Eltek Flatpack 2 User Manual
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Transcript of Eltek Flatpack 2 User Manual
Installation & Commissioning,
Operation & Maintenance Manual
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and
A112041.000 FlatPack2 systems
Page 1 of 64
Eltek Australia Pty Ltd Unit 1, 22 Narabang Way, Belrose, NSW, 2085, Australia
Telephone: +61 2 9479 4200 Facsimile: +61 2 9479 4292
Installation & Commissioning +
Operation & Maintenance manual for FlatPack2
SEF29-X-149, ‘150, ‘156 and A111171.000, A112040.000 and
A112041.000 systems
REVISION CONTROL
Rev Date Revision Description Orig Check App
H 25/10/06 Added extra wall mounting option. GT BD
I 29/11/07 Added system for this manual AL
J 14/04/11 Changed logo and fax number RB
K 14/06/11 Added Ethernet connection RB
L 23/11/11 4 Battery Shelves, SP18-RRU, SP18 DA
M 07/03/12 Updated to manufacturing version DA
This manual is in process of revision if you require updated manual please contact with
Eltek Australia engineering department
DOCUMENT DISTRIBUTION CONTROL
Copy No: 1 Controlled: X Uncontrolled:
Installation & Commissioning,
Operation & Maintenance Manual
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and
A112041.000 FlatPack2 systems
Page 2 of 64
Eltek Australia Pty Ltd ACN072 645 446 ABN 90 072 645 446
Unit 1, 22 Narabang Way
Belrose NSW 2085
Phone: (02) 9479 4200
Fax: (02) 9479 4292
E-Mail (Sales Dept.): [email protected]
E-Mail (Service Dept.): [email protected] E-Mail (all departments): [email protected]
Installation & Commissioning,
Operation & Maintenance Manual
TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and
A112041.000 FlatPack2 systems
Page 3 of 64
TABLE OF CONTENTS
1. SCOPE ............................................................................................................................................................... 5
2. SYSTEM OVERVIEW .................................................................................................................................... 5
3. REQUIREMENTS ......................................................................................................................................... 14
4. PACKING LIST ............................................................................................................................................. 16
5. SYSTEM CONFIGURATION ...................................................................................................................... 17
6. UNPACKING.................................................................................................................................................. 18
7. CABINET ASSEMBLY ................................................................................................................................. 19
7.1 SPECIALISED WALL MOUNTING KIT ................................................................................................................. 20
8. FLOOR INSULATION .................................................................................................................................. 22
9. EARTH CABLING ........................................................................................................................................ 23
10. CONNECTING THE BATTERIES ....................................................................................................... 24
11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS. ................................. 26
12. EXPANSION RACK ALARM CONFIGURATION ............................................................................ 28
13. INSTALATION & REFRESHING VOLTAGES OF BATTERIES .................................................. 29
14. EXPANSION RACK INSTALLATION CHECK LIST ....................................................................... 30
15. INSTALLATION AND OPERATION OF RECTIFIER MODULES ................................................ 31
15.1 VISUAL INDICATIONS..................................................................................................................................... 32 15.2 PLUGGING IN RECTIFIERS .............................................................................................................................. 33 15.3 IDENTIFICATION OF DIFFERENT RATED RECTIFIERS ....................................................................................... 33 15.4 REPLACING AND INSTALLING RECTIFIER MODULES ........................................................................................ 34
16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER (ETHERNET
CONNECTION) ..................................................................................................................................................... 35
17. OPERATION OF THE SMARTPACK CONTROLLER .................................................................... 38
17.1 FRONT PANEL OPERATION ............................................................................................................................. 38 17.2 OPERATING MENUS, (MENU MODE) .............................................................................................................. 40 17.3 FRONT KEYPAD MENU TREE FOR SMARTPACK CONTROLLER: ........................................................................ 41 USER ..................................................................................................................................................................... 41
Service ......................................................................................................................................................... 41
18. REMOTE ALARM CONNECTIONS.................................................................................................... 42
18.2 DIGITAL INPUTS. ............................................................................................................................................ 45
19. +24 V DC/DC CONVERTER .................................................................................................................. 47
20. AC MAIN SUPPLY INSTALLATION .................................................................................................. 49
21. DC DISTRIBUTION INSTALLATION ................................................................................................ 51
LOAD CABLE INSTALLATION CONSIDERATIONS .................................................................................................... 52
22. TEMPERATURE COMPENSATION ................................................................................................... 52
Installation & Commissioning,
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23. COMMISSIONING ................................................................................................................................. 54
PRE-START / INITIAL CHECKS ............................................................................................................................... 54 SYSTEM START-UP ................................................................................................................................................ 54 CHECKING THE ALARMS ....................................................................................................................................... 55 DEFAULT -48V SYSTEM SETTINGS ........................................................................................................................ 58
24. GENERAL MAINTENANCE CHECKS ............................................................................................... 58
25. MODULE MAINTENANCE .................................................................................................................. 59
26. GENERAL PROCEDURES.................................................................................................................... 59
27. SYSTEM COMPONENTS MINIMUM OPERATING LIFE ............................................................. 59
28. USING SMART SUITE SOFTWARE ................................................................................................... 60
28.1 INSTALLATION OF SMART SUITE SOFTWARE ................................................................................................. 63 SETTING UP COMMUNICATION BETWEEN PC AND SMARTPACK ............................................................................. 63 28.2 USING SMARTSUITE: A START UP GUIDE. ...................................................................................................... 63
29. ATTACHMENTS .................................................................................................................................... 64
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1. SCOPE
This Installation and Commissioning Manual provides simple instructions as to the installation
requirements for the Eltek -48 Volt DC Flatpack2 systems. All maintenance & installation
work must be carried out by suitably trained personnel.
This manual also includes Operation & Maintenance information and technical data regarding
the Flatpack2, Smartpack controller and DC/DC converters (factory fitted option.)
2. SYSTEM OVERVIEW
The Flatpack2 Mobile systems are 18kW -48V DC power system comprising of:
1 Main System Cabinet (fig 2.2, 2.3, 2.4, 2.7 & 2.8)
Up to 9 FlatPack2 -48V 2kW or 1.8kW rectifiers
1 Smartpack Control Module
4, 5 or 6 Battery strings
Expansion Battery Cabinet (optional, fig 2.5, 2.6 & 2.9)
Up to 4 off +24V 1.1kW DC/DC converters (factory fitted option in 600D rack only)
The Main System Cabinet is available in 2 configurations, a 600 deep cabinet option and a
400 deep cabinet option. The 600 deep cabinets can accommodate up to 6 strings of 100Ah
12FFT100 batteries or 4 strings of 190Ah SBS190 batteries, and the 400 deep cabinets can
accommodate up to 5 strings of 100Ah 12FIT100 batteries. If required, the main system
cabinets for either option can be supplemented with a battery expansion cabinet for increased
battery capacity. Details of the expansion battery cabinets are given later in this manual.
The system is also available with an optional DC/DC converter rack to supply +24V supply
as needed. This extra rack can deliver up to 4.4kW at 24V and has an extendable alarm output.
It input is supplied via an MCB on the -48V load distribution, with the 24V output given via a
top mounted Anderson connector.
Monitor fail
PCB
AC mains
input
Alarm PCBs
Battery Alarm for the
Expansion rack
+48VDC bar
(SPC)
Output cable
management
rail
Serial Number
Anderson
connector for
battery
expansion rack
Bulk feed point for
external battery
connection
(Available only in
SP18&SP18-RRU)
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Fig 2.2, Front and side views of an A111105.000 (SEF29-X-156).
2200(H)x 600(W)x 600(D)
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Fig 2.3, Front and side views of an A1110886.00x (SEF29-X-149).
2200(H)x 600(W)x 400(D)
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Fig 2.4, Front and side views of an A111160.00x (SEF29-X-150).
2200(H)x 600(W)x 600(D)
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Fig 2.5, Front and side views of an A451028.000 (SEB5-12FIT100-002) battery cabinet.
2200(H)x 600(W)x 400(D)
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Fig 2.6, Front and side views of an A461032.000 (SEB6-12FFT100-002) battery cabinet.
2200(H)x 600(W)x 600(D)
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Fig 2.7, Front and side views of a SP18-RRU A112040.000.
2200(H)x 600(W)x 600(D)
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Fig 2.8, Front and side views of a SP18 A112041.000.
2200(H)x 600(W)x 600(D)
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Fig 2.9, Front and side views of a SP18 Battery Expansion Rack A401049.000
2200(H)x 600(W)x 600(D)
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3. REQUIREMENTS
Installation:
Termination or configuration of the AC Mains connection is only to be performed by a
licensed electrical installer.
Standard tools used by an authorized Electrician
A torque wrench for installing the battery cables nuts.
The system should only be installed into locations that have restricted access to personnel.
Note: All tools should be insulated
For communication with the controller:
A laptop computer running either windows 2000 or windows XP.
SmartSuite software on CD (supplied with system)
Standard A-B type USB cable.
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WARNINGS
Communications Grade valve regulated gas recombination lead acid cells and
monoblocs are electrically live at all times and must be treated with care. The products
are generally capable of supplying high short circuit currents even if the case or lid is
damaged. Remember that the battery is electrically live at all times and cannot be
isolated in the conventional sense, although the voltage at any point can be reduced by
removal of appropriate inter battery links. Take care that short circuits are not caused by
accidentally dropping or touching metal objects onto the cell or monoblocs terminals.
Before connecting batteries and cables remove all metallic objects such as rings,
watches etc from your hands and wrists to avoid causing a short circuit.
Do not smoke or permit open flames near batteries. Avoid any activity near the batteries
that may cause sparks.
If the rectifier module is damaged in any way or develops a fault it should be replaced
immediately. This should only be done by appropriately qualified personnel. Refer to
the operations manual for instructions.
The equipment contains voltages that may be lethal. The AC distribution front cover
plate should not be removed without first isolating the AC supplies. AC supply
connection should only be done by appropriately qualified personnel.
Allow for adequate ventilation around the units. A 5 –10 mm clearance should be kept
between the batteries as they may expand in high temperatures.
Be aware that the rectifier is rated for high temperature operations. Therefore care must
be taken when handling the modules as they can reach temperatures of 60oC
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4. PACKING LIST
A fully equipped Flatpack2 system is dispatched from Eltek in a number of packages. Each
package is clearly marked indicating its content. The packages include the following.
1 x Rectifier Cabinet box
Including: Rectifier Cabinet, Manual on CD, lifting eye bolts, floor insulation kit and dyna
bolts/dynasets.
May contain up to 9 x 2kW FlatPack2 rectifiers already fitted. (see packing list).
1 x Battery Cabinet box (if ordered)
Including: Battery Cabinet, Floor Insulation Kit, dynabolts and battery rack to rectifier rack DC
power connection cable with Anderson connectors, earth cable & alarm extension cable. (See
packing list on box.)
Batteries crates
Each Crate contains batteries (Monoblocs) as required, including solid links & washers.
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5. SYSTEM CONFIGURATION
The different configurations of the Flatpack2 system and expansion battery cabinets are listed
below:
Part # Dimensions Battery Type Max #
strings
Notes
A1110886.00x
(SEF29-X-149)
2200(H)x600(W)x400(D) 12FIT100 5 Can
accommodate up
to 10 strings
using the SEB5-
12FIT100-002
Cabinet.
A451028.000
(SEB5-12FIT100.002) 2200(H)x600(W)x400(D) 12FIT100 5
Battery
Expansion
To suit
SEF29-X-149
A111160.00x
(SEF29-X-150)
2200(H)x600(W)x600(D) 12FFT100 6 Can
accommodate up
to 12 strings
using the SEB6-
12FFT100-002
Cabinet.
A111105.000
(SEF29-X-156) 2200(H)x600(W)x600(D) 12FFT100 5 As SEF29-X-
150, but with a
DC/DC converter
rack factory fitted
A461032.000
(SEB6-12FFT100.002) 2200(H)x 600(W)x600(D) 12FFT100 6
Battery
Expansion
To suit
SEF29-X-150 /
SEF29-X-156
A112040.000 2200(H)x600(W)x600(D) SBS190(Default)
PWL100 (Optional)
4(Default)
6(Optional)
Can
accommodate up
to 9 (or 11)
strings using the
A401049.000
SP18 battery
expansion rack
A112041.000 2200(H)x600(W)x600(D) SBS190(Default)
PWL100 (Optional)
4(Default)
6(Optional)
Can
accommodate up
to 9 (or 11)
strings using the
A401049.000
SP18 battery
expansion rack
A401049.000 2200(H)x600(W)x600(D) SBS190(Default)
PWL100 (Optional)
5 Battery
Expansion To
suit
A112040.000
A112041.000
Fig 5.1
System Part numbers
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Page 18 of 64
Component name Part number
Smartpack Controller 242100.100
Smartpack Controller 242100.118(later type)
Flatpack2 Rectifier 241115.002
Flatpack HE Rectifier 241115.105
DC/DC Converter 241114.503
SP18-RRU Label Kit A641031.000
Fig 5.2
Component Part numbers
6. UNPACKING
All equipment is suitable for being moved with a normal pallet truck whilst packed. When
unpacked, cabinets may weigh 145kg and are heavier at the top end of the cabinet.
CAUTION: THESE UNITS ARE TOP HEAVY, AND CAN TIP OVER UNEXPECTEDLY
IF NOT HANDLED WITH CARE.
Appropriate lifting equipment should be used, and suitable care must be taken while handling
these units. The most appropriate method of moving the racks is with the use of a hand trolley.
Some packaging material should be placed between the trolley and the rack to avoid damage to
the rack. It is however recommended that the complete boxes be positioned as close as possible
to the actual location where the system is to be installed.
Fig 6.1
Lifting arrangement for the cabinet, using eyebolts and spreader bar.
Lifting Cables
Spreader bar, used to
prevent eyebolts from
bending inwards
Eyebolt, placed in the wall
mounting brackets bolt
positions
Cabinet
If lifting using eye bolts, a spreader bar must be used.
