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Eltek FP2 IandC Manual
Eltek FP2 IandC Manual
Eltek FP2 IandC Manual
INSTALLATION, COMMISSIONING
AND OPERATIONS MANUAL FOR
FLATPACK2 OPTUS SYSTEM
REVISION CONTROL
Rev
Date
Revision Description
Orig
28/08/09
SW
27/11/09
SW
11/01/10
Update images
SW
24/01/10
SW
25/05/10
RB
20/11/10
RB/RZ
07/02/11
RZ
Check
App
Controlled:
Uncontrolled:
Page 1 of 70
sales@eltek.com.au
service@eltek.com.au
admin@eltek.com.au
Page 2 of 70
TABLE OF CONTENTS
1.
2.
3.
SCOPE .......................................................................................................................................... 5
SYSTEM OVERVIEW ................................................................................................................ 6
REQUIREMENTS ..................................................................................................................... 11
3.1 INSTALLATION REQUIREMENTS.....................................................................................................................11
3.2 FOR COMMUNICATION WITH THE CONTROLLER: ...........................................................................................11
3.3 WARNINGS ...................................................................................................................................................12
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
ATTACHMENTS ................................................................................................................... 70
Page 4 of 70
1. SCOPE
This Installation and Commissioning Manual provides simple instructions as to the
installation requirements for the Eltek -48 Volt DC Flatpack2 system. 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 and
Smartpack controller.
Part number
# battery strings
# rectifiers
A111223.001
1 x 12NDF100
2 x HE
A112007.001
1 x AG12V100F
2 x HE
SEF29-X-189
SEF29-5BS9-181
SEF29-11BS9-182
11
Note
All these systems can be expanded
with the
A461033.001 battery expansion
rack
Expanded with SEB6-12NDF100
Table 1.1
System Part numbers
Part number
Note/Component
A111223.xxx
A112007.001
A601182.000
242100.110
Smartpack Controller
242100.118
241115.100
2 kW Flatpack2 Rectifier
241115.105
A461033.001
12NDF100
AG12V100F
Page 5 of 70
2. SYSTEM OVERVIEW
The Flatpack2 system is a 18kW -48V DC power system comprising of:
If required, the main system cabinet can be supplemented with a battery expansion cabinet for
increased battery capacity. Details of the expansion battery cabinets are given later in this
manual.
Output cable
management
rail
Anderson
connector
for battery
expansion
rack
0V DC bar
(SPC)
95mm
earth
cable
Monitor
fail PCB
AC
mains
input
Serial
Number
lable
Load
CBs
System
connection
board
Battery
expansion
rack alarm
Symmetry
PCB
(hidden)
Figure 2.1
Top view with cover removed.
Alarm PCBs
Page 6 of 70
Figure 2.2
Front and side views of a A111223.xxx
2200mm(H) x 600mm(W) x 400mm(D)
Page 7 of 70
Figure 2.3
Front and side views of a A111223.xxx
2067mm(H) x 600mm(W) x 400mm(D)
Page 8 of 70
Figure 2.4
Front and side views of a A111223.001
2067mm(H) x 600mm(W) x 400mm(D)
Page 9 of 70
Figure 2.5
Front and side views of battery expansion cabinet with A461033.001, with 12NDF100/AG12V100F
2200mm(H) x 600mm(W) x 400mm(D)
Page 10 of 70
3. REQUIREMENTS
3.1 Installation requirements
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 cable bolts.
The system should only be installed into locations that have restricted access to personnel.
IMPORTANT: All tools should be insulated
3.2 For communication with the controller:
A laptop computer running either windows 2000 or windows XP (preferred).
PowerSuite software on CD (supplied with system).
Standard A-B type USB cable.
RJ45 cable for Ethernet connection (crossover cable for PC or straight cable for LAN)
IP Setup software on CD (supplied with system).
