Installation Guide: DC Power Supply System, 16kW, 48VDC

Installation Guide
DC Power Supply System, 16kW, 48VDC

Indoor 1.5m Cabinet
351486.033
1 Welcome
Information in this document is subject to change without notice and does not represent
a commitment on the part of Eltek Energy.
No part of this document may be reproduced or transmitted in any form or by any means
— electronic or mechanical, including photocopying and recording — for any purpose
without the explicit written permission of Eltek Energy.
Copyright ©: Eltek Energy, Norway 2007
Certificate no: 900005E Certificate no: 900005Q
Power Distribution
Centre for NS-EN ISO 14001: NS-EN ISO 9001:
Communications 1996 Certificate 1994 Certificate
Equipment No: 900005E No: 900005Q
35KS
This product is CE marked and complies with all current requirements for relevant
standards and directives.
This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).
EMC LVD
EN61000-6-2 Industrial Environment LVD73/23/EEC Low Voltage Directive
EN61000-6-3 Residential, Commercial and Light Industry EN60950 Safety of Technology Equipment
ETS 300386 Telecommunication Equipment UL60950,UL1801
“FP2 PRSB 16KW/48Vdc ID 1.5m” has part no. CF1030.003.
351486.033 Issue 3, 2007 June
Published 2007-06-19
Mfm
2 Installation Guide Flatpack2 PS System, 16kW, 48VDC, Indoor 1.5m Cabinet 351486.033, v3-2007-06
1 Welcome
Table of Contents
1. Welcome 4
About this Guide ............................................................................................................. 4
2. System Description 4

Location of Components ~ General Arrangement.............................................. 5
External AC Fuses ~ Recommended Ratings ................................................................ 6
Mains Reconfiguration ~ AC Terminal Block .................................................................. 6
Terminals & Pin-out Location, GMT Fuses ..................................................................... 7
Alarm Relays & Digital Inputs.......................................................................................... 7
Terminals & Pin-out Location, Alarm Interface Card ................................................................8
Terminals & Pin-out Location, System Interface Card ..............................................................9
LVD Latching Contactors ................................................................................................ 9
Monitoring, Control and Signal Interface .......................................................... 10
System Monitoring ........................................................................................................ 10
System Specification .......................................................................................... 11
3. Installation 12

Safety Precautions ........................................................................................................ 12
Installing the Modules ......................................................................................... 13
Mounting or Removing Smartpack and Flatpack2 Modules ...................................................13
Mounting and Removing Blind Panels ....................................................................................14
Correct Rectifier Position in Power Shelves ...........................................................................14
System Installation.............................................................................................. 15
Site Preparation ............................................................................................................ 15
Mechanical Installation .................................................................................................. 15
Electrical Installation ..................................................................................................... 16
4. Commissioning 19

Pre-Start Check ................................................................................................... 19
Commissioning Steps, Startup .......................................................................... 20
Startup and No-Load Adjustments ..........................................................................................20
Load Adjustments ...................................................................................................................21
5. Forms, Schematics & Drawings 22

Installation Check List .............................................................................................22
Commissioning Procedure.......................................................................................22
Maintenance Procedure ...........................................................................................22
General Arrangement Drawing ...............................................................................22
System Schematic Drawing .....................................................................................22
Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m ..........22
Load Distribution List .............................................................................................22
Installation Guide Flatpack2 PS System, 16kW, 48VDC, Indoor 1.5m Cabinet 351486.033, v3-2007-06 3
1 Welcome
1. Welcome
The Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m is a DC power supply for telecom
equipment suitable for indoor applications.
About this Guide

This booklet provides users of the Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m with
the required information to perform system installation, commissioning and maintenance.
The booklet also describes the system’s technical specifications, and includes check lists,
arrangement and schematic drawings.
Read also the generic documentation included in the system’s documentation set, Art.
No. 351486.003
2. System Description
The Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m is a DC power supply system based
on the Flatpack2 2000W 48V rectifier.
The system contains AC termination blocks, DC distribution, Flatpack2 Power Rack,
Flatpack2 2000W rectifier modules and the Flatpack2 Smartpack control unit. The system
is designed for cable entry from top and the cabinet size is 600x600x1500 mm
(23.6”x23.6”x59”) (WxDxH).
2 System Description
Location of Components ~ General Arrangement
AC Earth
Mains Protective Earth (PE)
Connection
(Cabinet main ground bar) DC Earth
Telecom Earth (TE)
Connection
Smartpack AC Mains
controller unit Terminals
Flatpack2
rectifier modules
Battery strings
and fuses in the
lower part of the AC Input Terminals
cabinet Located behind the front cover
DC Distribution
MCB Load, Alarm and Signal
Terminals located behind the front
cover
Figure 1 General Arrangement Flatpack2

PS System, 16kW, 48VDC,
ICab 1.5m
Battery DC (+) terminals

Bus bar, 35mm2, AWG 2 DC (+) Load Terminals
Common positive bus bar,
2
70 mm , AWG 2/0
Battery DC (-) terminals
Bus bar, 35mm2, AWG 2
DC (-) Load Terminals
(BTS2 MCBs) 2
25mm , AWG 4, 70mm , AWG 2/0
(on top of each load breaker)
Terminals for
GMT 10A
2
Load
Fuses, 1.5mm , AWG 16
Alarm Terminals Smartpack controller