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7. CABINET ASSEMBLY
The Cabinets will arrive packed in a box. The following are step by step instructions for
assembling this cabinet.
1. Inspect the installation site and determine where the system will be located. Position the
packages close to the final systems destination.
2. Each package will have affixed to it a complete packing list listing the contents of each
package and the quantity. Check to ensure that you have all items marked on the packing
list.
3. Unpack the cabinet from its box.
4. Follow the floor fixing instructions in the next section to fix the cabinet in position.
5. Attach the cabinet to the wall using wall mounting brackets as below.
Fig 7.1
Wall mounting brackets.
Note: the distance between the top of the cabinet and the wall will be 100mm larger for the
600mm cabinet type than for the 400mm cabinet, due to the greater battery depth.
600mm Cabinet example 400mm Cabinet example
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7.1 Specialised Wall mounting kit
This section details the mounting of an optional wall mounting kit, for mounting in
transportable huts.
Fig 7.2
Fig 7.4
Contained with the kit (Part number):
2 wall mount brackets (MB300)
12 ‘top hat’ washers (XZ045)
2 short wall insulators (KZ207)
2 Long wall insulators (KZ208)
Fig 7.3
Assembled brackets with insulators
& ‘hat washers’ in place.
Drill a counter sunk hole here to
correspond with the holes in the
vertical wall mount. Two extra holes
will need to be drilled in each of the
top five shelves. (See TG6308 in
attachments for a drawing)
The existing cross brace attachment
hole can be used as the 2nd
mounting
position. 61mm
Remove the ‘X’ brace
from all shelves.
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Fig 7.5
Each vertical bracket uses 4 ‘hat
washers’ & one long wall
insulator to insulate from the
wall.
Place the short edge of the
bracket against the wall in the
location shown to align with the
holes drilled in the rear of the
battery shelves.
Use the short wall insulator with 2 hat washers to
insulate the top ‘L’ bracket from the wall.
The insulator is installed between the wall &
bracket; shown here beside the ‘L’ bracket.
Remove the ‘X’ bracing
from all shelves.
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8. FLOOR INSULATION
All cabinets include an insulation kit, which isolates the racks from earth. One insulation kit
consists of appropriate insulation plates, 4 insulation washers, 4 round washers and 4 M8
dynabolts/dynasets. The insulating plate can be used as a template to mark the positions of the
holes on the concrete floor. After the holes have been drilled, position the insulating plate
between the cabinet and the cabinet floor. Bolt through the 4 holes in the bottom battery tray
using the dynabolts/dynasets provided. Note: the insulating plate may be provided in separate
pieces that need to be positioned on the floor.
Dyna-bolt/
Dyna-set
Fig 8.1 Dynabolt Fixing
Fig 8.2 Floor template and insulating plates 400mm option
Insulating Washer
Concrete
Floor
Nut
Washer
Insulating Plate
Cabinet
288mm
400mm
600mm
556mm
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Fig 8.3 Floor template and insulating plates, 600mm option
9. EARTH CABLING
Each cabinet should be bound to earth using links. There is one 95mm² earth cable shipped
with each cabinet (Except SP18-RRU system). Ensure this converter cubicle bond is bonding
the cabinet M8 bolt to the positive common bar (SPC) inside the cabinet. Also ensure flat and
spring washers are used and the links are secure. External earthing should be done to relevant
company standards.
Also connect the battery extension cabinet, if being used, to the SPC inside the rectifier cabinet
with the 95mm² earth cable supplied with the extension cabinet.
There is also a M6 bolt that is connected to the protective earth on the AC input terminals that
needs no further connections
.
540mm
563mm
600mm
600mm
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10. CONNECTING THE BATTERIES
The FlatPack2 system is supplied with a 100A battery circuit breaker with auxiliary for each
string. The battery CB’s are located on the left-hand side of each battery shelf.
System is supplied with cables from the battery CB’s to the battery trays already fitted. Ensure
that the battery CB’s are turned OFF before connecting the batteries.
NOTE:
For battery shelves not being used, ensure cable ends remain insulated with heat shrink
provided.
Installation Steps
1. Before commencing the installation, ensure that each battery is in good condition and has
not been damaged during transport.
2. Monoblocs are heavy; and accordingly the recommended lifting equipment should be used.
3. Remove retaining strap.
4. Position the batteries on shelves as per fig 10.1. We suggest that one monobloc be lifted
into place at a time. Leave a clearance space of between 5 – 10 mm between the batteries.
Slide the batteries gently back to the rear of the system to avoid any risk of damaging them
on the rear of the shelf.
5. Particular care should be taken when placing on the shelves to ensure the correct
positioning of the +ve and –ve terminals.
6. Connect inter battery flexible cables and inter tier links. To ensure a low resistance joint
clean the flat contact making surfaces of the terminal posts and connectors with a soft clean
cloth. The links do not normally require cleaning and can be fitted without any operation.
However in some cases the links could show encrustation and this should be removed using
Scotchbrite or fine grade abrasive paper. Do not use a wire brush and be especially careful
not to break through the lead plating. Apply a light coating of grease to the contact – mating
surfaces and place a solid connector strap or flexible link in position. Tighten the nuts
firmly: 7-8 Nm for a Stud type terminal; (12FIT100 [M6], SBS190 [M6]), 8-10 Nm for
a socket type terminal (12FFT100 [M8]) using an insulated torque wrench. (A non-torque
insulated wrench is supplied with the batteries. This should be used only when the installer
is familiar with battery installations and knows from experience what level of torque needs
to be applied) Lightly smear grease on the washer and nut.
WARNING: Particular care should be taken to ensure the batteries are not short-
circuited during this procedure.
7. Place terminal boots and battery link caps on all battery terminals.
8. Place the battery numbering labels in place starting at the first battery (on the bottom shelf)
and working to the last. Replace the battery
9. Wait 24 Hours and re-torque the battery terminals.
You will find the following colour coding on the battery cables. Blue (–) negative and Red (+)
Positive
The system must not be located in an explosive atmosphere, i.e. in the presence of
flammable gases and fumes. Suitable ventilation for the battery must be provided.
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Note: the solid battery links have slots that allow the batteries to be easier positioned and
connected, but may allow the batteries to come too close together if not installed correctly.
Please enure that there is proper spacing maintained between the batteries to allow for
ventilation of heat.
Fig 10.1
Front view of batteries, showing spacing & battery
circuit breaker position
(Cables / links are
not shown)
Battery Circuit
breaker.
Retaining
bracket
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11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS.
The Flatpack2 system can be supplied with an expansion battery cabinet. The following table
outlines which expansion cabinet is supplied with which system.
Part # Dimensions Type of
battery
Number
of battery
shelves
To suit System
A451028.000
(SEB5-12FIT100.002) 2200(H)x 600(W) x 400(D) 12FIT100 5 A1110886.00x
(SEF29-X-149)
A461032.000
(SEB6-12FFT100.002) 2200(H)x 600(W) x 600(D) 12FFT100 6 A111160.00x
(SEF29-X-150)
A401049.000 2200(H)x 600(W) x 600(D) SBS190
12FFT100 5
A112040.000
A112041.000
To install extra strings of batteries:
1. Position expansion cabinet and fix it to the floor in the same manner as the rectifier cabinet.
2. Ensure that all the individual string MCB’s are turned OFF
3. Install the batteries as detailed in section 10.
4. Double check all the string MCB’s are OFF and connect the flying lead with the Anderson
connector to the existing rectifier cabinet as in fig.11.2 below.
For SP18 and SP18-RRU systems, there is a bulk feed point supplied in the system
for direct connection of battery rack without using Anderson connector. (Fig 11.1)
Figure 11.1
Bulk Feed Point for External Battery Connection
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5. Once the battery strings are in place turn on the strings of batteries one by one. Pause
between turning each string on to let the system equalize with the string.
6. Check the string voltage and the battery current on the Smartpack display. There should be
a small positive current flowing to the batteries.
Each expansion battery cabinet is fitted with a flying lead with an Anderson connector on one
end to connect to the +ve/-ve bus bars in the system cabinet as shown below: (SP18 Expansion
rack has additional bulk feed connection)
Rectifier Cabinet Battery Cabinet
Figure 11.2
When connecting extra batteries to the system, the controller needs to be updated manually.
Use the keypad menu in Section 17 to change the battery charge current limit setting if no PC is
available. The battery charge current limit should be set to = [25% of the C10 rating of the
battery] x [the number of strings installed], which in the case of 12FFT100 & 12FIT100
batteries is 25A x [the number of strings.]
Flying Lead with
Anderson Connector Battery CB
alarm.
Earth cable
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12. EXPANSION RACK ALARM CONFIGURATION
The battery alarms provide signals to the Smartpack control module via auxiliary switch’s on
each battery circuit breaker. The purpose of this signal is to initiate an alarm condition if the
battery CB has tripped. This a normally closed loop which if broken, will create an alarm
Alarm Interconnection cables
Each system cabinet is supplied with an alarm interconnection cable that connects the system
cabinet to the expansion battery cabinet. The alarm interconnection cable is a 2000mm long, 2
way cable.
Installation Steps for Expansion Cabinet alarm wiring
There is a four way terminal block fitted in the rectifier cabinet on the LHS under the
distribution. When an external battery cabinet has been installed remove the link wire on the
top of the terminals:-
1. Connect one end of the 2 core alarm interconnection cable to the two terminals located in
the top LHS of the cabinet.
2. Run the cable through the top cover of the cabinet to the terminal block located in the top of
the battery cabinet.
3. Secure the alarm cable wiring with cable ties.
Figure 12.1 Battery Alarm Schematic showing expansion battery cabinet
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13. INSTALATION & REFRESHING VOLTAGES OF BATTERIES
If the batteries are in service on a temperature compensated power supply in temperatures
above an ambient of 20°C, the service life of the battery will be affected. See table 13.1 below.
Ambient temperature (deg C) Expected life (% of nominal)
20 100
25 70
30 50
35 35
40 25
45 18
50 15
Table 13.1
To check if a refresh is needed, follow the below procedure.
1. Check the open circuit voltage of each battery.
The minimum monobloc open circuit voltage that the battery can be considered as not
requiring refresh is 12.72V. Any monoblocs that are below this voltage will have to be
refreshed as below. Above this value, they may be considered acceptable for use & do not
need to be refreshed.
2. Put the batteries on a float voltage charge of 54.48V for a period of 48 hours at 20degC.
3. After float charging leave the batteries to settle for a further 48 hours.
4. Check the open circuit voltages of the monoblocs.
The minimum monobloc open circuit voltage after refresh is 12.72V. Any monoblocs that
are below this voltage cannot be considered as serviceable.
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14. EXPANSION RACK INSTALLATION CHECK LIST
Check these points OK
1. Check that the cabinet is fixed to the wall securely.
2. Check that the battery connections are all of correct polarity.
3. Check that the terminal boots and battery link caps are fitted on all the
batteries.
4. Check that the Anderson flying lead is connected.
5. Check that the battery rack expansion rack earth cable is securely
connected to the common positive bar (SPC) inside the rectifier cabinet.
6. Check that battery string voltage is between -48 and -55 V.
7. Check that the MCB alarm cabling to the main rack is installed and
terminated.
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15. INSTALLATION AND OPERATION OF RECTIFIER MODULES
If for any reason any of the rectifiers have to be removed, or additional rectifiers are being
fitted, please refer to the following procedure. See also section 25, for important information
regarding rectifier operation and positioning.
It is to be noted that the FlatPack2 rectifier module is a “Hot” plug rectifier allowing
expandability and serviceability without power shutdown. The current share functionality of the
modules ensures all modules deliver the same amount of current. The FlatPack2 rectifier
cabinet accommodates up to 9 rectifier modules.
Installing rectifiers
1. Unpack the rectifier modules from their packaging.
2. Refer to section 15.3: for information regarding the correct rectifier positioning.
3. With the system on, slide each module into place, but do not push the rectifier all the way
home at this point. Make sure the pull out handles have been released as shown in figs 15.1
and 15.2 below, then push the unit into place and lock the rectifier into position by pushing
the handles firmly into their housing.
Fig. 15.1
To remove a rectifier, follow the steps below:
1. Unlock and release the handles by inserting a small screw driver into the holes in the
upper corners of the rectifier front panel and carefully push it downwards. The handle will
release and pop out.
Fig. 15.2
2. Use the handles to pull the rectifier loose.
During continuous operation, the metal case of the rectifier unit can become hot.
There is no danger of contact burns occurring, but care should still be taken when
handling recently unplugged rectifiers.
Hole to release the handles spring mechanism
Handle in locked position
Handle in unlocked position
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Fig. 15.3 Flatpack2 front view
The Flatpack2 is intended for use as a stand-alone unit or in systems with multiple modules and
an external alarm / control module. The Flatpack2 will operate in a default mode if the control
module fails
The Flatpack2 Rectifier Module has the following LED indications:
“Power” (green) indicates whether the power supply is OFF, ON, or communicating.
“Alarm” (red) indicates an alarm situation.
“Notice” (yellow) indicates an atypical situation.
15.1 Visual Indications
LED Status Description
Power
(green) ON Rectifier is powered
Flashing Smartpack controller accessing information on the rectifier
OFF Mains are unavailable
Alarm
(red)
ON
Rectifier is in Shut-down Mode due to low mains (0 –
85VAC) or high internal temperature (+75 °C or higher)
Interna
CAN bus failure
OFF
No alarm situation is present
Notice
(yellow)
ON
Rectifier is in Derating Mode (reduced output power) due
to high internal temperature (+45 to 75 °C) or low input
voltage (lower than 185VAC) or fan failure
The remote Current Limit is activated
The rectifier is communication with the controller over a
current sharing / current limiting issue
AC input voltage is out o
Rectifier in stand-alone mode (or loss of communication
with the Smartpack controller
Flashing Rectifier is in Over-voltage Protection Mode
OFF No atypical situation is present
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15.2 Plugging in Rectifiers
When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller
assigns the next available ID number to the rectifier, starting with “01”. This ID number (or
CAN bus address) and the rectifier’s serial number are stored in both SmartPack and Rectifier
modules.