Page 11 of 70
3.3 Warnings
IMPORTANT: DO NOT mix the standard VRLA (12NDF100) and Polymer Gel
(AG12V100F) Batteries, despite having the same system settings, as batteries they
have different electrochemical properties (for example different internal resistance)
these characteristics can cause dissimilar performance during charging and
discharging process (example: particular string can be discharge faster than the others
but will be slow to recharge) which can affect the service life of the battery bank.
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
Page 12 of 70
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.
Narada 12NDF100 batteries are heavy, 33kg, & may require two people to lift.
Page 13 of 70
4. PACKING LIST
A fully equipped Flatpack2 system is dispatched from Eltek Pacific in a number of packages.
Each package is clearly marked indicating its content. The packages include the following:
1 x Rectifier Cabinet box
Rectifier Cabinet
Accessories
Insulation panel
Manual on CD
Controllers modules
Rectifier modules
OK
Note: The cabinet may contain 1 Smartpack controller and can have up to 9 x 2kW FlatPack2
rectifiers or up to 8 x 2kW FlatPack2 HE rectifiers already fitted.
Battery crates
Batteries as required (Monoblocs)
Solid links (Attached to the inside of the cardboard battery box)
OK
OK
5. SYSTEM CONFIGURATION
The different configurations of the Flatpack2 system and expansion battery cabinets are listed
below:
All systems except A111223.001 are 2200MM (H) x 600MM (W) x 400MM (D), and all
use Narada 12NDF100 batteries.
A112007.001 and A111223.001 system are 2067MM (H) x 600MM (W) x 400MM (D), and
they use either Narada 12NDF100 or AG12V100F batteries.
A112007.001 has maximum of 9 rectifier slots.
A111223.001 has maximum of 8 rectifier slots
Page 14 of 70
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.
IMPORTANT: 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.
IMPORTANT: If lifting using eye bolts, a spreader bar must be used.
Lifting Cables
M8 Eyebolt, placed
in the wall mounting brackets bolt
position
Cabinet
Figure 6.1
Lifting arrangement for the cabinet, using eyebolts and spreader bar
Page 15 of 70
7. CABINET ASSEMBLY
The Cabinets will arrive packed in a box. The following are 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 insulation kit.
Figure 7.1
Top wall mounting bracket and insulation kits
Page 16 of 70
8. FLOOR FIXING
All cabinets include a fixing kit. One fixing kit consists of 4 round washers and 4 dynabolts.
Bolt through the 4 holes in the bottom using dynabolts.
Nut
Washer
Cabinet
Dyna-bolt
Concrete Floor
Figure 8.1
Dynabolts Fixing
9. EARTH CABLING
Each cabinet should be bound to earth using links. There is one 95mm earth cable shipped
with each cabinet. Ensure this converter cubicle bond is bonding the cabinet M8 bolt to the
positive common bar (SPC) inside the cabinet, creating a bonded -48V DC supply. External
earthing should be done to relevant company standards, to the common positive bar.
Also connect the battery extension cabinet, if being used, to the SPC inside the rectifier
cabinet with the 95mm earth cable supplied with the extension cabinet.
Page 17 of 70
Page 18 of 70
symmetry connection
Negative
battery cable
Battery 4
Positive
battery
cable
Battery 1
Figure 10.1
Symmetry connection point, to either side of the middle hard link
Rectifier rack
Controller
CON 3
CON 4
Symmetry
PCB
Battery
symmetry
connections
Symmetry
PCB
Temperature
probe
Battery
symmetry
connections
Page 19 of 70
Smartpack
CAN
CAN
CAN
Symmetry
Monitor Box
CON4
CAN
Symmetry
Monitor Box
Temperature
probe
Battery
symmetry
connections
Battery
symmetry
connections
M6 Ring terminals
for battery
Figure 10.3
Symmetry Monitor Box connection points
Page 20 of 70
Rectifier
capacity alarm
setting (60%)
Number of
rectifiers
2 (37A)
3 (74A)
4 (111A)
5 (148A)
6 (185A)
7 (222A)
8 (259A)
9 (296A)
22A
44A
67A
89A
111A
133A
155A
178A
2
3
4
5
6
7
8
9
Number of
battery
modules
(strings)
1
2
3
4
5
6
7
8
9
10
11
Battery
current limit
setting
10
20
30
40
50
60
70
80
90
100
110
Table 10.1
Controller settings for each level of upgrade
This value is needed for correct battery testing as this value is multiplied by the Ah of the
battery to give the total system capacity.