2
1.5mm , 16AWG and CON 4 (monitoring
(Front access) terminals on the controller’s
rear panel)
External AC Fuses ~ Recommended Ratings

The site’s AC supply quality is of great importance. In general, a site with better AC
supply quality (stable nominal voltage) may use smaller breakers.
Use the type of external AC fuses recommended in the table below.
External AC Fuses ~ Recommended Ratings
AC Mains Type External Fuse Type

400VAC +N, 3 ph 50A – C-char.
230VAC, 1 ph 100A – C-char.
230VAC, 3 ph 63A – C-char.
208VAC, 1 ph 70A.
Note: An external AC breaker is required on all sites,
and it must be switched off under installation.
Mains Reconfiguration ~ AC Terminal Block

The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase & N.
To reconfigure the system’s AC mains feed, perform the following:
1. Switch OFF the AC supply fuses in external fuse boards

2. Connect the AC Mains wires to the AC terminal block, and mount the fish
plate(s) shipped with the cabinet, according to the type of AC mains to be
used, as shown in the actual example in this section
3. Rewire internal cables N2 and N4 as shown, ONLY when reconfiguring to
“∇ Mains, IT Three-phase, 230VAC”. Do not rewire the rest of the internal cables
AC Mains
Cable
Fish Plate AC Mains
Fish Plate AC Mains Cable
L1 L2 L3 AC Mains Cable
wires AC Mains
N N L1 L2 L3 Fish Plate wires L1 L2 L3
L1 L2 AC Mains
Wires wires
Links N N L1 L2 L3
N N L1 L2 L3
AC Mains
Terminal
Block AC Mains
AC Mains Terminal
N2 N4 Terminal Block
Block
(To internal connections) Rewire!
N4 N2
N2 N4 Swap the position of internal cables
Flatpack2 DC Power System N2 and N4.
(To internal connections) (To internal connections)
Factory configured
AC Mains terminal block. Flatpack2 DC Power System Flatpack2 DC Power System
Υ Mains, TN Mains Δ Mains, IT
Three-phase & N, 400VAC One-phase, 230VAC/208VAC Three-phase, 230VAC/208VAC
Terminals & Pin-out Location, GMT Fuses

Pin 16 Pin 1
GMT fuses
F12 Max. 10A each
F5
F8
2
Figure 2 GMT fuse board (max. cable size 1.5mm , AWG 16)
The table below shows the pin-out location for the GMT load fuse card:
Pin Assignment for GMT Fuse

Pin Signal Function Pin Signal Function
1 + GMT fuse 1 (F5) 9 + GMT fuse 5 (F9)
2 — 10 —
4 — 12 —
6 — 14 —
8 — 16 —
Alarm Relays & Digital Inputs

The alarm outputs in Flatpack2 systems use the Fail-Safe Operation Mode (relay coils
energized in the system’s normal operation mode). When the system is in alarm mode,
the alarm relay coils are de-energized.
The figure shows the position of the relay contacts when the relay coils are de-energized
(PS system in alarm mode)
Alarm Relays & Digital Inputs
Alarm Relay Specification

Normal Mode NO 30 VDC, 2A Nominal switching capacity
Relay X Com +
(Energized coil) NC 60W (resistive load) Maximum switching power
— 220 VDC Maximum switching voltage
Alarm Mode NO
Relay X Com + 2A DC Maximum switching current
(De-energized coil) NC
—
Flatpack2 PS System
Correct Use of Alarm Outputs (example)
Digital Input X + Normal Mode

(Normal mode) External Relay Y
— (Energized coil)
In order to implement monitored fail-safe
Digital Input X + Alarm Mode
(Activated)
—
External Relay Y digital inputs circuits, the external relay coil
(De-energized coil)
must be energized and the contacts closed
Flatpack2 PS System
in the system’s normal mode of operation.
Correct Use of Digital Inputs (example)
Terminals & Pin-out Location, Alarm Interface Card

The Smartpack controller’s alarm and digital input monitoring signals are accessible from
the controller’s rear panel, on mini power connector CON1 (2 outputs & 2 inputs) and on
D-Sub connector CON2 (4 outputs & 4 inputs).
Using the Alarm Interface Card (Art. 105954) – located on top of the controller; see page
5 -- and two interface cables, you can make the signals on CON1 & 2 accessible at any
suitable location inside your system.
For detailed information about the card’s pin-out location and terminal block connections,
refer to the figures in this section.
Alarm Outputs & Digital Inputs

Voltage free relay outputs and Configurable monitoring digital inputs
Card Art.105954 FUNCTION SIGNAL PIN-OUT

1
In Out *X1:
Digital Input 1 + 1 Input Circuit 1
− 2
external equipment)
Digital Input 2 + 3 Input Circuit 2
−
(To and from

4
Relay 1 NO 5
OVP Alarm COM 6 Alarm Circuit 1
NC 7
Terminals & Pin-out Location Relay 2 NO 8
High Battery Alarm COM 9 Alarm Circuit 2
System Connections
Card, Art. 200625 Battery Connections NC 10
To Smartpack,
CON1
CON2 Card, Art. 200576

*X2:
CON1
(From external equipment)