When a previously installed (hot plugged) Flatpack2 rectifier is inserted in a power shelf, the
Smartpack controller “recognizes” the module, and assigns the same ID to the rectifier. In
other words, the controller and the rectifier “remember” the assigned ID and serial numbers,
even after removing and reinserting the rectifier in the shelf.
To achieve a more controlled ID assignment, you should always insert & hot-plug new
Flatpack2 rectifiers in the power shelves, one module at a time, starting with shelf position 1, 2,
3 and so on.
During continuous operation, the metal case of the rectifier unit can become hot.
There is no danger of contact burns occurring, but all care should still be taken
when handling recently unplugged rectifiers.
15.3 Identification of different rated rectifiers
Three different types of Flatpack2 rectifiers are compatible these systems; a 1.8kW rectifier &
a 2.0kW rectifier and a 2.0kW HE rectifier. These interoperate fully, including alarms &
current sharing (current sharing is by a percentage of total output). The only functional
difference between the 1.8kW and 2.0kW rectifiers is their maximum power output. For easy
identification, the 1.8kW rectifier has a silver front, the 2kW rectifier has a light blue front and
2kW HE rectifier has a black front.
Fig. 15.4
Flatpack2 1.8kW & 2kW and 2kW HE rectifiers.
Black
2.0kW
Silver
1.8kW
Blue
2kW
‘2000w’
label
HE and 2000W label
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15.4 Replacing and installing rectifier modules
If a upgrading a system with additional rectifiers: Place the new rectifiers into the next highest rectifier position, in order. See table below. Their
existence will be automatically logged by the controller, no further configuration is required.
If a replacing a faulty rectifier and a replacement rectifier is
immediately available: 1. Unclip handles of faulty rectifier as shown above and pull out rectifier.
2. Fit the new rectifier into the position left by the faulty rectifier.
3. Eliminate any rectifier alarm by performing a ‘rectifier recount’ [rectifier reset, under
rectifier info] that resets the number of rectifiers using the front keypad, under user
menu (see section 17.3)
If a replacing a faulty rectifier and a replacement rectifier is not
immediately available: 1. Unclip handles of faulty rectifier as shown above and pull out rectifier.
2. Remove the highest ID rectifier (important) and fit into the vacant faulty rectifier
position, in order to maintain continuity.
3. Eliminate any rectifier alarm by performing a ‘rectifier recount’ [rectifier reset, under
rectifier info] that resets the number of rectifiers using the front keypad, under user
menu (see section 17.3)
NOTE: The highest ID rectifier is now reassigned to the ID of the faulty
rectifier in the system
4. When a new rectifier is obtained, fit it into the highest vacant ID position. Its existence
will be automatically logged by the controller (as in the above scenario, ‘upgrading a
system with additional rectifiers’.)
Smartpack
(controller) ID1 ID4 ID7
(Blank) ID2 ID5 ID8
(Blank) ID3 ID6 ID9
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16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER
(ETHERNET CONNECTION)
The Smartpack controller is physically held in place using similar method as the Flatpack2
rectifiers: It incorporates handles that serve both to lock the module into position and to pull it
out of its housing.
CAUTION: Do not hand-carry the controller by its handles. Cables are plugged to the
controller’s rear panel.
If in the event that the Smartpack needs to be removed for any reason the following procedure
should be used:
1. Release the handles (using similar method as the Flatpack2 rectifiers as described above)
2. Grasp the Smartpack by the handles at either side of the unit and pull the unit out.
The connection cables are attached to the rear of the controller via several ‘D’ type
connectors. Pull out the controller enough to access the rear of the unit, and unplug the
cables as detailed over page. NOTE: make a record of which positions the connectors
were removed from for future reference.
Open the handles before inserting the controller into the power shelf.
To refit the Smartpack:
1. Carefully reconnect the cables to the appropriate positions in the rear of the controller.
2. Slide the controller unit into place making sure that all cables are not overly bent.
3. Fasten the unit by firmly pushing the handles into their housing.
Removing the Smartpack controller
Open the handles (insert a screwdriver into the
holes to release the spring mechanism)
Remove the module
Use both handles to pull the module gently
loose; support it from underneath; hidden
cables are connected to the rear panel.
Fig. 16.1
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WARNING: the rear cables from the system carry live -48V voltages. If completely
disconnecting the controller from the system, ensure that the cable to CON5 is removed
last, as this cable provides the controller with its 48V power. When removing, be careful
that the male plug doesn’t make contact with any metallic material that can cause a short
circuit on the pins. There is no danger to personnel.
Early controllers rear view:
Later controllers with Ethernet connection (242100.118) rear view:
For connection to the internet for remote monitoring, connect CAT5 cable to the back of the
Smartpack and route the cable out through the letterbox aperture at the top rear of the power
rack.
Refer to Webpower section of accompanying CD for information on setting up the network
connection.
NOTE: Do not plug networked cables in to the CAN1 connector, this will damage the CAN bus
internally on the controller.
Ethernet port
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Removing the cables for replacement purposes:
Fig. 16.2
Note, CON 3 is unused, and CON 4 is only used for connection
of the temperature compensation probe.
Remove the controller until the
rear connectors are exposed.
Unplug the cables, leaving CON5
(red surrounds) until last.
Reverse the procedure when
reconnecting the new controller
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17. OPERATION OF THE SMARTPACK CONTROLLER
The Smartpack unit controls, monitors and regulates each FlatPack rectifier module and
provides battery & system surveillance in order to protect and optimize the battery lifetime.
If the alarm module is removed, voltage control / regulation will be lost and system voltage will
equal to default rectifier voltage.
17.1 Front Panel Operation
This chapter describes the Smartpack controller’s keys and indicators, and how to
operate the Flatpack2 DC power system from the controller’s front panel.
Description of Keys, Display and Indicators
The Smartpack controller’s front panel consists of two functional areas: the
presentation area (LCD display and LED lamps) and the control area (keys).
`
LED indicators
The Smartpack controller has the following LED indications:
“Power” (green LED) indicates that the power supply is ON or OFF
“Alarm” (red LED) indicates an alarm situation (major alarm)
“Notice” (yellow LED, or minor warning) indicates an atypical situation.
LCD Display
The graphic display is an important part of the power supply system’s user
interface. The display can be shown in Status Mode (displays the system’s status)
or in Menu Mode (displays the menu structure). Depending on the display’s mode,
the upper line shows the output voltage or menu options, while the lower line
displays battery and load current, alarms, or information about which key to press.
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Front Keys
You can control the whole Flatpack2 DC power system via a network of software
menus accessed with the controller’s front keys.
o Press the key to change from Status Mode to Menu Mode.
o Press the or keys to scroll up or down and navigate to find menu
options (function or parameter).
o Press then the key to select the function.
Modes of Operation
The controller’s display is either in Status Mode or in Menu Mode.
Status Mode
When the front keys are not in operation, the display is in Status Mode. The
following information is then scrolled through the display:
The upper line continuously displays the battery voltage.
The lower line continuously scrolls the following information:
Battery Current
Load Current
Active alarms
Other messages
Menu Mode
When the front keys are in operation, the controller’s display switches to Menu
Mode and the following information is scrolled through the display:
The upper line shows the name of the active menu or sub-menu
The lower line indicates which key to press
Notice: If no keys are pressed within 30
seconds the display will automatically switch
from Menu Mode to Status Mode.
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17.2 Operating Menus, (Menu Mode)
The Flatpack2 DC power system’s functionality is accessed via a network of
software menus and submenus, enabling you to configure and control the whole
power system.
The functionality is divided in two different hierarchical menu structures: the User
Options menus and the Service Options menus (password protected, only
authorized personnel have access to them).
Special, not so frequently used options — such as calibration and adjustments —
are accessible in the Service Options sub-menus.
User Options
When you “enter” Menu Mode, you access the User Options.
How to browse the display menus:
To enter Menu Mode
Press on the key to change from Status Mode to Menu Mode
o Browsing “down” to a menu option
Press the key, to scroll down within the same menu level, and find menu
options (functions or parameters)
o Selecting a menu option
Press the key to select the displayed menu option or parameter
o Browsing “up” to a menu option or level
Press the key to scroll up to the previous menu option, and out to the previous
menu level.
Service Options
When you enter Menu Mode, you access the User Options. You may then scroll
down to the password protected Service Options.
The Service Option’s password is factory-programmed to <0003>. If the wrong
password is entered three times, the controller will be locked out for a period of
time.
Notice: If no keys are pressed within 30
seconds the display will automatically
switch from Menu Mode to Status Mode.
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17.3 Front keypad menu tree for Smartpack controller:
Fig 17.1
NomVolt
BoostVolt
LowBatt1
LowBatt2
HighBatt1
High Batt2
LVD1
LVD2
Sw Info SwInfo
Rectifier Info
NoOfRects. Nn
RECTIFIER RESET
RectCurrent
RectSerialNumber
Rect.PrimaryVolt
Rectifier Status
Rectifier Temp
Mains Info NoOfPhases nn
Mains Status
Mains Voltage
Temp Level Info Temp Level Info
Display messages Display messages
Serial Number Controller S/N
User
VoltAdjustment
Password = Service password
Alarm Reset Alarm Reset
Voltage Info NomVolt
BoostVolt
LowBatt1
LowBatt2
HighBatt1
High Batt2
LVD1
LVD2
Service
Volt Calibration VoltCal
Change Password Password
SetBoostTime BoostTime
Start/StopBoost StartBoost/StopBoost
Auto Boost Cfg Enable/Disable
Threshold
Batt. Test Setup Nxt Test Date Time
End Volt
Max Test Duration
Test Interval
Guard Time
Start/Stop Test StartTest/StopTest
Charge Curr Lim Enable/Disable
Max ChargeCurr
Battery Setup NumOfString
OutputControl Temp.Comp
VoltageControl Change Date/Time
Relay Test Alarm Output 1
Batt Contactor
Load Contactor
Alarm Output nn
Alarm Output 2
BattLifeTime Rst BattLifeTime Rst
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18. REMOTE ALARM CONNECTIONS
The Smartpack controller incorporates 6 alarm relay outputs and provides both normally open
and normally closed states on the output relay. See table 18.1 for pin connections.
PLEASE NOTE: Normal operation is when the system is energized and there are no alarms present on the system.
Fig 18.1 Alarm terminal blocks
Relay Output
Card 2
Relay Output
Card 1
Monitor fail
DCDC converter alarm
terminal block.
Black: common.
White: normally closed
(failsafe)
Brown: normally open. Battery fuse alarm
extension.
Relay Output Card 3
(SP18, SP18-RRU)
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ALARM CONTACT RELAY
# PIN #
TB
Mains Fail
NC
1
5
TB2
COM 6
NO 7
High Load / Low Load
NC
2
8
COM 9
NO 10
High Float / Low Float
NC
3
9
TB1
COM 10
NO 11
Battery Fuse/CB fail
NC
4
12
COM 13
NO 14
Rectifier Fail
NC
5
15
COM 16
NO 17
Off Normal
NC
6
18
COM 19
NO 20
NC
External PCB Monitor Fail NO
COM
Figure 18.2 Output relay pin out assignment for SP18 and SP18-RRU Systems
ALARM CONTACT RELAY # RELAY
OUTPUT CARD #
PIN #
Mains Fail NO
1 1
5
Mains Fail COM 6
Mains Fail NC 7
High Load / Low Load NO
2 1
8
High Load / Low Load COM 9
High Load / Low Load NC 10
High Float / Low Float NO
3 2
9
High Float / Low Float COM 10
High Float / Low Float NC 11
Load / Battery CB fail NO
4 2
12
Load / Battery CB fail COM 13
Load / Battery CB fail NC 14
Rectifier Fail NO
5 2
15
Rectifier Fail COM 16
Rectifier Fail NC 17
Off Normal / BCM NO
6 2
18
Off Normal / BCM COM 19
Off Normal / BCM NC 20
Monitor Fail NO External PCB located LHS, above Smartpack controller
Monitor Fail COM
Monitor Fail NC
Table 18.3 Output relay PIN connection for other systems
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Figure 18.4
Top view of monitor fail PCB showing connection points for monitor fail alarm
Alarm name Trigger
Failed AC supply Total loss of any one phase or all phases AC
supply to the system.
Battery CB tripped Failure of any battery CB
Load CB tripped Failure of any load fuse
High Load voltage System voltage is above 57.0Vdc
High Float voltage System voltage is above 55.70Vdc
Low Load voltage System voltage is below 48Vdc
Low Float voltage System voltage is below 52.8Vdc
Failed Rectifier Loss of output and input information from a
rectifier, Loss of communication between
Smartpack controller and rectifier
System monitor failure Smartpack output failure
Table 18.5 Alarm trigger conditions
Common
Normally closed
Normally open
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18.2 Digital inputs.
For SP18 / SP18-RRU Systems:
The alarm PCB also has up to six digital inputs that can be used on, two of which are pre set for
Generator Feed and Off Normal (but disabled).
Input 1: Generator input.
Input 2: Off normal input.
Figure 18.6 Alarm PCB showing digital input pin outs
Input voltage range 0-75V
Terminal impedance 200kΩ
Operating current between terminals 30mA
Figure 18.7 Digital input specification
Input 1: Generator input (Disabled).
When operating on AC mains, the digital input is left open, (its normal state.) If this input is
closed (shorted), the controller will assume that it is now operating from a generator. The
controller will then limit the battery charge current down to a small value in order to limit the
strain introduced on the generator. In this way, the generator can be used to supply only the
load, and not be burdened by also trying to recharge discharged batteries at the same time.