DO NOT change
this value
Figure 10.4
String number screen (using Power Suite 3.x)
Page 21 of 70
2.
No. of rectifiers
(system current
rating)
Rectifier
capacity alarm
setting (60%)
Number of
rectifiers
2 (37A)
3 (74A)
4 (111A)
5 (148A)
6 (185A)
7 (222A)
8 (259A)
9 (296A)
22A
44A
67A
89A
111A
133A
155A
178A
2
3
4
5
6
7
8
9
Number of
battery
modules
(strings)
1
2
3
4
5
6
7
8
9
10
11
Battery
current limit
setting
10
20
30
40
50
60
70
80
90
100
110
Table 10.2
Controller settings for each level of upgrade
Important!
Make sure BOTH
major and minor
alarms are set to the
new value
Figure 10.5
Rectifier over-current alarm setting screen (using Power Suite 3.x)
Page 22 of 70
Rectifier
capacity alarm
setting (60%)
Number of
rectifiers
2 (37A)
3 (74A)
4 (111A)
5 (148A)
6 (185A)
7 (222A)
8 (259A)
9 (296A)
22A
44A
67A
89A
111A
133A
155A
178A
2
3
4
5
6
7
8
9
Number of
battery
modules
(strings)
1
2
3
4
5
6
7
8
9
10
11
Battery
current limit
setting
10
20
30
40
50
60
70
80
90
100
110
Table 10.3
Controller settings for each level of upgrade
Figure 10.6
Battery charge current limit setting (using Power Suite 3.x)
Page 23 of 70
Figure 10.7
Symmetry activation setting screen (using PowerSuite 3.x)
Install
probe in
this area
Figure 10.8
Install probe within the rack above batteries
Page 24 of 70
Battery
Flying Lead with Anderson
Connector
Battery CB
alarm &
symmetry
cable.
Earth cable
Figure 11.1
Expansion rack connections
Page 25 of 70
Important Note: Redeploy temperature compensation probe to the top of the uppermost
installed battery string when installing extra battery strings. (Use cable ties to fix it into
place.)
Page 26 of 70
Install
probe in
this area
Figure 13.1
Temperature probe deployment should be near, but not touching, above the uppermost string of batteries.
Battery type
Max
compensation
V/cell
Min compensation
V/cell
Reference voltage
Slope mV/deg/cell
12NDF100
2.310
2.205
2.25
-3.0
AG12V100F
2.310
2.205
2.25
-3.0
@ 25C/cell
Table 13.1
Battery temperature compensation values.
Important Note: All power settings are the same for both AG12V100F and 12NDF100
Batteries.
Battery
CBs
Retaining
bracket
Figure 13.2
Front view of batteries, showing spacing & battery circuit breaker position.
(Cables / links are not shown)
Page 27 of 70
OK
Check that the terminal boots and battery link caps are fitted on all the batteries.
Check that the battery rack expansion rack earth cable is securely connected to the
common positive bar (SPC) inside the rectifier cabinet.
Check that the MCB alarm cabling to the main rack is installed and terminated.