Battery Connections
Alarm Outputs & Digital
CON2A
Smartpack 1
+ Input Circuit 3
Card, Art. 200576 Digital Input 3
Inputs Card, Art. 105954 CON1A −
2
Digital Input 4 3
+ Input Circuit 4
CON1A CON2A −
4
Digital Input 5 5
+ Input Circuit 5
−
6
*X1 *X2 Digital Input 6 +
7 Input Circuit 6
−
8
Relay 3 NO 9
1 10 1 20 Low Battery Alarm COM 10 Alarm Circuit 3
(To external equipment)

NC 11
Alarm Outputs & Digital Inputs Card, Art. 105954
Relay 4 NO 12
Fuse Alarm COM 13
To Smartpack,
CON2
Alarm Circuit 4
Load & Battery NC 14
Relay 5 NO 15
Battery Alarm: -10°C >Temp>50°C COM 16 Alarm Circuit 5
& Rectifier Alarm NC 17
Relay 6 NO 18
Mains Alarm & COM 19 Alarm Circuit 6
Mains Low & High Alarms NC 20
2
(Customer Connections) 1.5 mm , max.
wire section
The figure shows the position of the relay contacts when the relay coils are de-energized
(PS system in alarm mode. Factory Settings in bold).
Terminals & Pin-out Location, System Interface Card

Flatpack2 systems are shipped from factory with the CON5 signals already connected.
Some of the Smartpack controller’s internal system signals are accessible on D-Sub
connector CON5, on the controller’s rear panel.
Using the System Interface Card (Art. 200625) and a standard 15 pins D-Sub cable, the
signals on CON5 may be accessible at any suitable location inside your system.
For detailed information about the card’s pin-out location and terminal block connections,
refer to the figures in this section.
Terminals & Pin-out Location
In Out X:*****
10 + 1 Power Input
Terminal Board, Art. 200625

CON5A
System Connections
15 − 2
(To Smartpack, CON5)

System Connections
Card, Art. 200625 CON5
Battery Connections 6 + 3 Batt. Current 1
For Internal Use Only!

Card, Art. 200576
7 − 4
Battery Connections 12 + 5 Batt. Fuse Fail 1
Alarm Outputs & Digital Card, Art. 200576 13 −
Inputs Card, Art. 105954 Smartpack 6 Load Fuse Fail 1
9+, Neg.D. 7
JP2
LVD1A
Pos. Distr. 11−,Pos.D. 8 LVD Common LVD1
JP1 Neg. Distr. 1+/− 9
LVD2A
JP1 JP2 3 3+/− 10 LVD Common LVD2
2 JP2
1 2+/− 11
1 (To latching contactors
2 LVD1 & LVD2)
X***** 3
(Internal Connections)
Neg. Distr.
1 11 CON5A Pos. Distr. JP1 and JP2 are used to configure the
System Connections Card, Art. 200625 system for Negative DC distribution (48 and
60V systems) or Positive DC distribution
(24V systems)
LVD Latching Contactors

Flatpack2 systems’ LVBD and LVLD1 functionality is implemented by the Smartpack
controlling magnetically latching contactors.
Latching Contactors, LVD1 & LVD2

A latching contactor changes state only when a
reversed pulse voltage is applied to its coil
Warning! The bidirectional
diode must always be
ON OFF mounted to avoid dam-
aging the controller.
+ Pulse - Pulse Y
PCB Art.
200625 LVD1A
+ X Bidirectional
Latching
Contactor diode
X:***** LVD1
8 Y
9 LVD Common
10 LVD2A
X
X
11 Latching
Contactor
— LVD2
Smartpack Y Latching Contactor
Unit
LVD Common
Flatpack2 PS System (internal)
Correct Use of Latching Contactors (example)
The coil of latching contactors is not energized in any state. They change state from open
to close, or vice versa, when a reversed pulse is applied to the coil.
1
LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect
Monitoring, Control and Signal Interface

The Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m is available with basic functionality
for monitoring and control of the system, and is equipped with:
o Relay outputs, 6 pcs
o Digital inputs, 6 pcs
System Monitoring
The Smartpack Control Unit monitors and controls the entire rectifier system including
distribution and batteries, as well as other equipment on site. The unit also incorporates
a communication port for connecting computers via the USB interface.
The Flatpack2 system can be operated and configured locally via the keypad on the
Smartpack unit, by selecting commands from set-up menus in a hierarchical menu
system.
Remote system monitoring and configuration may also be performed using PowerSuite --
a Windows-based program that runs on a connected PC.
Following configuration tasks require the use of a PC:

o Installation settings
o System calibration
o Battery configuration
o Alarm setup
o Alarm log retrieval
o Site information
o Site specific configuration
Please, refer to the Smartpack controller’s User’s Guide --Art. No. 350003.013 – and to
the PowerSuite program’s online help (press function key F1) for detailed information
about system monitoring and functionality.
System Specification
Technical Specification DC OUTPUT

Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m Voltage 48VDC
Max. number of 8 Current Up to 16 KW – 340A
rectifiers CONNECTIONS
AC INPUT Battery connections Battery cable, M8 bolts
Voltage 1 phase 230VAC (max 3 Load MCB Negative distribution, Negative load
rectifiers, 6kW) connections cable, 70mm2 cable clamps
3 phase 208VAC ( Δ ) Common positive bus bar, 70mm2
3 phase 230VAC ( Δ ) cable clamps
3 phase 400VAC+N ( Y ) Alarm connections Plug-in wire connectors front access
Frequency 45 to 66Hz DISTRIBUTION OPTIONS
Maximum See Flatpack2 48VDC datasheet No. of DC Load Up to 4 x 3pole 150A
Current (241115.001.DS3) breakers
OVP Live – surge arrestor No. of Battery Up to 3 x 150A MCBs mount next to
(Optional) Neutral – spark gap breakers each battery shelf
Class C, type II No. of Aux. fuses 8 x 10A GMT type
In(8/20) – 40kA Programmable LVD Standard: 1 LVBD (max. 300A)
MONITORING OTHER SPECIFICATIONS
Monitoring Unit Smartpack Isolation 3.0 KVAC – input and output
Local operation Menu driven software via keypads 1.5 KVAC – input earth
and LCD or PC (WinPower) 1.0 KVDC – output earth
Remote operation PowerSuite via modem or Web Operating temp -10 to +50°C (14 to +122°F)
NMS via SNMP-agent Storage temp -10 to +85°C (14 to +185°F)
Alarm relays 6 relays are standard Dimensions 600 x 600 x 1500mm (WxDxH) (23.6”
Visual indications Green LED – System ON x 23.6” x 59”)
Amber LED – Minor Alarm Weight Approx. 52kg excl. rectifiers and
Red LED – Active alarm(s) batteries
LCD – system status Max. 250kg load per battery shelf
Digital inputs 6 (for monitoring of external APPLICABLE STANDARDS
equipment) Electrical safety EN 60950
Current Battery current UL 60950
measurements Rectifier current EMC ETSI EN 300 386 (telecommunication
Load current network)
Alarms Load fuse alarm EN 61000-6-3 (emission, light
Battery fuse alarm industry)
LVD operated EN 61000-6-2 (immunity, industry)
Low output voltage alarms Environment ETSI EN 300 019-2
(2 individual alarm levels) ETSI EN 300 132-2
High output voltage alarms 2002/95/EC RoHS Compliant
(2 individual alarm levels)
Battery capacity
Temperature alarm
Symmetry alarm
Individual Mains detect alarm
Rectifier Input Voltages

Type VAC Note Type VAC Note
Nominal 230 High voltage 1 185 – 275 Full output power
Range 185 – 275 Full output power High voltage 1 275 –300 Full power, reduced power factor
Low voltage 1 0 – 85 Shutdown High voltage 2 300 – 350 Shutdown
Low voltage 2 85 – 185 Linear between 850W and 2000W High voltage 3 350 – 420 Shutdown* (see note below)
* Note: If the input voltage is > 300Vac the rectifier will go into self protective mode. At no load, the rectifier will survive 350Vac. With load
or battery connected, it will survive 420Vac.
Specifications are subject to change without notice
3 Installation
3. Installation
This section describes how to install the Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m.
Step-by-step procedures will guide you through the installation.
Read also the generic documentation included in the system’s documentation set, Art.
No. 351486.003
Safety Precautions
To be installed only in restricted access areas or the like, in accordance with
articles 110-16, 110-17, and 110-18 of the National Electrical Code,
ANSI/NFPA 70
For supply connectors use wires suitable for at least 75˚C (167˚F)
Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.
Use copper conductors only
The equipment described in this manual must only be operated by

Eltek Energy personnel or by persons who have attended a suitable
Eltek Energy training course
CAUTION: Even though the product incorporates protection circuitry and

other safeguards, it can be damaged, perform poorly or have a reduced
lifecycle if it is exposed to incorrect treatment during transport, installation
or service.
The equipment represents an energy hazard and failure to observe this

could cause terminal injury and invalidate our warranty
There are hazardous voltages inside the power system. As the modules
incorporate large charged capacitors, it is dangerous to work inside the
system even if the mains supply is disconnected
Products into which our components are incorporated have to comply with a
number of requirements. Installation is to be in accordance with the
recommendations herein
Please read the manual carefully before using the equipment
3 Installation
Installing the Modules

CAUTION:
- The modules may be warm, but do not hand-carry them by their handles
Device - Open the handles before inserting them into the power shelves (hot-pluggable)
hazard The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing
Mounting or Removing Smartpack and Flatpack2 Modules

Note that cables are plugged to the Smartpack’s rear panel. When mounting the
controller, you must plug the cables before step 2. When removing it, unplug the cables
during step 2.
Hole to release the

Smartpack handle’s spring
controller mechanism Flatpack2
rectifier
Handle in
unlocked position
Handle in locked position
1. Unlock the handles by

inserting a screwdriver into the holes to release the spring mechanism
2. Insert or remove the module by
sliding it fully into the power shelf, so that the module makes proper contact
(for Smartpack, plug cables first)
or
using both handles to pull the module loose. Support from underneath before
the unit is completely free. Unplug the cables, when removing the Smartpack
module
3. Lock the handles by
pushing the handles up into their housings (locked position). Then, the module
will be securely locked in the shelf, or ready for transport
4. Mount blind panels in
Electric unused module locations
shock
3 Installation
Mounting and Removing Blind Panels

Screwdriver to Blind panel’s upper
release the locking locking tabs
tabs
To remove blind panels, carry out the following:
1. Release the panel’s upper left and right corners by

inserting a small screwdriver into the panel’s upper left gap and carefully press
down and out to release the locking tabs. Repeat on the upper right gap.
2. Remove the blind panel by
using you hand to pull the panel loose
To mount blind panels, carry out the following:
1. Insert the panel’s upper edge by

pressing gently so that its upper locking tabs engage
2. Lock the panel’s lower edge by
pressing with your hand so that the blind panel’s lower tabs lock into position.
Correct Rectifier Position in Power Shelves