Input 2: Off normal input (Disabled).
When in a normal state the digital input is left open. If this input is closed (shorted), the
controller will extend an off normal alarm on the alarm relay output (relay 6.), This could be
used in combination with a switch to indicate someone is on site.
Input 3: Spare Connection.
Input 4: Load MCB fail alarm.
When a load MCB is in the off position and alarm will be generated and sent to the
Smartpack which will change the state for relay #4. (see Fig 13-3)
Alarm State TB Pin
Input 1 + 2
1
Input 1 - 2
Input 2 + 2
3
Input 2 - 4
Alarm State TB Pin
Input 3 + 1
1
Input 3 - 2
Input 4 + 1
3
Input 4 - 4
Input 5 + 1
5
Input 5 - 6
Input 6 + 1
7
Input 6 - 8
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Input 5: Used for external load fuse alarm (Disabled).
Input 6: Spare Connection.
For more information, refer to Quick Start Guide: Flatpack2, PS System
(356804.103).
For other Systems:
The Smartpack controller accepts up to 6 inputs to the system, 2 are used.
Input 1: Generator input. Normally closed.
Input 2: Off normal input. Normally closed.
Alarm State TB Pin
Input 1 + 1
1
Input 1 - 2
Input 2 + 1
3
Input 2 - 4
Alarm State TB Pin
Input 3 + 2
1
Input 3 - 2
Input 4 + 2
3
Input 4 - 4
Input 5 + 2
5
Input 5 - 6
Input 6 + 2
7
Input 6 - 8
Input 1: Generator input.
When operating on AC mains, the digital input is left open, (its normal state.) If this input is
closed (shorted), the controller will assume that it is now operating from a generator. The
controller will then limit the battery charge current down to a small value in order to limit the
strain introduced on the generator. In this way, the generator can be used to supply only the
load, and not be burdened by also trying to recharge discharged batteries at the same time.
Input 2: Off normal input.
When in a normal state the digital input is left open. If this input is closed (shorted), the
controller will extend an off normal alarm on the alarm relay output (relay 6.)
Pin 1 Pin 10
Pin 1 Pin
20
TB1
TB2
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19. +24 V DC/DC CONVERTER
The Flatpack DC/DC 48/24, a modular hot plug-in DC/DC converter.
Fig 19.1 A DC/DC converter module
The converter is specially designed to provide a high quality and highly reliable DC output
voltage. The module has a soft start power-up and an internal blocking diode allows hot plug-in
and isolates any faults in the converter output from the DC bus. Several internal protection
circuits ensure safe operation, even outside specified limits for normal operation.. A module
failure alarm is given if the module shuts down due to high output voltage, or in case of an
internal failure. Converters connected in parallel will exhibit active load sharing via CAN bus.
Front LEDs show power ON/OFF and alarm status in addition to a LED bar graph for output
current indication. The Flatpack DC/DC 48/24 will operate in ambient temperatures up to
+75°C (+167°F). At temperatures above +65°C the output power may be derated.
This unit has the part number: 241114.503, and is only included in SEF29-X-156 systems .
The output of the 24V DC/DC converter is found on top if the cabinet, via a 175A red
Anderson connection.
The 24V output of the SEF29-X-156 systems are floating. That is, to achieve a non floating
+24V output with respect to the -48V output, the negative of the DC/DC converter will need to
be brought back to the common positive bar inside the distribution at the top of the cabinet.
The alarms extended from the DC/DC converter are to be found on a labeled terminal block
inside the -48V distribution area.
See the attachments for more data regarding the DC/DC Converter.
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Fig 19.2
Do not use the top battery shelf if the DCDC converter rack is being used. If additional battery
strings are needed, please use a battery extension rack. Note: This is relevant only for systems
with a DCDC converter rack fitted.
DCDC converter
rack with 4
modules in place
Do not use this
top battery shelf if
the DCDC
converter rack is
being used.
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20. AC MAIN SUPPLY INSTALLATION
AC mains connection terminals are provided for the AC mains connection. The terminals are
pre-connected to the rectifier modules. Cables of up to 10mm2 size can be connected to these
terminals. Termination or configuration of the AC Mains connection is only to be performed by
a licensed electrical installer.
When connecting power to this system, a nearby AC mains disconnect device should be
integrated into the circuit to facilitate servicing. This could be an isolating switch, circuit
breaker or equivalent device.
Phase distribution on rectifiers
The system is pre-wired to suit a 3-phase +N and Earth AC supply. Other configurations are
possible, see above. The phase distribution for the rectifiers is shown below. While installing
the rectifiers please ensure that they are distributed evenly between phases to ensure a balanced
load on each phase where possible.
Figure 20.1 Cabinet Front view.
Distribution
controller L1 L1 L1
(Blank) L2 L2 L2
(Blank) L3 L3 L3
DC/DC Converter DC/DC Converter
DC/DC Converter DC/DC Converter
Figure 20.2 AC Phase arrangement
9 Way Rectifier Rack – showing AC Phase positions
and (optional) DC/DC converters
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Figure 20.3 Three-Phase
Figure 20.5 1xSingle-Phase
Termination or configuration of the AC Mains connection is only to be performed by a licensed electrical installer.
Three-Phase Input Remove the top panel to access the AC mains terminals.
1) Bring the mains cable into the cabinet through the
top of the cabinet. The cable entry is through the
punch out holes on top of the cabinet. Cable
grommets (gland) need to be installed around the
hole for cable protection.
2) Ensure that the neutral bridges are in place.
3) Connect Earth conductor to terminal PE, Phase
conductors to terminals L1, L2 and L3, and
Neutral conductor to terminal N.
4) Tie the incoming AC cables securely with cable
ties for support. Ensure that cables do not pass
through any sharp edges.
3 x Single-Phase Input(s) Remove the top panel to access the AC mains terminals.
1) Bring the mains cable into the cabinet through the
top of the cabinet. The cable entry is through the
punch out holes on top of the cabinet. Cable
grommets (gland) need to be installed around the
hole for cable protection.
2) Ensure that any neutral bridges are removed.
3) Connect Earth conductor to terminal PE, Phase
conductors to terminals L1, L2 and L3, and
Neutral conductors to terminals N1,N2,N3.
4) Tie the incoming AC cables securely with cable
ties for support. Ensure that cables do not pass
through any sharp edges.
1 x Single-Phase Input Include bridges across the active terminals to activate all 9
rectifier positions, as well as bridges across the neutral
terminals.
Alternatively, if no active bridges are on hand and the
system has need for only three rectifiers, it is possible to
only use the three rectifier positions that are powered by the
single connected phase.
In all these cases the system must be labeled
accordingly.
L1 L2 L3 N N N PE
N Bridges in place
Figure 20.4 3xSingle-Phases
L1 L2 L3 N1 N2 N3 PE
Remove
bridges
L1 L2 L3 N N N PE
Active
bridges
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21. DC DISTRIBUTION INSTALLATION
The FlatPack2 System is equipped with a 24-way distribution module fitted at the top of the
cabinet. The circuit breakers that can be fitted on the standard comb bus are 6x 80-125A
(27mm pitch) + up to 18x 1-63A standard width (18mm pitch) type. The common terminal bar
is located behind the load circuit breakers and is accessible by removing the top cover.
Note: -48V will be present on the output terminals of the MCB’s even when in the off position
and no load is connected, due to MCB monitoring. There is no risk to personnel from this
voltage. The current available from the source for the fuse fail diode matrix (through the
reverse biased diode) at short circuit using a 20MOhm multimeter= 0.0052A when direct
connection is made to the cathode of the sensing diodes. This can be considered a safe level.
When installing DC load cables, be aware of the position of the AC input terminal block, behind the positive common bar.
The circuit breakers are arranged from left to right as:
Position # from
left
Accommodate CB
size CB Factory fitted
1 80 to 125A 100A
2 80 to 125A 100A
3 80 to 125A 125A
4 80 to 125A (125A for DCDC
converter if fitted)
5 80 to 125A
6 80 to 125A
7 1 to 63A 32A
8 1 to 63A 32A
9 1 to 63A 32A
10 1 to 63A 32A
11 1 to 63A 32A
12 1 to 63A 32A
13 1 to 63A 32A
14 1 to 63A 32A
15 1 to 63A
16 1 to 63A
17 1 to 63A
18 1 to 63A
19 1 to 63A 10A
20 1 to 63A 4A
21 1 to 63A 4A
22 1 to 63A 4A
23 1 to 63A
24 1 to 63A
Fig 21.1 DC distribution
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Load Cable Installation Considerations
Consideration should be given to the entry arrangement of load cables to ensure easy
installation of additional load cables when the system is operating.
Ensure protective edging is fitted to any sharp edges over which cables pass.
Ensure cables are suitably supported by a cross beam, making sure not to over stress the
common positive bar and circuit breakers.
22. TEMPERATURE COMPENSATION
The system is supplied with a temperature-sensing probe for temperature compensation
charging. The temperature compensation cable is temporarily cabled tied to the system. The
cable should be carefully untied and the transistor probe should be placed in the middle of the
battery string(s) for measurement of air temperature as close as possible to the batteries. Do not
rest the probe directly against any of the batteries as this will give a false reading in the event of
that individual battery having a fault.
Fig 22.1 Temperature probe deployment should be near, but not touching, the middle string of
batteries.
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Installation Checklist
Check these points OK
Check that the incoming AC connections are correct.
Check that the terminal boots and battery link caps are fitted on all the batteries.
Check that the load connections are of correct polarity
Check that battery string voltage is between -48 and -55 Vdc
Check that the external alarm cabling is installed and terminated
Check that the temperature probe is extended to the batteries.
Check that the temperature compensation is on (activated by default).
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23. COMMISSIONING
Pre-Start / Initial Checks
Check the following: OK
System installation is completed
Check that the system installation has been correctly performed (ref. Installation
sections of this manual).
Battery and load are disconnected
Verify that the battery circuit breakers and load circuit breakers are in the OFF
position.
Rectifier modules are connected
Verify that all rectifier modules are plugged in properly & the front pull out levers
are pushed in. NOTE: Rectifiers are allocated with a ID that is relevant to its
position in shelves.
Rectifier system connected to mains supply and Protective Earth
Check that the system’s mains cable is connected to the mains supply.
System Start-Up
Check the following: OK
Turn the system ON from the AC input supply
Read output voltage* (approx. 54- 55V)
Wait for about 1 min. and check there is DC output voltage* on the alarm module’s
display
Measure output voltage
Use a Digital Voltmeter* to verify that the output voltage is in accordance with
the system’s Default Settings (end of this section) and note in the section
immediately to the right.
VDC
Rectifier modules are ON and without fault alarms
Verify that the Flatpack2 modules are in normal operating mode (not reporting
alarms)
Check and calibrate voltage reading in the alarm display
If the measured voltage deviates more than 0.2V from the display
reading, re-calibrate the alarm module.
Measure
DVM*
Display in
Alarm Mod.
Switch the system OFF at the Input supply
Connect the load MCB
Battery circuit breakers are NOT connected Switch the system ON at the input supply.
Measure the Battery Voltage*
Using a DVM measure the battery voltage Measured
with DVM*
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Adjust output voltage to equal the measured battery voltage from the alarm module’s
keypad adjust the rectifier output voltage to equal ( 1 V) the measured battery
voltage. Temperature-compensated charging must be deactivated when adjusting the
output voltage.
Close the battery circuit breakers
It is important that the system is switched ON before connecting the batteries.
Otherwise, the battery terminals could be damaged by high currents trying to charge
the rectifiers’ internal capacitors.
Adjust output voltage (float voltage) from the alarm module’s
keypad to the voltage recommended by the battery manufacturer
(54.0Vdc at 25°C)
Verify that the Low Battery Alarm is not activated. Record the
voltage*
Measured with DVM*
* DVM must be a Calibrated True RMS meter
Checking the Alarms
The Alarms are factory preset and should not require any re-setting on site. To verify the
operation of the Alarms use the following procedure.
Check the following: OK
1. Mains Fail
Turn off the mains power at the input MCB’s and let the batteries supply
the load.
Verify if the Alarm LED is illuminated on the Alarm Module. Using a
Continuity Tester, check the operation of the N/O N/C relays at the
alarm PCB. Refer to table 18.1. Please ensure batteries are connected
prior to starting this test. Turn on the mains again and verify that the
Active alarm is automatically reset.
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2. The voltage alarms can be tested using any method in which the system
voltage can be varied, or the alarm setting can be adjusted. Two methods
are listed here. Refer to table 18.1 for relay outputs:
External Power Supply Method
ISOLATE THE BATTERIES FROM THE SYSTEM AND CONNECT A
0-60VDC EXTERNAL POWER SUPPLY TO THE OUTPUT BARS. ENSURE THE
CORRECT POLARITY WHEN CONNECTING!
Once the mains to the system is turned off, the controller will display
the output voltage of the external power supply. The power supply can then
be adjusted to activate the various high and low voltage alarms.
This method will have a constant mains alarm as well as the alarms
being tested.
Adjusting Alarm Activation Level Method Connect a PC/laptop to the Smartpack controller and run the latest
version of Powersuite.
Note: Once each of the alarms (below) have been tested, ensure you
change their alarm levels back to their original values. Each alarm is to
be tested, one at a time.
To test High Battery Alarm 1 (High Float), change its value to at
least 0.5V below the system voltage. This will activate an alarm on
the display and at the alarm PCB. Using a Continuity Tester, check
the operation of the N/O N/C relays at the alarm PCB.
To test High Battery Alarm 2 (High Load), change its value to at
least 0.5V below the system voltage. This will activate an alarm on
the display and at the alarm PCB. Using a Continuity Tester, check
the operation of the N/O N/C relays at the alarm PCB.
To test Low Battery Alarm 1 (Low Float), change its value to at least
0.5V above the system voltage. This will activate an alarm on the
display and at the alarm PCB. Using a Continuity Tester, check the
operation of the N/O N/C relays at the alarm PCB.