Table 14.1
Expansion Rack Installation Check List
Page 28 of 70
Figure 15.2
Page 29 of 70
Figure 15.3
Front view of Flatpack2 2kW and HE rectifier modules
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
OFF
Alarm
(red)
ON
OFF
Notice
(yellow)
All off
ON
Flashing
OFF
Page 30 of 70
Smartpack
(controller)
ID1
ID4
ID7
(Blank)
ID2
ID5
ID8
(Blank)
ID3
ID6
ID9
Table 15.2
Rectifier ID positions for C801047
Page 31 of 70
Smartpack
(controller)
ID1
ID2
ID3
ID4
ID5
ID6
ID7
ID8
Table 15.3
HE Rectifier ID positions for A111223.00x
Page 32 of 70
Figure 16.1
Rectifier locking mechanism
Page 33 of 70
Figure 16.2
The rear of the smartpack controller
Plug
Function
CAN 1
CAN 2
CON 1
CON 2
CON 3
CON 4
CON 5
Figure 16.3
The rear of the Smartpack controller Web/SNMP
Plug
Function
CAN 1
CAN 2
CON 1
CON 2
CON 3
Not Available
Ethernet
CON 4
CON 5
Page 34 of 70
Figure 17.1
Smartpack front panel
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 systems user
interface. The display can be shown in Status Mode (displays the systems status)
or in Menu Mode (displays the menu structure). Depending on the displays
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.
Page 35 of 70
Front Keys
You can control the many of the Flatpack2 DC power systems via a network of
software menus accessed with the controllers front keys.
Press the
Press the
or
keys to scroll up or down and navigate to find menu
options (function or parameter).
Modes of Operation
The controllers 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: Press
forward through the messages.
Battery Current
Load Current
Active alarms
Other messages
to fast
Menu Mode
When the front keys are in operation, the controllers 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
IMPORTANT: If no keys are pressed within 30 seconds the display will automatically
switch from Menu Mode to Status Mode.
Page 36 of 70
IMPORTANT: If no keys are pressed within 30 seconds the display will automatically
switch from Menu Mode to Status Mode.
Page 37 of 70
Service
Password = 0003
Change Language
Alarm Reset
Alarm Reset
Voltage Info
NomVolt
VoltAdjustment
NomVolt
BoostVolt
BoostVolt
LowBatt1
LowBatt1
Volt Calibration
VoltCal
LowBatt2
Change Password
Password
HighBatt1
Set MANBoostTime
BoostTime
High Batt2
Start/StopBoost
StartBoost/StopBo
ost
LVD1
Enable/Disable
LVD2
LowBatt2
HighBatt1
High Batt2
LVD1
LVD2
Display messages
Display messages
Sw Info
SwInfo
Threshold
Start/Stop Test
Serial Number
Controller S/N
No of Rects
RECTIFIER
RESET
Rectifier Info
NoOfRects. Nn
End Volt
Test Interval
Enable/Disable
Guard Time
RectCurrent
RectSerialNumber
Rect.PrimaryVolt
Max ChargeCurr
Battery Setup
NumOfStrings
OutputControl
Temp.Comp
Rectifier Status
Change Date/Time
VoltageControl
Rectifier Temp
Rect OutputVolt
Relay Test
Alarm Output 1
Alarm Output 2
Rectifier SW Ver
Batt Contactor
Mains Info
NoOfPhases nn
Load Contactor
Mains Status
Alarm Output nn
Mains Voltage
BattLifeTime Rst
BattLifeTime Rst
Figure 17.2
Rectifier reset is now under the service menu.
Page 38 of 70
Figure 18.1
Relay Output Card 1; inputs 1 & 2, and outputs 1 & 2
Figure 18.2
Relay Output Card 2; inputs 3 to 6 and outputs 3 to 6
Figure 18.3
Monitor Fail PCB
Page 39 of 70
Relays
Alarm
Relays
Low load
1&4
Low float
High load
High float
1&6
2&6
Mains fail
2&5
1&3
LVD disconnect
1&4
Table 18.1
Alarm relay output positions
Relays 1,2 are on Relay output card 1, relays 3,4,5,6 are on relay output card 2. Monitor fail
is on a separate card. See the attachments section for full alarm matrix.
