 6 (F9)

5 6

+ —

GMT fuse 3 (F6) 13 14

+ —

GMT fuse 7 (F10)

7 8

+ —

GMT fuse 4 (F7) 15 16

+ —

GMT fuse 8 (F11)

GMT fusesMax. 10 A each

Pin 16 Pin 1


4 Specifications Flatpack PRSB 15kW, 48VDC, Air Conditioned

Site Power Outdoor cabinet

SPECIFICATION

Max. number of rectifiers 10 AC INPUT Voltage 1 phase 230 VAC (max. 4

rectifiers) 3 phase 208 VAC ( ∆ ) 3 phase 230 VAC ( ∆ ) 3 phase 400 VAC+N ( Y )

Frequency 45 to 66Hz

Maximum Current

See Flatpack 1500 48VDC datasheet (241114.100.DS3)

Protection Soft start Surge protection (varistors) Disconnect above 312 VAC

MONITORING Monitoring Unit Flatpack MCU Local operation Menu driven software via

keypads and LCD or PC (WinPower)

Remote operation

WinPower via modem or Web NMS via SNMP-agent

Alarm relays 6 relays are standard

Visual indications Green LED – System ON Red LED – Active alarm(s) LCD – system status

Digital inputs 5 (for monitoring of external equipment)

Current measurements

Battery current tifier current Load fuse alarm Battery fuse alarm LVD operated Low output voltage alarms (2 individual alarm levels) High output voltage alarms (2 individual alarm levels) Battery capacity Temperature alarm

Alarms

Symmetry alarm

DC OUTPUT Voltage 48 VDC

Current Up to 15 KW – 300 Amps

CONNECTIONS Battery connections

Battery cable, M8 bolts

Load MCB connections

Negative distribution, Load cable, M8 bolts. Common positive bus bar, M8 bolts

Alarm connections

Plug-in wire connectors front access

DISTRIBUTION OPTIONS No. of DC Load breakers

3 x 50 Amps -150Amps MCBs

No. of Battery fuses

Up to 3 x 150 Amps MCBs mount next to each battery shelves

No. of Aux. fuses

8 x 10 Amps GMT type

Programmable LVD

Standard: 1 LVBD (max. 400 Amps)

OTHER SPECIFICATIONS Isolation 3.0 KVAC – input and output

1.5 KVAC – input earth 1.0 KVDC – output earth

Operating temp -40 to +50°C (-40 to +122°F) Storage temp -40 to +85°C (-40 to +185°F) Dimensions 770 x 910 x 2000mm (WxDxH)

(30.3 x 35.8 x 78.7”) Weight Approx. 235kg excl. rectifiers and

batteries Max. 250kg per battery shelf

APPLICABLE STANDARDS Electrical safety

EN 60950 UL 60950

EMC

ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry)

Environment

ETSI EN 300 019-2 ETSI EN 300 132-2


5 Appendix: Schematics, Drawings, Figures, etc.

General Arrangement drawing

See also Figure 2, page 4, for more detailed information about DC distribution.

Figure 9 General Arrangement drawing, PRSB 15kW, 48VDC Outdoor Cabinet, Air Conditioned

Battery MCB FB1

Battery MCB FB3

Battery MCBFB4

LTE FusesMCBs

DC Distribution, Alarm, AC Terminals, etc.

Heater MCB (AC)

Battery MCB FB2

Rectifiers

Main Protective Earth (PE)


System Schematic — PRSB 15kW, 48VDC, Outdoor Cabinet, Air Conditioned

Figure 10 Schematic drawing, PRSB 15kW, 48VDC system


On Site Door Removal — Outdoor Cabinet, Air Conditioned

Step Description Ok

1 Switch OFF AC supply to Air Condition

2 Remove the AC supply cables from the door terminals. Make sure the AC cable is completely freed from the door.

3 Disconnect the earth connection cable on the bottom of the door

4 Lift the door off the hinges. This might require two or more persons, since the door is heavy.

5 When the door is mounted back on, lift the door back on to its hinges

6 Reconnect the earth and AC supply cable.

7 Fasten the AC supply cable to the door.

8 Switch the AC supply back ON.

Air Condition AC supply cable.

Eart connection cable

Air Condition AC supply cable connection terminal


Holes for mounting the cabinet to the ground without a plinth.

Holes for the plinth.

Holes for the plinth.

Drilling Template

Figure 11 Top view of the cabinet’s bottom plate. 700x700 mm external dimensions

The cabinet overhangs by 35 mm outside the plinth on the rear, on the left hand and on the right hand side


Air Condition unit schematic drawing

Figure 12 Air Condition unit schematic drawing

Main Office:

Eltek Energy AS P.O. Box 2340 Strømsø N-3003 DRAMMEN Norway Phone: 47 32 20 32 00 Fax: 47 32 20 32 10 E-Mail: [email protected] Internet: www.eltekenergy.com

Art. No. 351406.033 Issue 4, 2004 December

Published 2004-12-06

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