To test Low Battery Alarm 2 (Low Load), change its value to at least
0.5V above the system voltage. This will activate an alarm on the
display and at the alarm PCB. Using a Continuity Tester, check the
operation of the N/O N/C relays at the alarm PCB.
3. Off Normal
This alarm indicates that a battery test initiated by a PC is in progress,
and can be tested using a PC and the Powersuite software.
Alternatively, short pins 3 & 4 on TB1 to create an off normal ( see
section 18.2 Digital inputs)
4. Rectifier Fail
Ensure the rectifier is off then insert a plastic object into the fan of the
rectifier. Turn ON rectifier; this should give a rectifier fail alarm. Using
a Continuity Tester, check the operation of the N/O N/C relays at the
alarm PCB. The fan should never be stopped by inserting an object into
it while running, as this could damage the fan.
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5. Load Fuse
Turn off one of the load circuit breakers. (Note: The CB must be
connected to a load). This will activate an Alarm on the Display and at
the alarm PCB. Using a Continuity Tester check the operation of the
N/O N/C relays at the alarm PCB.
6. Battery Fuse
NOTE: All battery CB’s have to be ON for there to be NO Battery fuse
alarm. Ensure all vacant battery shelves have heatshrink on their loose
cables When the Battery is connected, simply switch off one Battery circuit
breaker. This will activate an Alarm on the Display and at the alarm PCB.
Using a Continuity Tester, check the operation of the N/O N/C relays at the
alarm PCB.
7. Monitor Fail:
Unlock and release the handles of the SmartPack alarm module by inserting
a small screw driver into the holes in the upper corners of the front panel and
carefully push it downwards. The handle will release and pop out. Remove
CON5 from the rear on the Smartpack controller. This will activate the
Monitor Fail Alarm. Using a Continuity Tester, check the operation of the
N/O N/C relays at the Monitor Fail PCB.
8. DCDC Converter Fail.
Ensure the Converter is off then insert a plastic object into the fan of the
rectifier. Turn ON converter; this should give a converter fail alarm. Using a
Continuity Tester, check the operation of the N/O N/C relays at the
converter alarm PCB. The fan should never be stopped by inserting an
object into it while running, as this could damage the fan.
The DCDC converter alarm terminal block is located to the left of the
cabinet below the monitor fail alarm, and is mounted with the battery
expansion alarm extension. See section 18.
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Default -48V System Settings
Alarm & Boost Settings Factory set
Default
Checked
System Voltage 54.00
High Load Voltage (High Batt 2) 57.60
High Float Voltage (High Batt 1) 55.70
Low Load Voltage (Low Batt 2) 48.00
Low Float Voltage (Low Batt 1) 52.80
Boost Voltage 52.00 -56.00 Disabled
24. GENERAL MAINTENANCE CHECKS
The following general maintenance checks should be performed on all equipment. Detailed
maintenance procedures for specific equipment is included later in this document.
Step Comments
Documentation available Ensure that all relevant site-specific
drawings are available i.e. Layouts, cabling
schedule, signal connections.
Remove front Panels Allowing access to system components.
Carefully vacuum inside underneath and on
top using an insulated hose
Ensuring the system is free from dust and
dirt.
Ensure that all connections are correct Look for any possible defective or loose
connections, and excessive temperatures.
Ensure that all equipment is free from
damage
Verify that damage has not occurred since
installation and commissioning
Check the alarm voltage settings using the
“User” menu via the front keypad
Verify that all alarm voltage settings are set
as the system default settings.
Check alarm relay operation to remote
monitoring by toggling individual relays
using the “Service” menu via the front
keypad.
Call remote monitoring station and confirm
operation as required.
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25. MODULE MAINTENANCE
The Flatpack2 rectifier has no customer
serviceable components
Should a rectifier exhibit a fault, simply pop
the handles out, and pull out using these same
handles on the front of the module
(Contact Eltek Pacific for repairs/
replacement)
The DC/DC converter has no customer
serviceable components.
Should a converter exhibit a fault, simply pop
the handles out, and pull out using these same
handles on the front of the module
(Contact Eltek Pacific for repairs/
replacement)
26. GENERAL PROCEDURES
As a general requirement we would recommend the following checks be made to the system at
six monthly intervals.
Check Frequency Purpose
Visual inspection Monthly To identify any obvious problems. Such as
corrosion to terminal posts, leaking batteries,
not excessively dirty or dusty, not
mechanically damaged in any way
Battery Discharge
Test via control
module
6 monthly To determine battery performance
Check and adjust
DC output voltage
6 Monthly To ensure rectifier is charging at correct
voltage level.
Torque battery
terminals
6 Monthly To ensure correct level of torque as per battery
manufacturers install instructions.
General clean 6 Monthly Wipe down systems remove any dust build up
27. SYSTEM COMPONENTS MINIMUM OPERATING LIFE
Description Minimum
Operating
Life (years)
Potential
Failure
Indication Action
FlatPack2
Rectifier
>15 Fault LED
lit
Red LED lit Replace
Module
Smartpack
Control Module
>15 Monitor
Failure
Monitor fail
relay
Replace
Module
DC/DC Converter >15 Failure Red LED lit Replace
Module
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28. POWERSUITE AND WEB POWER
Installation and Using of PowerSuite Software.
The PowerSuite system communication software must be installed on your personal
computer. PowerSuite is available on CD-ROM. By inserting the CD-ROM in the CD-
ROM drive. The installation program will guide you through a complete installation.
Setting up Communication between PC and Smartpack.
There are two methods to build the connection between a computer and a SMARTPACK.
Firstly, a connection can be set from a computer, via an A-B USB cable, to the USB port in
the front panel of a SMARTPACK.
The following steps show how to login to PowerSuite.
1. Via USB connection open PowerSuite 3.3, go to “Connect” “Serial (Virtual USB) 1”
“Find COM Port #” enter Password “3” and click “Connect”.
Figure 28.1 Connect to the Smartpack
2. If you have an Ethernet connection plugged into the back of the Smartpack, then you
can communicate with the Smartpack. You will need to setup the IP address of the
Smartpack following the Webpower system manual (which is on the accompanying
CD). To open an Ethernet connection, open PowerSuite 3.3, go to “Network” “New
Connection”, fill in the IP address, enter password “3” and click “Connect”.
On the CD you will find “Webpower install” folder and the EVIPsetup file in the Eltek
Network Utility folder that can be used to set up the IP address of the Smartpack.
Following the manual (also in this folder) will show how to setup the IP and log into the
PowerSuite via local network.
Figure 28.2 Contents of accompanying CD
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Configuration of the Smartpack
The Smartpack is pre-configured before shipment, and all the pre-configuration is saved in an
“xml” file on the CD. To upload the configuration to the Smartpack, simply import the “xml”
file to Smartpack via PowerSuite. If it is necessary to re-configure it, please follow the step
below.
1. Import the required “.xml” file into Smartpack. Go to “Power Suite” “Tools”
“Import/Export Configuration” “Source” “Read from file” .Click “Open…”
Figure 28.3 Import “xml” file (a)
2. Check the box “Read from file” and click “NEXT”, browse to your xml file on the CD
and follow the prompts.
Figure 28.4 Import “xml” file (b)
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Using PowerSuite to Monitor the Smartpack
The site information should be updated at the beginning of the commissioning (Fig 15.6).
Message 1 and 2 will be filled out already with some information.
Figure 28.5 Site Information Window
The status of each part of the power system can also be read
form PowerSuite. To check the status of any particular part
of the system, simply double click the name of the coloured
indicator in the “Power Explorer”. Alarm indicators:
The “Green” shows working normally.
The “Red” means a failure is present or power is
disconnected.
Figure 28.6 Power Explorer bar
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The other parameters of the power system can be read and set in the function block above the
Power Explorer.
Figure 28.7 Other Configuration Tools
The Active alarm group window under “Alarms Overview” will give you a quick snapshot of
the alarms that are on the system.
Figure 28.8 Activate Alarm Group Window
For more detailed information on using PowerSuite see the attachment:
PowerSuite User Guide (356807.063)
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29. ATTACHMENTS
29.1 Flatpack2 2kW rectifier Datasheet
29.2 Flatpack2 1.8kW rectifier Datasheet
29.3 Smartpack Datasheet
29.4 Flatpack DC/DC -48/+24 Datasheet
29.5 12FFT100 Battery Datasheet
29.6 12FIT100 Battery Datasheet
29.7 Battery MSDS
29.8 TG6209 Battery bracket label swatch
29.9 TG5537 Front panel label swatch
29.10 TG5536 Black on Yellow self adhesive vinyl labels
29.11 TG6208 Software setting file FP2
29.12 TG6223 Alarm matrix FP2
29.13 TG6228 Alarm matrix DC/DC converter
29.14 TG6217 Alarm pinout FP2
29.15 TG6210 General arrangement SEF29-X-149
29.16 TG6211 General arrangement SEF29-X-150
29.17 TG6215 General arrangement SEB5-12FIT100-002
29.18 TG6216 General arrangement SEB6-12FFT100-002
29.19 TG6222 General arrangement SEF29-X-156
29.20 TG6308 Cabinet to wall support channel
29.21 TG6224 Wiring diagram (Legacy)
29.22 TG6682A Schematic for SP18 System
29.23 TG6683A Schematic for SP18-RRU System
29.24 TG6678A General arrangement SP18 system
29.25 TG6667D General arrangement SP18-RRU system
29.26 TG9280A General arrangement SP18 Battery Extension Rack
29.27 PowerSuite User Guide (356807.063)
www.eltekvalere.com See reverse side for specifications
Flatpack2 48/2000 HE Rectifier Module
Product Features and Advantages Flexibility and reliability Extensive use of digital controllers has enabled advanced functionality to meet most customers’ requirements. It also provides intelligent self-protective features like reduced output power at high temperatures or low mains. Plug and play Plug a new rectifier into the system, and it automatically logs on, gets an assigned ID, downloads the system set parameters from the control system and starts up with a minimum of installation time, and without interrupting the system or attached equipment. The HE rectifier is made fully compliant with the standard Flatpack2 rectifier which means it can be used in any FP2 system solutions, whether it is in new installations, site expansions or replacement programs. Global compliance Eltek Valere is among the market leaders in all regions in the world, and designs the core products to be compliant to all relevant standards and customer requirements. All Flatpack2 rectifiers are CE marked, UL recognized and NEBS compliant. Patents pending Flatpack2 HE is a result of intensive research over many years. Several unique technical solutions are introduced, protected by patent applications.
The most efficient rectifier in the industry!
The combination of innovative design, efficiency and reliability makes
the Flatpack2 HE stand out. With an efficiency up to 96.5%, the losses
have been reduced by 50% compared to the current industry standard.
In a global perspective, considering the high energy consumption in the
telecom industry, this technology breakthrough is not only reducing
operational cost for the operators, but it can also have a significant environmental impact.
Applications Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost effective and compact DC power systems. Flatpack2 HE delivers an industry leading power density and superb reliability at lowest lifetime cost. The HE rectifier also has an extremely high efficiency at low load, which historically has been a drawback with most modern soft switching technologies.
Broadband and network access Increasing network speed demands flexible and expandable DC power solutions. The Flatpack2 HE rectifiers are your key building blocks for future needs.
Small and large Due to the high power density, cost competitive design and a highly flexible system communication interface, Flatpack2 HE rectifiers are used in system solutions from 2kW to 192kW.
www.eltekvalere.com
Eltek Valere Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
Applicable Standards Electrical safety IEC 60950-1
UL 60950-1 CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 EN 61000-6-1 (immunity, light
industry) EN 61000-6-2 (immunity, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-4 (emission, industry) Telcordia NEBS GR1089 CORE
Mains Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2-1 Class 1.2 ETSI EN 300 019-2-2 Class 2.3 ETSI EN 300 019-2-3 Class 3.2 ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant
Specifications are subject to change without notice
Efficiency
85%
90%
95%
100%
200 400 600 800 1000 1200 1400 1600 1800 2000
Output Load (W)
96% 95%
241115.105.DS3 – v9
Flatpack2 48/2000 HE Additional Technical Specifications
Ordering Information
Part no. Description 241115.105 Flatpack2 48/2000 HE
AC Input Voltage 85-300 VAC (Nominal 185 – 275 VAC)
Frequency 45 to 66Hz
Maximum Current 11.6 Arms maximum at nominal input and full load
Power Factor > 0.99 at 50% load or more
Input Protection o Varistors for transient protection o Mains fuse in both lines o Disconnect above 300 VAC
DC Output Voltage 53.5 VDC (adj. range: 43.5-57.6 VDC)
Output Power 2000 W at nominal input
Maximum Current 41.7 Amps at 48 VDC and nominal input
Current Sharing ±5% of maximum current from 10 to 100% load
Static voltage regulation
±0.5% from 10% to 100% load
Dynamic voltage regulation
±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms
Hold up time > 20ms; output voltage > 43.5 VDC at 1500W load
Ripple and Noise o < 100 mV peak to peak, o 30 MHz bandwidth o < 2 mV rms psophometric
Output Protection o Overvoltage shutdown o Hot plug-in - Inrush current limiting o Short circuit proof o High temperature protection
Other Specifications Efficiency >96% at 30-70% load
Isolation 3.0 KVAC – input and output 1.5 KVAC – input earth 0.5 KVDC – output earth
Alarms: o Low mains shutdown o High temperature shutdown o Rectifier Failure o Overvoltage shutdown on output o Fan failure o Low voltage alarm at 43.5V o CAN bus failure
Warnings: o Low temperature shutdown o Rectifier in power derate mode o Remote battery current limit activated o Input voltage out of range, flashing at
overvoltage o Loss of CAN communication with
control unit, stand alone mode
Visual indications
o Green LED: ON, no faults o Red LED: rectifier failure o Yellow LED : rectifier warning
Operating temp
-40 to +75°C (-40 to +167°F)
Storage temp -40 to +85°C (-40 to +185°F)
Cooling Fan (front to back airflow)
Fan Speed Temperature and current regulated
MTBF > 350, 000 hours Telcordia SR-332 Issue I, method III (a) (Tambient : 25°C)
Acoustic Noise
< 20dBA at nominal input and full load (Tambient <= 25°C)
< 56dBA at nominal input and full load (Tambient > 40°C)
Humidity Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing
Dimensions 109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)
Weight 1.950 kg (4.3lbs)
www.eltekvalere.com See reverse side for specifications
Flatpack2 48/2000 Rectifier Module
Key Features
Highest efficiency in minimum space Resonant topology makes the module efficiency industry leading and contributes to the rectifier’s ultra compact dimensions. Digital controllers Primary and secondary controls are digitalized, enabling excellent monitoring and regulation characteristics. Thus, the number of component has been reduced by 40% - for highly reliable, long life, trouble free DC power systems. Heat management Front-to-back air flow with chassis-integrated heat sinks gives the module the most suitable working environment and no limitations in the scalability of the desired system solution. Unique connection A true plug-and-play connection system: time-to-install and cost-reducing solution. Global approvals Flatpack2 is CE marked, UL recognized and NEBS certified for worldwide installation.