Flatpack2 DC power systems are normally shipped from factory with empty power
shelves. The rectifier modules are shipped in separate packaging, and you have to
install the modules in the correct position in the power shelves, with respect to their
ID number (or CAN bus address). Do not relocate already pre-installed rectifiers.
Follow the scheme below to install the Flatpack2 rectifier modules:
o Insert & hot-plug the rectifiers in the indicated power shelf positions,
one module at a time, allowing a 2s delay between them and starting with ID
number 1, 2, 3, and so on. (indifferent after ID# 6)
Correct Rectifier Position in the Power Shelves

Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers
Phase 1
Δ Mains and Υ Mains
Three-phase, 230VAC Three-phase & N, 400VAC
Flatpack2
Smartpack rectifier Phase 2
controller
02 05 Position 4
01 04
Position 1 --- --- Position 8
03 06 Phase 3
--- ---
--- --- ---
---
Position 9 --- --- ID number
(Assigned CAN
bus address)
3 Installation
System Installation
Site Preparation
Refer also to chapter “Location of Components ~ General Arrangement” on page 5.
Step Action OK
o Check min. clearances for cabinet access:
front access, 60cm, top access, 20cm.
If Flexi Kit(s) are going to be installed,
ensure sufficient space behind the cabinet to
allow access to rear panel
1. Organize the
o Check that the levelled surface is able to
installation site
support 600 kg (cabinetized systems). Refer
to System Specification, page 11.
o Ensure the installation site is suitably
ventilated and in a non-explosive
atmosphere. 60V systems in RAL areas
2. Prepare the Check that insulated tools suitable for telecom
installation tools installations are used
3. Prepare AC Supply: AC Check the AC supply is the correct type, and that
input cable(s) and the external AC fuses and AC input cable(s) are
fuses suitably rated. Refer to page 6
Mechanical Installation
Step Action OK
o Check you have received all the parts,
correct cabinet, documentation, batteries (if
applicable), etc
4. Remove packaging o Inspect the equipment for physical damage
and check equipment (report any damages)
o Leave rectifier modules in their packaging or
in the selves, if factory installed.
(commissioning task)
o This is required for accessing the connection
terminals
o Check that cable entry from the top is
5. Remove top cover,
possible
dummy front panels
o Please refer to “Assembly Guide for IFC”,
and Tool Kit
doc. no. 351478.033, chapter 2 “Description
of the Toolbox” for detailed information on
how to remove the tool kit.
3 Installation
Step Action OK
6. Position and fasten
the cabinet
Cabinets on levelled surface, adjust the legs. If
necessary, unscrew the legs and fasten the cabinet
to floor
Start (if applicable) on the lower shelf first, and

continue upwards. Use kits, if supplied; refer to the
7. Mount the batteries on “Installation Guide for Battery string + Indoor
the shelves Shelf”, Dc. No 351485.033, for details.
Do not terminate the battery cables yet!
Electrical Installation
Refer also to chapter “Location of Components ~ General Arrangement” on page 5.
Step Action OK
8. Make the system
Switch OFF or remove ALL load fuses (MCB1, MCBx),
completely
battery fuses (Fb1, Fbx) and external AC supply fuses
voltage free
o Check AC configuration: The AC terminals are
correct configured to the external AC supply
o Connect the AC Earth wire (PE) to the

terminals AC Earth (PE)
- Terminal AC Earth (PE) is mechanically connected
to cabinet chassis. Refer to page 5
9. AC Connections
o Connect the AC input cable(s) to the terminals.
Cable and terminal block labelling are to correspond.
Read pages 5 and 6.
o Fasten the cables to the horizontal metal bar (I)

as strain relief.
3 Installation
Step Action OK
o Terminate DC Earth (TE)
- Terminals DC Earth (TE) is mechanically connected
to cabinet chassis. Refer to page 5.
- The Common Positive Bus bar is internally cabled
to DC Earth (TE); thus the positive output of the
rectifiers is connected to ground (TE), and the
negative output represents the –48VDC supply
voltage. Refer to Figure 1 General Arrangement
Flatpack2 PS System, 16kW, 48VDC,
ICab 1.5m, on page 5.
10. DC Connections The Common DC Output Rail is to be connected to
Load Circuits TE at only one place.
- If required, you can remove the internal cable that
connects the positive bus bar to local TE.
o Terminate DC Load Circuits

The kit includes two copper bridges. One for 100 A
(two pins) and one for 150 A (three pins). If the
load current is larger than 50 A use the two pin
3-pole link for CBI MCB copper bridge. Then the 3rd hole in the breaker
cannot be used.
If the load current is larger than 100 A, use the
three pin copper bridge. Insert the chosen copper
bridge on to the top of the MCB.
- Connect the orange alarm wire to the copper
bridges with a screw if the bridges are used.
2-pole link for CBI MCB - Connect the positive cable(s), max 70 mm sq
(AWG 2/0), to the common positive bus bar on the
top of the power core. 2
- Connect the negative (-48V) cables, max 25 mm
sq each (AWG 3), to the top of the MCBs or the
copper bridges.
o Terminate GMT Fuse Load Circuits