18.3 Alarm connections
CONTACT
RELAY #
NO
COM
PIN #
5
NC
NO
COM
NC
10
NO
COM
10
NC
11
NO
12
COM
13
NC
14
NO
15
COM
16
NC
17
NO
18
COM
NC
19
20
Table 18.2
Output relay pin connections
Page 40 of 70
Normally closed
Normally open
Common
Figure 18.4
Top view of monitor fail PCB showing connection points for monitor fail alarm.
Trigger
Failed AC supply
Rectifier fail
LVBD
Rectifier capacity
System monitor
failure
Smartpack failure
Table 18.3
Alarm triggers
Page 41 of 70
State
Input 1
Input 1
Input 2
Input 2
Relay
Card
1
Pin
1
2
3
Pin 1
Pin 10
4
Relay Card 1
Alarm
State
Input 3
Input 3
Input 4
Input 4
Input 5
Input 5
Input 6
Input 6
Relay
Card
2
Pin
1
2
3
4
5
Pin 20
Pin 1
Relay Card 2
7
8
Figure 18.5
Digital input locations
Page 42 of 70
Phase 1
Phase 2
Phase 3
Figure 19.1
Cabinet Front view.
Distribution
Controller
L1
L1
L1
(Blank)
L2
L2
L2
(Blank)
L3
L3
L3
Table 19.1
AC Phase arrangement.
Page 43 of 70
Figure 19.2
Cabinet Front view (A111223.00x)
Figure 19.3
Cabinet Front view (A111223.00x).
Smartpack
(controller)
L1
L2
L3
L1
L2
L3
L1
L2
Table 19.2
AC Phases arrangement (A111223.00x).
Page 44 of 70
3xSingle - Phases
May be cable
jumpers
Figure 19.5
1 x Three-Phase input
16 C
25 C
40 C
Figure 19.6
AC input CB size recommendation
Page 45 of 70
Accommodate CB size
CB Factory fitted
1 to 63A
63
1 to 63A
1 to 63A
1 to 63A
1 to 63A
1 to 63A
1 to 63A
1 to 63A
1 to 63A
10
1 to 63A
11
1 to 63A
12
1 to 63A
13
1 to 63A
14
1 to 63A
15
1 to 63A
16
1 to 63A
17
1 to 63A
18
1 to 63A
19
1 to 63A
20
1 to 63A
21
1 to 63A
22
1 to 63A
23
1 to 63A
24
1 to 63A
63
63
63
40
40
40
40
10
10
4
Table 20.1
DC load circuit breaker distribution (A111223.00x)
Load Cable Installation Considerations should be given to the entry arrangement of load
cables to ensure correct 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 the internal cable management rail, making sure not to over stress
the common positive bar and circuit breakers.
IMPORTANT: Be aware that AC voltages are present within the system when
installing DC load cables.
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Page 46 of 70
OK
Check that the terminal boots and battery link caps are fitted on all the batteries.
Check that battery string voltage is between -48 and -55 Vdc
Table 21.1
Install Checklist
Table 22.1
Pre-Start / Initial Checks
VDC
Page 47 of 70
Meas
ure
Display in
Alarm
Mod.
DVM*
Measured
with DVM*
Adjust output voltage to equal the measured battery voltage from the alarm modules keypad
adjust the rectifier output voltage to equal ( 1 V) the measured battery voltage. Temperaturecompensated charging must be deactivated when adjusting the output voltage.
Adjust output voltage (float voltage) from the alarm modules keypad to
the voltage recommended by the battery manufacturer (54.0Vdc at 25C)
Verify that the Low Battery Alarm is not activated. Record the voltage*
Measured
with DVM*
2) Voltage Alarms
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.
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 are 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.
Page 48 of 70
Connect a PC/laptop to the Smartpack controller and run the latest version of Powersuite.
Once each of the alarms (below) has 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) 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.
4) 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.
5) Battery Fuse
NOTE: All battery CBs 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.