Versatile and powerful solution for any application
The combination of cost-effective design, power density and
reliability makes the Flatpack2 a product family that truly stands
outs and provides unparalleled network availability. The versatility
of the Flatpack2 rectifier means that it can be used in a wide variety of 48VDC and 24VDC applications across the globe.
Applications
Wireless, fiber and fixed line communication Today’s communications demand state of the art, cost effective and compact DC power systems. Flatpack2 delivers an industry leading power density and superb reliability at lowest lifetime cost
Broadband and network access Increasing network speed demands flexible and expandable DC power solutions. The Flatpack2 rectifiers are your key building blocks for future needs.
Small and large Due to the high power density, cost competitive design and a highly flexible system communication interface, Flatpack2 rectifiers are used in system solutions from 5kW to 96kW. Product Description The Flatpack2 is a battery charger and rectifier for stand-alone use or for working in parallel as part of a DC power system controlled and monitored by the Smartpack. Flatpack2 is optimized for a wide range of system sizes. Digital communication over CAN bus with Smartpack simplifies system design and enhances flexibility. Realization of Flatpack2 systems is possible by fitting 4 rectifiers across a 23” or 19” shelf.
www.eltekvalere.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
Applicable Standards Electrical safety IEC 60950-1
UL 60950-1 CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-1 (immunity, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-4 (emission, industry) Telcordia NEBS GR1089 CORE
Mains Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2 (-1, -2, -3) ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant
Specifications are subject to change without notice 241115.100.DS3 – v6
Flatpack2 48/2000 Additional Technical Specifications
Ordering Information
Part no. Description 241115.100 Flatpack2 48/2000
Input AC Voltage 85-300 VAC (Nominal 185 – 275 VAC)
Frequency 45 to 66Hz
Maximum Current 12.5 Arms maximum at nominal input and full load
Power Factor > 0.99 at 50% load or more
DC Voltage 120-275VDC (Rated 140 – 250VDC)
Input Protection o Varistors for transient protection o Mains fuse in both lines o Disconnect above 300 VAC
DC Output Voltage 53.5 VDC (adj. range: 43.5-57.6 VDC)
Output Power 2000 W at nominal input
Maximum Current 41.7 Amps at 48 VDC and nominal input
Current Sharing ±5% of maximum current from 10% to 100% load
Static voltage regulation
±0.5% from 10% to 100% load
Dynamic voltage regulation
±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms
Hold up time > 20ms; output voltage > 43.5 VDC at 1500W load
Ripple and Noise o < 100 mV peak to peak, o 30 MHz bandwidth o < 0.96 mV rms psophometric
Output Protection o Overvoltage shutdown o Blocking diode o Short circuit proof o High temperature protection
Other Specifications Efficiency Typical 92%, min. 91% at 40-90% load
Isolation 3.0 KVAC – input and output 1.5 KVAC – input earth 0.5 KVDC – output earth
Alarms: o Low mains shutdown o High temperature shutdown o Rectifier Failure o Overvoltage shutdown on output o Fan failure, one or two fans. o Low voltage alarm at 43.5V o CAN bus failure
Warnings: o Low temperature shutdown o Rectifier in power derate mode o Remote battery current limit activated o Input voltage out of range, flashing at
overvoltage o Loss of CAN communication with
control unit, stand alone mode
Visual indications
o Green LED: ON, no faults o Red LED: rectifier failure o Yellow LED : rectifier warning
Operating temp
-40 to +75°C (-40 to +158°F)
Storage temp -40 to +85°C (-40 to +185°F)
Cooling 2 fans (front to back airflow)
Fan Speed Temperature and current regulated
MTBF > 350, 000 hours Telcordia SR-332 Issue I, method III (a) (Tambient : 25°C)
Acoustic Noise
< 55dBA at nominal input and full load (Tambient < 30°C)
Humidity Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing
Dimensions 109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)
Weight 1.9 kg (4.19lbs)
www.eltekenergy.com I www.flatpack2.com
Flatpack2 48/1800
Switch Mode Power Supply 48VDC
Key Features
ü Highest efficiency in minimum space
Resonant topology makes the module efficiency industry
leading and contributes to the rectifier’s ultra compact
dimensions.
ü Digital controllers
Primary and secondary controls are digitalized, enabling
excellent monitoring and regulation characteristics.
Thus, the number of component has been reduced by
40% - for highly reliable, long life, trouble free DC
power systems.
ü Heat management
Front-to-back air flow with chassis-integrated heat sinks
gives the module the most suitable working
environment and no limitations in the scalability of the
desired system solution.
ü Unique connection
A true plug-and-play connection system: time-to-install
and cost-reducing solution.
ü Global approvals
Flatpack2 is CE marked, UL recognized and NEBS
certified for world wide installation.
Product Description
The Flatpack2 is a battery charger and rectifier for
stand-alone use or for working in parallel as part of a
DC power system controlled and monitored by the
Smartpack.
Flatpack2 is optimized for a wide range of system sizes.
Digital communication over CAN bus with Smartpack
simplifies system design and enhances flexibility.
Realization of Flatpack2 systems is possible by fitting 5
rectifiers across a 23” shelf and 4 rectifiers across a 19”
shelf.
Applications
Wireless, fiber and fixed line communication
Today’s communications demand state of the art, cost
efficient and compact DC power systems. Flatpack2
delivers the industry leading power density of 21W/in3
and superb reliability at lowest lifetime cost.
Broadband and network access
Increasing network speed demands flexible and
expandable DC power solutions. Flatpack2 is your key
building block for future needs.
Flatpack2 Switch Mode Power Supply 48VDC
109.00
41.5
0
327.22
(coming up…)
109 mm 327 mm
41,5
mm
Location Company Telephone Fax Europe Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10 Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118 Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602 China Eltek Energy Ltd. +852 28982689 +852 28983189 Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175
www.eltekenergy.com I www.flatpack2.com
Flatpack2 Additional Technical Specifications AC Input
Voltage 85-290 VAC (Nominal 185 – 275 VAC)
Frequency 45 to 66Hz
Maximum Current
10.7 Arms maximum at nominal input and full load
Power Factor > 0.99 at 20% load or more
Input Protection Varistors for transient protection Mains fuse in both lines Disconnect above 290 VAC
DC Output Voltage 53.5 VDC (adj. range: 43.5-56.0 VDC)
Output Power 1800 W at nominal input
Maximum Current 37.5 Amps at 48 VDC and nominal input
Current Sharing ±3% from true average current between modules
Static voltage regulation
±0.5% from 10% to 100% load
Dynamic voltage regulation
±5.0% for 10-90% or 90-10% load variation, regulation time < 50ms
Hold up time > 20ms; output voltage > 43.5 VDC at 1500W load
Ripple and Noise < 100 mV peak to peak, 30 MHz bandwith < 0.96 mV rms psophometric
Output Protection Overvoltage shutdown Blocking diode Short circuit proof High temperature protection
Other Specifications Efficiency Typical 92%, min. 91% at 40-90% load
Isolation 3.0 KVAC – input and output 1.5 KVAC – input earth 0.5 KVDC – output earth
Alarms: Warnings:
Low mains shutdown High temperature shutdown Rectifier Failure Overvoltage shutdown on output Fan failure, one or two fans. Low voltage alarm at 43.5V CAN bus failure Rectifier in power derate mode Remote battery current limit activated Input voltage out of range, flashing at overvoltage Loss of CAN communication with control unit, stand alone mode
Visual indications
Green LED: ON, no faults Red LED: rectifier failure Yellow LED : rectifier warning
Operating temp
-40 to +70°C (-40 to +158°F)
Storage temp -40 to +85°C (-40 to +185°F)
Cooling 2 fans (front to back airflow)
Fan Speed Temperature and load regulated
MTBF > 250, 000 hours Telcordia SR-332 Issue I, method III (a)
Acoustic Noise < 50dBA at nominal input and 70% load (Tambient < 30°C)
Humidity Operating: 5% to 95% RH non-condensing Storage: 0% to 99% RH non-condensing
Dimensions 109 x 41.5 x 327mm (wxhxd) (4.25 x 1.69 x 13”)
Weight 1.8 kg (3.97 lbs)
Applicable standards Electrical safety IEC 60950-1
UL 60950-1 CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 (telecommunication network) EN 61000-6-4 (emission, industry) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry) EN 61000-6-1 (immunity, light industry) Telcordia NEBS GR1089 CORE
Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2 ETSI EN 300 132-2 Telcordia NEBS GR63 CORE Zone 4 RoHS compliant (pending)
Specifications are subject to change without notice. ORDERING INFORMATION
Part no. Description
241115.001 Flatpack2 48V
Document Rev. No.: 241115.001.DS3 v.05
www.eltekvalere.com See reverse side for specifications
Smartpack Controller Monitoring and Control Unit
Key Features ü Front panel LCD and buttons for on-site service without
PC. (Not on Basic Slave model)
ü USB- or RS-232 interface for PC connection locally or remote monitoring and control via modem, Ethernet, web or SNMP.
ü 6/2 user programmable relay outputs for traditional remote monitoring
ü 6/2 user programmable inputs for monitoring of other equipment on site
ü Battery monitoring and testing without site attendance
ü Temperature compensated charging for increased battery lifetime
ü Battery lifetime indication
ü Password protected operator access levels
ü Alarm/event log with time and date
ü Windows-based PC communication software
Powerful and cost effective control module
The Smartpack controller is a monitoring and control unit used as
the vital nerve center of the DC power plant. You operate the
system from the elegant front panel, using three front keys and the
LCD-display. They represent the main interface between you and the system.
Applications
CAN bus communication Smartpack utilizes a digital interface architecture (CAN bus communication). It allows the unit to support dedicated communication channel with each rectifier, providing for increased number of functions and greater flexibility.
Modular design The Smartpack is extremely flexible in its expandability. Additional units connected to the CAN bus can be added to provide extended functionality and increased number of measuring points. Accordingly, system components can be set up and upgraded to meet the demand of any tailor-made power solution. Product Description The Smartpack controller is a powerful and cost-effective module, developed for monitoring and controlling a wide range of Eltek Valere’s DC power supply systems, such as Powerpack, Flatpack2 and Minipack DC power systems. You can also operate the system locally via a PC using the PowerSuite PC application, or remotely via modem, Ethernet and the Web. The module then utilizes the USB- or RS-232 ports to interface with a local PC, SNMP or Web adapters.
www.eltekvalere.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
Specifications Input Voltage 24/48/60 VDC
nominal system voltages
Dimensions (WxHxD)
109 x 44 (1U) x 140mm 4.3 x 1.7 x 5.5”
Specifications are subject to change without notice 242100.100.DS3– v7
Smartpack Controller Additional Technical Specifications
Ordering Information
Part no. Description 242100.110 Smartpack Extended (6 + 6 I/O, 2 String Battery connection) 242100.111 Smartpack RS-232 front (RS-232, 6 + 6 I/O, 2 String Battery connection) 242100.112 Smartpack RS-232 rear (RS-232, 6 + 6 I/O, 1 String Battery connection) 242100.113 Smartpack WEB/SNMP (Ethernet, 2 + 2 I/O, 2 String Battery connection) 242100.118 Smartpack WEB/SNMP (Ethernet, 6 + 6 I/O, 1 String Battery connection) 242100.000 Smartpack Basic Slave (without display, buttons & internal power for distributed systems)
Remote Monitoring and Control ü From a PC running PowerSuite
a Windows-based communication program installed on a remote computer, the system can be monitored and controlled via modem or Ethernet network
ü From a PC running a WEB Browser the system can be monitored and controlled via Ethernet network
ü From an NMS via Ethernet (SNMP) With an SNMP agent connected to the Smartpack, the system can be monitored and controlled from a Network Management System (NMS) through Ethernet on Simple Network Management Protocol (SNMP)
ü Using alarm relays (voltage free contacts) 6/2 internal failsafe alarm relays provide voltage free contacts that can be connected to equipment used for traditional alarm monitoring
Features System o Output Voltage Measurement o Total Load Current Measurement o Load/Battery Disconnect o Alarm Level Settings (major / minor) o Alarm Log (up to 1000 events, 10k on HW v2) o Real Time Clock with Battery Backup o Site Text/ID o Test of Relay Outputs o Voltage Level setup o Data logging (up to 7000 data points)
Battery o Battery Current Measurement o Battery Temperature Measurement (optional) o Battery Testing (acc. to discharge table or set time limit) o Battery Test Information (10 latest tests) o Setup of Battery Data o Battery shunt setup o Battery quality indication o Battery Boost Charging o Battery Cable Voltage Drop Compensation o Temperature Compensated Charging o Protection against Temperature Probe Failure
Rectifier o Available information about each rectifier, e.g. serial o number, version, internal temperature o Individual Rectifier Current Measurement o Individual Rectifier Input Voltage o Efficiency Management
Local Monitoring and Control ü From a PC running PowerSuite
a Windows-based communication software, can also communicate with the Smartpack through an USB serial or RS-232 cable
ü LCD and three keypads for local operations If any alarm (major or minor) is activated, a (red or yellow) LED is lit in the front panel, the alarm text appears in the LCD and the corresponding alarm relay is activated In normal operation, the front LCD will display the output voltage, battery current, load current and charge mode. (Not on Basic Slave version)
Available Alarms All alarms can be set up with monitoring of minor, major, average and peak levels. System o Mains Failure (individual phases) o Digital Inputs (programmable names) o Load Disconnect (voltage or timer) o Load Fuse o Load Current
Battery o High Battery voltage o Low Battery voltage o High Battery temperature o Low Battery temperature o Battery Capacity o Battery Disconnect o Battery Fuse o Symmetry Failure o Battery quality indication Battery discharge current
Rectifier o Rectifier Failure o Critical Rectifier Failure (> 1, programmable) o Rectifier Capacity w. programmable level o Rectifier Current Limit o Rectifier Overvoltage Protection o Rectifier Current
Flatpack DC/DC | 48/24DC/DC Converter
The converter is specially designed to provide a high
quality and highly reliable DC output voltage.