Connect the adequate cables, 1.5 mm sq (AWG 16),
to the GMT fuse card according to the table on page
7
o Terminate Alarm Circuit cables to the relay output
11. DC Connections terminals.
Alarm & Signal Refer to chapter “Terminals & Pin-out Location,
Circuits Alarm Interface Card” on page 8.
2
The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted at delivery.
3 Installation
Step Action OK
The positive and negative (-48V) battery cables are
connected from factory to the common positive bus bar and
to the battery MCBs (additional battery string kits are not).
The battery temperature sense cable is also pre wired to

CON4, and temporally fixed to the cabinet’s wall.
12. DC Connections o Connect all battery inter-cell links

Battery Cables o Connect the loose end of the battery cables to the
battery terminals; blue cable to the negative
terminal and black cable to the positive terminal.
o Fix battery cables. Use attached cable ties

o Place the temperature sensor, located at the end of
the battery temperature sense cable, on top of the
topmost battery string
4 Commissioning
4. Commissioning
The commissioning of Flatpack2 PS System consists of following stages:
I. Perform a pre-start check before the PS system is switched ON
II. Switch ON the system with disconnected load; adjust output voltage
III. Adjust the nominal output voltage with connected batteries and load
I Pre-Start Check
Power is
OFF! Check off in the Commissioning Procedure, that you find in the pullout section of this folder.
If you have just finished the system installation successfully and filled in the Installation Check
List, jump over the Pre-Start Check and continue with stage II.
Before you switch ON the Flatpack2 PS system, verify the following:

1. System installation is completed
o Ensure a correctly performed system installation, with correct polarity on all
connections, has been carried out (Installation Check List filled in)
Device
hazard o All cabling and copper bars are securely terminated and supported
o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
2. Battery and load fuses are disconnected
o Verify that all battery and load MCBs/ fuses are switched OFF or removed
3. AC input cable(s) and AC Earth wire (PE) are terminated
o Make sure that the AC input cable(s) are connected to correctly configured AC terminals
o Verify that the AC input cable(s) and external AC fuses are sized and rated as specified
o Check that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)
4. Site specific parameters and settings are known
o Read the system specific drawings and documentation
5. AC supply and all MCBs, fuses are switched OFF
o Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF
4 Commissioning
Commissioning Steps, Startup

Check off in the Commissioning Procedure, that you find in the pullout section of this folder.
After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you will
switch ON the Flatpack2 PSS — while the batteries and load are disconnected ⎯ then measure
the output voltage, and adjust it if required. Carry out the following:
II Startup and No-Load Adjustments

Power is
ON! 1. Disconnect all rectifier modules, without removing them (keep original location)
o Read how to install modules, on page 13. Also, read about the correct rectifier position
on page 14, and then,
o If Flatpack2 rectifier modules are installed, unlock the handles and pull the modules
Device
partially out (fan housing visible), but do NOT physically remove them from the
hazard power shelves
o If Flatpack2 rectifier modules are not yet mounted, release their handles and insert
them partially into the correct position in the shelves
2. Switch ON the system
o Switch ON the AC input supply (external AC fuses) to the PS cabinet
3. Measure and verify that the AC input voltage is correct
o Measure the AC input voltage at the cabinet’s mains connection box
o Verify the AC voltage is within range
4. Mount all Flatpack2 rectifier modules in the power shelves (keep original location)
o Push all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯ to
plug them in the same shelf location. Lock their handles. Refer also to page 13
o Mount blanking panels over unused positions
5. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON
o Verify correct operation, by monitoring the modules’ LED lamps and display:
No alarms are present on rectifiers; The Smartpack displays fuse alarms
6. Connect a PC to the PS system (to facilitate operation)
o Plug a standard USB A-B cable between the PC and the Smartpack controller
o Start PowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite
o On the toolbar, click the “Connect” button to establish connection
7. Measure and adjust DC output voltage
o Read the DC output voltage on the controller’s display
o With a multi-meter, measure the DC output voltage at the most accessible point, e.g.
between the common DC rail and the lower connection of one of the priority load MCBs
o If required, adjust the voltage using the controller’s front keys or via PowerSuite
8. Verify the alarm relays are working correctly (alarm relay test)
o Run the alarm relay test using the controller’s front keys or via PowerSuite (select the menu
Go > Output Test)
9. Make sure the System Setup is in accordance with configuration
o Verify system settings using the controller’s front keys or via PowerSuite
o Use the opportunity to enter site related information, number of used AC phases, type
of batteries, etc.
4 Commissioning
Load Adjustments
III
Power is
Now, you can begin with stage III, where you will adjust again the output voltage to the battery ON!
voltage, and connect the batteries and the load. Carry out the following:
10. Adjust DC output voltage to equal measured battery voltage
o Measure the battery voltage is within range (check connections have correct polarity)
o Adjust DC output voltage — using the controller’s front keys or via PowerSuite— to Device
hazard
equal the measured battery voltage.
(Important adjustment to avoid arcing when connecting the batteries)
11. Unplug all rectifiers but one, and connect the battery fuses /MCBs
(CAUTION: Have only one rectifier connected, when switching ON the battery fuses.
Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.)
o Disconnect all rectifiers but one, by unlocking the handles and pulling them partially Device
hazard
out (fan housing visible). Do NOT physically remove them from the power shelves
o Switch ON all battery fuses or MCBs
12. Adjust DC output voltage again to equal the nominal battery voltage
o Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to
equal the nominal battery voltage (or the nominal load voltage, when not using batteries)
13. Plug in again all rectifiers, and verify the rectifiers’ current sharing
o Connect all rectifiers again by pushing them firmly inwards ⎯ Repeat step 4, in stage II
o Wait for about 2 min., and check — using the PowerSuite application —that each of the
rectifiers delivers the same output current. A deviation of 1A is acceptable.
14. Connect the load breakers and verify that no alarms are displayed
o Switch ON all load MCBs/ fuses
o Verify correct operation: rectifiers and controller display no alarms
5 Forms, Schematics & Drawings
5. Forms, Schematics & Drawings