6) 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.
7) LVBD Active. (Low Voltage Battery Disconnect)
With an external power supply connected, Disconnect the batteries & turn off the AC supply.
Set the supply to a value below that of the LVBD disconnect. The contactor should open & the
system be turned off. The LVBD alarm should activate. NOTE: As a safety mechanism, the
voltage of the rectifiers cannot be deliberately set below that of the LVBD value.
8) In order to test the Battery Test Fail Alarm, the procedure below must be
followed:
1. With the system running normally, i.e. no alarms, turn off all the batteries.
2. Attach an external DC source to a pair of the spare battery leads (Ensure the
polarity if correct). If there are no spare battery leads connect via a spare
circuit breaker.
3. Turn ON the external DC source and increase to 54 VDC.
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS
MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
Page 49 of 70
4. Follow steps in Figure 22.1. Select the simplified battery test, click Start Test
button
Figure 22.1
5. Wait until battery test warning MANUAL TEST appears at the bottom of the
screen.
6. Follow the steps in Figure 22.2
a. Click Alarms Overview
b. Click Summary
c. Check that Battery test active alarm is present
d. Check if Relay #5 has changed state.
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Relay #5 change
states
Ensure the
Battery test Act
alarm activates
Figure 22.2
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Figure 22.3
Click OK to reset
battery test fail
alarm
Figure 22.4
Table 22.3
Checking the alarm
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Ensure that the system values ( current & symmetry) are setup as per Section 10.2.
Battery test setup.
Change the battery test start date to be 6 months from the install date to prevent all systems
nationwide from commencing a battery test on the same day.
Table 22.4
Other Commissioning Checks
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Factory set
Default
Checked
System Voltage
54.50
57.60
55.70
47.00
52.80
43.20
Boost Voltage
56.00
Disabled
1.8V
Table 22.5
Default-48V System settings
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Comments
Documentation available
Table 23.1
General Checks
Frequency
Purpose
Visual inspection
Monthly
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6 Monthly
Torque battery
terminals
6 Monthly
General clean
6 Monthly
Table 23.2
General ongoing maintenance procedures
Minimum Operating
Life (years)
Potential
Failure
Indication
Action
FlatPack2 Rectifier
>15
Replace Module
Smartpack Control
Module
>15
Monitor Failure
Replace Module
Table 23.3
System components Minimum Operating life
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Then connect:
Figure 24.1
Correct Software installation
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Figure 24.2
Powersuite Startup guide
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3
4
Figure 24.3
The Main Screen
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Apply the
changes
Check the box to enable the
temperature compensation
Figure 24.5
Battery Configuration
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Choose settings of
the Shunt, and click
Apply
Figure 24.7
Shunt Configuration
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Figure 24.9
Event log
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Event log download: Use the [Latest XX events] & [Get all] to download the controller alarm
events. It can store up to 1000 events before overwriting the oldest event.
[Export to file] will create an .XML file that can be imported into Excel. When importing use
the option as an XML list
The events and time of occurrence can now be examined.
Download time.
Event time.
Event.
Type of event
Figure 24.10
Event log downloading
Change setting of
system voltages at
here
Figure 24.11
System Voltages
Page 63 of 70
Contact Open
Contact Close
Click on it
for testing
Testing timeout
Figure 24.12
Output Relays
Choose controller
module, such as
Smartpack or I/O box
Figure 24.13
Alarms Overview
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Figure 24.15
Module number resetting
Page 65 of 70
Figure 24.16
Active alarms & battery test results
Company name
System S/N:
Reference No. for
service and warranty
Location / Site
name or No.
Click here to
update to today
Figure 24.17
System Information
Figure 24.18
Efficiency Manager (Load Shedding)
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Page 68 of 70
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25. ATTACHMENTS
25.1
25.2
25.3
25.4
25.5
25.6
25.7
25.8
25.9
25.10
25.11
25.12
25.13
25.14
25.15
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