Switch mode technology with soft switching and high
switching frequency is used to minimise volume and
weight, and to obtain fast output voltage regulation.
The module has a soft start power-up. When working in
parallel, the converters provide active current sharing.
An internal blocking diode allows hot plug-in and
isolates any faults in the converter output from the DC-
bus.
Several internal protection circuits ensure safe
operation, even outside specified limits for normal
operation.
The Flatpack DC/DC 48/24 is a modular hot plug-inDC/DC converter prepared for stand-alone use, or forworking in parallel as part of a DC/DC rack system.
A module failure alarm is given if the module shuts down
due to high/low input voltage, high output voltage
(selective), or in case of an internal failure.
Converters connected in parallel will exhibit active load
sharing, even without a Monitoring and Control Unit via
CAN bus.
Front LEDs show power ON/OFF and alarm status in
addition to a LED bar graph for output current indication.
The Flatpack DC/DC 48/24 will operate in ambient
temperatures up to +75°C (+167°F). At temperatures
above +65°C (+149°F), the output power may be
derated.
Location Company Telephone FaxEurope Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602China Eltek Energy Ltd. +852 28982689 +852 28983189Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175
FLATPACKDC/DC 48/24
SPECIFICATIONS
INPUTInput Voltagerange
40.0-60 VDC
Maximum Current 32 Amps at 40.0 VDC inputProtection Soft start
Internal fuseAutomatic shutdown for inputvoltages < 40 VDC and >62 VDC
OUTPUTOutput Voltage 24-28 VDCOutput Power 1100 W at 27.5 VDCOutput Current 40 Amps at 24 VDCCurrent Share ± 2 AmpsStatic VoltageRegulation
±0.5% from 0 to full load
Dynamic VoltageRegulation
±4.0% for 10-90%or 90-10% load variation
Ripple and Noise <100 mV peak to peak,30 MHz bandwidth
Protection Blocking diodeNon-destructive short circuitoperation and selective highoutput voltage shutdown(30 V)
OTHER SPECIFICATIONSIsolationVoltages
Input/ Earth: 600 VDCInput/ Output: 600 VDCOutput/ Earth: 600 VDC
Converteralarms
No output voltageOvervoltage shutdownFan failure 1 or 2High temperature shutdownShort circuit/ fold back activated
Converterwarnings
DC input voltage out of rangeSingle fan failureHigh temperature/ derating activatedCurrent limit
Visualindications
Green LED: ON, no faultsRed LED: No output, converter failureYellow LED bargraph: measuringoutput current (0-100%)
Efficiency 90% typicalOperatingTemp
-40 to +65°C (-40 to +149°F)+65 to +75 °C (+149 to +167°F):Temperature dependent powerlimiting may occur
Storage Temp -40 to +85 °C (-40 to +185°F)Cooling Temperature controlled fansAcoustic Noise 6.3 BelsDimensions 218 x 43 x 240mm (wxhxd)
(8.58 x 1.69 x 9.45”)Weight < 3kg (< 6.6lbs)
APPLICABLE STANDARDSElectrical 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)EN 61000-6-4 (emission, industry)EN 61000-6-1 (immunity, lightindustry)Telcordia GR1089 CORE
Environment ETSI EN 300 019-2ETSI EN 300 132-1ETSI EN 300 132-2Telcordia GR63 CORE Zone 4ETSI EN 300 753 class 3.1(acoustic noise)
Specifications are subject to change without notice.
ORDERING INFORMATIONPart no. Description
241114.503 Flatpack DC/DC 48/24 converter
241114.503. DS3 v.02
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Industrial Batteries DepartmentViale Europa, 63 - 36075 Montecchio Maggiore (VI)
ITALY
MATERIAL SAFETY DATA SHEET
FIAMM BATTERIES: Monolite
PRODUCT CHARACTERISTICS
PRODUCTValve Regulated Lead Acid Sealed batteries with absorbed electrolyte wet (non spillable).
PRODUCT TECHNICAL COMPONENTS
Components Description %Lead and Compounds Pb, PbO2, PbSO4 70-80Electrolyte Sulphuric acid in max concentration of 35% 12-20Polymer ABS 6-9
TECHNICAL NAME OF DANGEROUS SUBSTANCESealed batteries containing a solution of sulphuric acid and distilled water, completely
absorbed in separators.
PROPERTIES OF CONTAINERABS polymer, flame retardant FV0, anti-cracking.
PROPERTIES OF DANGEROUS SUBSTANCELiquid, clear, colourless.
BOILING POINT OF DANGEROUS SUBSTANCE110o C
CLASSIFICATION OF DANGEROUS SUBSTANCEClass 8Code page IMDG IMCO No.8121UN No 2800
PACKAGING REQUIRED FOR TRANSPORTATIONBatteries have to be packed in strong outer packagings after insulating each cell
terminals.Packaging Group III
IMPORTANT NOTEThere is no electrolyte in liquid status inside the battery due to the fact that this
electrolyte is completely absorbed by a spungy material.This means that even if you turn upside down (ermetically closed) there will be no
leakage of the electrolyte.Conditions will not change below boiling point (110o C).
SAFETY DATA
NATURE OF HAZARDCorrosive liquid electrolyte causes damage to eyes, skin & air passages.Attacks many materials & clothing.Attacks many metals with liberation of hydrogen which is flammable and forms an
explosive mixture with air.Stored electrical energy.
PROTECTIVE MEASURESGoggles giving complete protection to eyes, acid resistant clothing and gloves, and
safety footwear.Have available an eyewash bottle with clean water.Store in a cool dry place.Keep all vent plugs in position.Charge in a well ventilated area, avoid breathing mist.Keep away from sources of ignition, do not allow smoking or any naked lights.Keep away from children.For safe operating practices see BS 6287:1982
FIRST AIDIf substance has got into eyes, immediately wash out with plenty of water.If ingested drink copious amounts of water and seek immediate medical attention.Remove any contaminated clothing and wash skin with water.Seek medical treatment.
SPILLAGEClose off or contain leak if without risk, using plastic containers if available.Neutralise with soda ash, sodium carbonate or sodium bicarbonate.If undiluted substance has entered a watercourse or contaminated soil or vegetation,
advise local authority.
FIREIf circuit still made, and if safe to do so, the emergency services may sever cables with
fireman’s axe.Smother with dry powder or foam.If necessary keep containers cool by spraying with water.
DISPOSALThis product is defined in SI 232:1994 as being for fitment to an excluded appliance.The cells contain heavy metal and must not be put out for collection in refuse containers.Keep all constituents enclosed and upright.Dispose of only to authorised scrap recoverer.Move only in accordance with local authority requirements.Do not incinerate or throw away.
_____________________________________________________________________________Fiamm Asia Pacific Pte Ltd36 Tuas CrescentSingaporeTel 0065 8653278Fax 0065 8626550
Industrial Batteries DepartmentViale Europa, 63 - 36075 Montecchio Maggiore (VI)
ITALY
MATERIAL SAFETY DATA SHEET
FIAMM BATTERIES: SLA/FAT/UMTB
PRODUCT CHARACTERISTICS
PRODUCTValve Regulated Lead Acid Sealed batteries with absorbed electrolyte wet (non spillable).
PRODUCT TECHNICAL COMPONENTS
Components Description %Lead and Compounds Pb, PbO2, PbSO4 70-80Electrolyte Sulphuric acid in max concentration of 35% 12-20Polymer ABS 6-9
TECHNICAL NAME OF DANGEROUS SUBSTANCESealed batteries containing a solution of sulphuric acid and distilled water, completely
absorbed in separators.
PROPERTIES OF CONTAINERABS polymer, flame retardant FV0, anti-cracking.
PROPERTIES OF DANGEROUS SUBSTANCELiquid, clear, colourless.
BOILING POINT OF DANGEROUS SUBSTANCE110o C
CLASSIFICATION OF DANGEROUS SUBSTANCEClass 8Code page IMDG IMCO No.8121UN No 2800
PACKAGING REQUIRED FOR TRANSPORTATIONBatteries have to be packed in strong outer packagings after insulating each cell
terminals.Packaging Group III
IMPORTANT NOTEThere is no electrolyte in liquid status inside the battery due to the fact that this
electrolyte is completely absorbed by a spungy material.This means that even if you turn upside down (ermetically closed) there will be no
leakage of the electrolyte.Conditions will not change below boiling point (110o C).
SAFETY DATA
NATURE OF HAZARDCorrosive liquid electrolyte causes damage to eyes, skin & air passages.Attacks many materials & clothing.Attacks many metals with liberation of hydrogen which is flammable and forms an
explosive mixture with air.Stored electrical energy.
PROTECTIVE MEASURESGoggles giving complete protection to eyes, acid resistant clothing and gloves, and
safety footwear.Have available an eyewash bottle with clean water.Store in a cool dry place.Keep all vent plugs in position.Charge in a well ventilated area, avoid breathing mist.Keep away from sources of ignition, do not allow smoking or any naked lights.Keep away from children.For safe operating practices see BS 6287:1982
FIRST AIDIf substance has got into eyes, immediately wash out with plenty of water.If ingested drink copious amounts of water and seek immediate medical attention.Remove any contaminated clothing and wash skin with water.Seek medical treatment.
SPILLAGEClose off or contain leak if without risk, using plastic containers if available.Neutralise with soda ash, sodium carbonate or sodium bicarbonate.If undiluted substance has entered a watercourse or contaminated soil or vegetation,
advise local authority.
FIREIf circuit still made, and if safe to do so, the emergency services may sever cables with
fireman’s axe.Smother with dry powder or foam.If necessary keep containers cool by spraying with water.
DISPOSALThis product is defined in SI 232:1994 as being for fitment to an excluded appliance.The cells contain heavy metal and must not be put out for collection in refuse containers.Keep all constituents enclosed and upright.Dispose of only to authorised scrap recoverer.Move only in accordance with local authority requirements.Do not incinerate or throw away.
_____________________________________________________________________________Fiamm Asia Pacific Pte Ltd36 Tuas CrescentSingaporeTel 0065 8653278Fax 0065 8626550
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els
Bat
tery
Vol
tage
54.0
VB
oost
Vol
tage
55.0
VB
atte
ry T
est S
tand
by V
olta
geN
AR
ectif
ier S
tand
by V
olta
ge43
.0V
Hig
h Fl
oat A
ctiv
e (H
igh
Bat
tery
1)
55.7
VLo
w F
loat
Act
ive
(Low
Bat
tery
1)
52.8
VH
igh
Load
Act
ive
(Hig
h B
atte
ry 2
)57
.6V
Low
Loa
d A
ctiv
e (L
ow B
atte
ry 2
)48
.0V
Tem
pera
ture
1.1
Hig
h B
atte
ry45
degC
Hig
h B
atte
ry50
degC
Low
Tem
p.-1
0deg
CLo
w T
emp.
0deg
CA
larm
Set
up/D
ispl
ayH
igh
Floa
t Act
ive
(Hig
h B
atte
ry 1
)R
elay
3Lo
w F
loat
Act
ive
(Low
Bat
tery
1)
Rel
ay 3
Hig
h Lo
ad A
ctiv
e (H
igh
Bat
tery
2)
Rel
ay 2
Low
Loa
d A
ctiv
e (L
ow B
atte
ry 2
)R
elay
2B
atte
ry F
use
Rel
ay 4
Load
fuse
Rel
ay 4
Rec
tifie
r Fai
lR
elay
5C
ritic
al R
ectif
ier F
ail (
>1)
Rel
ay 5
Mai
ns F
ail
Rel
ay 1
Off
norm
alR
elay
6B
atte
ry te
st fa
ilR
elay
6M
onito
r Fai
lC
onfig
ured
to e
xter
nal r
elay
Con
figur
able
Inpu
tsP
rogI
nput
1 -
"Gen
erat
or in
put"
Nor
mal
y O
pen
Pro
gInp
ut 2
- "O
ff no
rmal
"N
orm
aly
Ope
nP
rogI
nput
3N
orm
aly
Clo
sed
Pro
gInp
ut 4
Nor
mal
y C
lose
dP
rogI
nput
5N
orm
aly
Clo
sed
TG62
08F
Eric
sson
FP
2 S
yste
m S
ettin
g fil
e.xl
sH
:\elte
k\(T
G) C
ontro
lled
Doc
umen
ts\T
G62
08F
Eric
sson
FP
2 S
yste
m S
ettin
g fil
e.xl
sP
age
1 of
f 2
TG62
08F
Eric
sson
FP
2 S
yste
m S
ettin
g fil
e.xl
sE
ltek
Pac
ific
Pro
gInp
ut 6
Nor
mal
y C
lose
dSi
te In
foC
ompa
ny"S
et to
cus
tom
er n
ame"
Site
Info
Ent
er L
ocat
ion
Mod
elFl
atP
ack2
sys
tem
Inst
all d
ate
To b
e en
tere
d by
the
inst
alle
r on
site
Ser
ial #
(sys
tem
ser
ial)
Ent
er s
eria
l no
Ser
vice
dat
eTo
be
ente
red
by th
e in
stal
ler o
n si
teR
espo
nsib
leE
nter
nam
eM
essa
ge 1
For s
ervi
ce c
all E
ltek
Pac
ific
Mes
sage
2(0
2) 9
479
4200
Bat
tery
Set
upB
atte
ry D
escr
iptio
nE
nter
bat
tery
nam
eC
apac
ity (A
h)E
nter
bat
tery
cap
acity
Bat
tery
Inst
all d
ate
To b
e en
tere
d by
the
inst
alle
r on
site
Bat
tery
tabl
e (o
nly
rele
vant
if b
att.
test
ena
bled
)*E
nter
bat
tery
dis
char
ge ta
ble
in A
mps
to 1
.9V
Ref
eren
ce v
olta
ge (V
/cel
l)2.