This section includes following forms and schematic drawings:
Installation Check List
Commissioning Procedure
Maintenance Procedure
General Arrangement Drawing
System Schematic Drawing
Configuration Settings ~ Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m
Load Distribution List
INSTALLATION CHECK LIST
System Data Flatpack2 PS System
Flatpack2 Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:
Site Preparations
CARRY OUT FOLLOWING: OK
1. Organize the installation site
o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm
o Check that the levelled surface is able to support 600 kg (cabinetized systems)
EMC o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas
regard 2. Prepare the installation tools
o Check that insulated tools suitable for telecom installations are used
3. Prepare AC Supply: AC input cable(s) and fuses
o Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated
Mechanical Installation Power is OFF!

4. Remove packaging and check equipment
o Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc
Device o Inspect the equipment for physical damage (report any damages)
hazard o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
5. Remove top cover, dummy front panels and Tool Kit
o Check that cable entry from the top is possible; Read how to remove the Tool Kit on Doc. No. 351478.033
6. Position and fasten the cabinet
o Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor
7. Mount the batteries on the shelves

o Start (if applicable) on the lower shelf first, and continue upwards. Use kits, if supplied; refer to Doc. 351485.033
o Do not terminate the battery cables yet!
Electric
shock
Electrical Installation Power is OFF!
8. Make the system completely voltage free
o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses
9. AC Connections
o Check AC configuration: The AC terminals are correct configured to the external AC supply
o Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
10. DC Connections ⎯ Load Circuits
o Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place
o For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB
Electric
shock
11. DC Connections ⎯ Alarm & Signal Circuits
o Refer to your system’s connection drawings and configuration
o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output terminals, if applicable
12. DC Connections ⎯ Battery Cables Careful! Use correct polarity.
For each battery shelf,
o Mount 3 intercell links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks)
o Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-)
o Connect battery symmetry cables, if applicable, to the input terminals
o Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the
end of the cable) to a suitable place in the middle of the installed battery bank
Approval
Responsible of installation, sign.: Date: Approved by customer, sign.:
COMMISSIONING PROCEDURE
Supplier’s Order No.: Flatpack2 Power Supply System, type: Article No.:
Site, name:
AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:
I Pre-Start Check
CHECK FOLLOWING:
Power is OFF!
OK
1. Flatpack2 system installation is completed; The Flatpack2 Installation Check List is filled in.
All cabling is securely terminated with correct polarity
Device 2. All battery and load MCBs/ fuses are disconnected
hazard
3. AC input cable(s) and AC earth wire (PE) are terminated
4. Site specific parameters and settings are known
5. AC supply and all MCBs/ fuses are switched OFF
Start-up, No-Load & Load Adjustments Power is ON!

II CARRY OUT FOLLOWING: OK
1. Disconnect all rectifier modules, without removing them (keep original location)
Device
2. Switch ON the system (external AC fuses ON)
hazard
3. AC input voltage is correct; Measure and verify
4. Insert all Flatpack2 rectifiers in their original locations in the power shelves
5. The Smartpack and all rectifier modules are working, LEDs are ON; Verify
6. Connect a PC to the PS system Install the PowerSuite software, if required
7. DC output voltage; Measure and adjust
8. Alarm relay test; Verify all alarm relays are working correctly
9. System Setup is in accordance with configuration Enter site spec. info in PowerSuite
III 10. Adjust DC output voltage to equal measured battery voltage Check correct polarity!
11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs
Device 12. Adjust DC output voltage to equal nominal battery or load voltage
hazard
13. Plug in again all rectifiers, and verify the rectifiers’ current sharing
14. Connect all load MCBs/ fuses, and verify no alarms are displayed
Approval
Responsible of commissioning, sign.: Date: Approved by customer, sign.:
MAINTENANCE PROCEDURE
Flatpack2 Power Supply System, type: Article No.:
Site, name:
AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:
WARNING: Maintenance work on live equipment is only to be performed by authorized and

Electric qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.
shock
System Inspection Power is ON!
1. Site specific parameters and settings are known.
User manuals and site specific connection & arrangement drawings are available.
2. The battery bank has been fully charged in advance.

At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration
3. The equipment is free from damage, dust or dirt; verify.

Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.
4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.
5. The Smartpack & all rectifier modules are ON, no alarm present; verify.
Otherwise, correct and put the PS system in normal mode of operation.
6. All rectifier’s functionality & Smartpack’s keys and display work OK; verify
Correct possible abnormalities before continuing.
7. Connect the PS system to a PC (install the PowerSuite application if required)

The PowerSuite program in the PC enables system configuration from the PC.
8. Rectifiers’ load current sharing; verify.