25 V
/cel
lR
efer
ence
tem
pera
ture
( C
)25
deg
CTe
mpe
ratu
re s
lope
(mV
/C/c
ell)
4 m
V/C
/cel
lM
in c
ompe
nsat
ion
volta
ge (V
/cel
l)2.
21 V
/cel
lM
ax c
ompe
nsat
ion
volta
ge (V
/cel
l)2.
30 V
/cel
lB
atte
ry T
est S
etup
*(
Thes
e se
tting
s w
ill o
nly
take
effe
ct if
the
batte
ry te
st is
ena
bled
)A
uto
Boo
stD
isab
led
Man
ual B
oost
Dur
atio
nS
et to
10h
rs 0
min
Gua
rd T
ime
NA
Inte
rval
Boo
stN
AIn
terv
alN
AS
tart
Tim
eN
AC
urre
nt L
imit
Cfg
Ena
bled
Max
imum
cha
rge
curr
ent
Set
to 2
5% o
f ins
talle
d C
10 c
apac
ity X
no.
Stri
ngs
Out
put C
ontr
olTe
mpe
ratu
re C
ompe
nsat
ion
Rec
tifie
r OV
P57
.0 V
App
rova
l to
proc
eed
Nam
e:
Sig
ned:
Dat
e:
Ple
ase
sign
and
fax
this
bac
k to
Elte
k P
acifi
c E
ngin
eerin
g de
partm
ent (
02) 9
450
1661
Dis
able
d
TG62
08F
Eric
sson
FP
2 S
yste
m S
ettin
g fil
e.xl
sH
:\elte
k\(T
G) C
ontro
lled
Doc
umen
ts\T
G62
08F
Eric
sson
FP
2 S
yste
m S
ettin
g fil
e.xl
sP
age
2 of
f 2
ALARM MATRIX (Eltek Flatpack2 Ericsson)
Alarm Causes AC Mains fail
High Load / Low load
High Float / Low Float
Battery CB / Load CB
Rectifier fail Off-Normal / BCM
Monitor fail
(Relay output) (1) (2) (3) (4) (5) (6) (External)
Failed AC supply
Low mains / High mains supply
High Bus Voltage X X
Low Bus Voltage X X
Large Voltage deviation
Small Voltage deviation
Load CB tripped
Battery CB tripped
Failed Rectifier
Rectifier Overload X X
Rectifier High Voltage
BCM has started
Alarm module failure *
X X X X X X
X – may cause - will always cause * On Alarm module failure, all alarms from the controller (relays 1-6) will enter an open state, giving an alarm on the normally closed (failsafe) output terminals.
TG6223A Alarm Matrix FP2 Ericsson.doc
ALARM MATRIX (Eltek DC/DC Converter Ericsson)
Alarm Causes Alarm Output
DC input voltage >60VDC
Alarms: Red LED
Warnings: amber LED
DC input voltage <40VDC
Single fan failure
High temperature / Derating activated
Current limit
No output voltage
Over voltage shutdown ( 30V )
Both fans failed
High temperature shutdown
Short circuit / fold back activated
All of the above situations will cause an alarm signal to be output, however, the warnings will produce an amber light to appear on the module, and an alarm will cause a red light to appear.
TG6228A Alarm Matrix Ericsson DCDC converter.doc
Ala
rmSt
ate
Rel
ayTB
Pin
Ala
rmSt
ate
Rel
ayTB
Pin
Ala
rmSt
ate
Rel
ayTB
Pin
Mai
ns F
ail
NO
5H
igh
Floa
t / L
ow F
loat
NO
9O
ff N
orm
al /
BC
MN
O18
Mai
ns F
ail
CO
M6
Hig
h Fl
oat /
Low
Flo
atC
OM
10O
ff N
orm
al /
BC
MC
OM
19N
orm
ally
clo
sed
Mai
ns F
ail
NC
7H
igh
Floa
t / L
ow F
loat
NC
11O
ff N
orm
al /
BC
MN
C20
Nor
mal
ly o
pen
Hig
h Lo
ad /
Low
Loa
dN
O8
Load
/ B
atte
ry C
B fa
ilN
O12
Mon
itor F
ail
NO
Com
mon
Hig
h Lo
ad /
Low
Loa
dC
OM
9Lo
ad /
Bat
tery
CB
fail
CO
M13
Mon
itor F
ail
CO
MH
igh
Load
/ Lo
w L
oad
NC
10Lo
ad /
Bat
tery
CB
fail
NC
14M
onito
r Fai
lN
CR
ectif
ier F
ail
NO
15R
ectif
ier F
ail
CO
M16
Rec
tifie
r Fai
lN
C17
Mon
itor F
ail C
ard
(top
view
)
ALA
RM
OU
TPU
T C
ON
FIG
UR
ATI
ON
TG62
17A
62
Ext
(see
dia
gram
M
onito
r Fai
l car
d)22
5
1
[NC
and
NO
indi
cate
s whe
n sy
stem
is e
nerg
ized
w
ith n
o al
arm
s]2
213
14
Pin
1P
in 1
0P
in 1
Pin
20
TB1
TB2
TG62
17A
Rel
ay p
inou
t lab
el fo
r FP
2 E
ricss
on S
yste
ms.
xls
Revisionnote
FE
1RevNo
2
C DBA
12
FOL
D
3Date
Checked
Signature
THIRDANGLE
MATERIAL:
FINISH:
Checked
Released
Approved 6
Designed
Drawn
SHEET
7REVISION
SCALE
8
FE
34
56
C DB
78
A
GENERALARRANGEMENT
FLATPACK2400D
N.E.01/12/05
F.M.
12/12/05
DNTS
1/1
BBATTERYSHELFGAPDIMENSIONFROM38mmTO50mm
18/01/06
CADDNOTEDETAILS
19/01/06
DAMENDEDBATTERYSHAPE
30/01/06
SEF29-X-149
TG6210
EltekPacificPtyLtd
Unit1,22NarabangWay
BelroseNSW2085
AustraliaEltek
PACIFIC
SIDEVIEW
SCALE0.14:1
TOPVIEW
SCALE0.14:1
FRONTVIEW
SCALE0.14:1
ITEMNO.
DESCRIPTION
1LoadCircuitBreakers
2SmartPackModule
3FlatPack2PowerRacks
412FIT100TypeBattery
5BatteryCB'swithAuxiliaries
2200
460
600108
287
1 2 3 4 5
400
50337
Notes:
1.BatteriesShownare12FIT100Type.
2.EachMonoblocWeighs33Kg.
3.SystemContains3FlatPack2PowerRackswitha
Totalof9RectifierPositions.
4.WeightofEachRectifieris1.8Kg.
5.WeightofSystemExcludingBatteriesand
Rectifiersisapprox.120Kg.
6.SystemContainsa24WayDistributionPanel.
7.TotalWeightis810Kg.
8.FloorLoadingis33.75Kpa.
Revisionnote
FE
1RevNo
2
C DBA
12
FOL
D
3Date
Checked
Signature
THIRDANGLE
MATERIAL:
FINISH:
Checked
Released
Approved 6
Designed
Drawn
SHEET
7REVISION
SCALE
8
FE
34
56
C DB
78
A
GENERALARRANGEMENT
FLATPACK2600D
N.E.01/12/05
F.M.
12/12/05
DNTS
1/1
BBATTERYSHELFGAPDIMENSIONFROM47mmTO50mm
18/01/06
CADDNOTES
19/01/06
DCHANGEDCONTAINSDISTRIBUTIONPANELFROM26TO24
03/01/06
SEF29-X-150
TG6211
EltekPacificPtyLtd
Unit1,22NarabangWay
BelroseNSW2085
AustraliaEltek
PACIFIC
SIDEVIEW
SCALE0.14:1
TOPVIEW
SCALE0.14:1
FRONTVIEW
SCALE0.14:1
ITEMNO.
DESCRIPTION
1LoadCircuitBreakers
2SmartPackModule
3FlatPack2PowerRacks
412FFT100TypeBattery
5BatteryCB'swithAuxiliaries
600126
230
2200
460
1 2 3 4 5
600
50280
Notes:
1.BatteriesShownare12FFT100Type.
2.EachMonoblocWeighs38Kg.
3.SystemContains3FlatPack2PowerRackswitha
Totalof9RectifierPositions.
4.WeightofEachRectifieris1.8Kg.
5.WeightofSystemExcludingBatteriesand
Rectifiersisapprox.140Kg.
6.SystemContainsa24WayDistributionPanel.
7.TotalWeightis1080Kg.
8.FloorLoadingis30Kpa.
Revisionnote
FE
1RevNo
2
C DBA
12
FOL
D
3Date
Checked
Signature
THIRDANGLE
MATERIAL:
FINISH:
Checked
Released
Approved 6
Designed
Drawn
SHEET
7REVISION
SCALE
8
FE
34
56
C DB
78
A
BATTERYRACKWITH5STRINGS
OF12FIT100
N.E.01/12/05
F.M.
12/12/05
BNTS
1/1
BAMENDEDBATTERYSHAPE
30/01/06
SEB5-12FIT100-002
TG6215
EltekPacificPtyLtd
Unit1,22NarabangWay
BelroseNSW2085
AustraliaEltek
PACIFIC
SIDEVIEW
SCALE0.14:1
TOPVIEW
SCALE0.14:1
FRONTVIEW
SCALE0.14:1
ITEMNO.
DESCRIPTION
112FIT100TypeBattery
2BatteryCB'swithAuxiliaries
600
108
287
2200
400
1 2
50337
Note:
1.BatteriesShownare12FIT100Type.
2.EachMonoblocWeighs33Kg.
3.WeightofSystemExcludingBatteriesisapprox.
85Kg.
4.TotalWeightis745kg.
5.FloorLoadingis31Kpa.
Revisionnote
FE
1RevNo
2
C DBA
12
FOL
D
3Date
Checked
Signature
THIRDANGLE
MATERIAL:
FINISH:
Checked
Released
Approved 6
Designed
Drawn
SHEET
7REVISION
SCALE
8
FE
34
56
C DB
78
A
BATTERYRACKWITH6STRINGS
OF12FFT100
N.E.01/12/05
F.M.
12/12/05
ANTS
1/1
SEB6-12FFT100-002
TG6216
EltekPacificPtyLtd
Unit1,22NarabangWay
BelroseNSW2085
AustraliaEltek
PACIFIC
SIDEVIEW
SCALE0.14:1
TOPVIEW
SCALE0.14:1
FRONTVIEW
SCALE0.14:1
ITEMNO.
DESCRIPTION
112FFT100TypeBattery
2BatteryCB'swithAuxiliaries
2200
230
126
600
50
1 2
280
600
Notes:
1.BatteriesShownare12FFT100Type.
2.EachMonoblocWeighs38Kg.
3.WeightofSystemExcludingBatteriesisapprox.
105Kg.
4.TotalWeightis1017Kg.
5.FloorLoadingis28.25Kpa.
Revisionnote
FE
1RevNo
2
C DBA
12
FOL
D
3Date
Checked
Signature
THIRDANGLE
MATERIAL:
FINISH:
Checked
Released
Approved 6
Designed
Drawn
SHEET
7REVISION
SCALE
8
FE
34
56
C DB
78
A
GENERALARRANGEMENT
FLATPACK2600D
WITHDC/DCCONVERTER
N.E.
01/12/05
F.M.
30/01/06
BNTS
1/1
BREMOVEDTOPSTRINGOFBATTERIES
18/04/06
F.M.
G.T.
SEF29-X-156
TG6222
EltekPacificPtyLtd
Unit1,22NarabangWay
BelroseNSW2085
AustraliaE
lte
kP
AC
IF
IC
SIDEVIEW
SCALE0.14:1
TOPVIEW
SCALE0.14:1
FRONTVIEW
SCALE0.14:1
ITEMNO.
DESCRIPTION
1LoadCircuitBreakers
2SmartPackModule
3FlatPack2PowerRacks
4+24VDC/DCConverter
512FFT100TypeBattery
6BatteryCB'swithAuxiliaries
Notes:
1.BatteriesShownare12FFT100Type.
2.EachMonoblocWeighs38Kg.
3.SystemContains3FlatPack2PowerRackswitha
Totalof9RectifierPositions.
4.WeightofEachRectifieris1.8Kg.
5.WeightofSystemExcludingBatteries,Rectifiers
andDC/DCConvertersisapprox.140Kg.
6.SystemContainsa24WayDistributionPanel.
7.SystemContainsupto4DC/DCConverters.
8.WeightofEachDC/DCConverteris3Kg.
9.TotalWeightis943Kg.
10.FloorLoadingis26.2Kpa.
1 2 3 4 5 6
126
600
230460
2200
600
50280