Use the PowerSuite PC application to check all rectifiers output the same amount of current (±1A)
9. Display the stored log of Alarm Messages.

Using the keypad on the Smartpack controller or from the PC.
System Adjustment
1. DC Output Voltage Calibration; ensure correct display readings.
If measured DC output voltage at the load terminals deviates more than ±1% from the display reading, calibrate the
output voltage from the Smartpack’s keypad or the PC.
2. Load & Battery Current Calibration; verify correct display readings.

Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery
current. If the calculated total values deviate more than ±1% from the display readings, calibrate the current from the
PC (calibration value>50% of system’s max. capacity)
3. DC Output Voltage Adjustment; measure and adjust.

Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery manufacturer.
(Voltage measurements to be done at the DC rail, with little load current)
4. Alarm Relay Test; verify all alarm relays are working correctly.
From the Smartpack’s keypad or PC use the Relay Test function; verify activation of external equipment
5. Battery bank control; measure and verify battery specifications.

Follow the recommendations of the actual battery manufacturer.
Approval
Responsible of maintenance control, sign.: Date: Approved by customer, sign.:
32U
30U
28U AC Mains Connection behind

panel.
*OVP Option behind panel.
26U
24U
22U
20U
18U
16U
14U
12U
16KW Power System
48Vdc – 8 rectifier slots
10U
This Power System consists of:
8U - Smartpack – Monitoring/Control
- LVBD Contactor
- 1x150A Battery breaker
6U - 2x150A Load breakers
- 8x10A GMT Fuses
4U
2U
HxDxW: 1500x600x600mm
Figure 3 General Arrangement Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m Doc, 24nnnn.yy, XvX
*OPTION
Customer connections
Circuits -48Vdc
48Vdc
Battery Strings Load circuits -48Vdc
GMT Load circuits -
203929
Load Load
Alarm Alarm
Customer connections
POS. DIST.
NEG. DIST.
POS. DIST.
NEG. DIST.
Figure 4 System Schematic Flatpack2 PS System, 16kW, 48VDC, ICab 1.5m Doc, 2020388, 2v0
Note! The values in this table are default factory settings. The settings of a Smartpack controller in
an installed system may be different from the above settings, depending on the system’s final
configuration of optional kits, number/type of batteries, alarm setup and/or any other changes done
to the system and/or the Smartpack controller after the system was shipped from the factory.
LOAD DISTRIBUTION LIST
System Data
Flatpack2 PSS, type: Article No.:
Site, name:
FUSE TYPE RATING CABLE CABLE

FUSE SIZE SIZE
BTS GMT LTE LOAD DESCRIPTION
ID AMPERE mm2 AWG
MCB FUSE MCB
F1 X
F2 X
F3*
F4*
F5 X 10
F6 X 10
F7 X 10
F8 X 10
F9 X 10
F10 X 10
F11 X 10
F12 X 10
F13* 10
F14* 10
F15* 10
F16* 10
F17* 10
F18* 10
F19* 10
F20* 10
*Optional fuses/breakers.
Form xxx-gb-v1-C01_351476-033_instgde_fp2-pss-16kw-48vdc-ocab-fanc-2m0.doc_ts/mfm_2007-06-19
F3 & F4 are only fitted if optional BTS breaker kit(s) are installed in the cabinet.
F13-F20 are only fitted if optional LTE kit is installed in the cabinet
Breakers F1, F2 and GMT fuses F5-F12 are always part of cabinet
LTE MCB`s
(Optional)
For details, see installation manual
for LTE kit (351480.033)
BTS MCB`s
For details, see chapter
“Location of Components General
arrangement”
GMT FUSES
For details, see chapter
“Terminals and pin-out location
GMT fuse”
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com

Tel. +47 32 20 32 00
ELTEK Energy
P-O- BOX 2340 StØmsØ
N-3003 DRAMMEN
NORWAY
Phone: +47 32203200

Telefax: +47 32203210
Internet: http://www.eltekenergy.com
e-mail: eltek@eltekenergy.com
Location Company Telephone Fax

Norway 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. +769 22651108
Europe Eltek Energy UK Ltd. +44 1442 219355 +44 1442 245894
www.eltekenergy.com
Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175

Installation Guide: DC Power Supply System, 16kW, 48VDC

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Installation Guide: DC Power Supply System, 16kW, 48VDC

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Installation Guide

DC Power Supply System, 16kW, 48VDC

Copyright ©: Eltek Energy, Norway 2007

Certificate no: 900005E Certificate no: 900005Q

“FP2 PRSB 16KW/48Vdc ID 1.5m” has part no. CF1030.003.

351486.033 Issue 3, 2007 June

2. System Description 4

3. Installation 12

4. Commissioning 19

5. Forms, Schematics & Drawings 22

About this Guide

Location of Components ~ General Arrangement

Figure 1 General Arrangement Flatpack2

Battery DC (+) terminals

Alarm Terminals Smartpack controller

External AC Fuses ~ Recommended Ratings

Use the type of external AC fuses recommended in the table below.

External AC Fuses ~ Recommended Ratings

AC Mains Type External Fuse Type

Mains Reconfiguration ~ AC Terminal Block

To reconfigure the system’s AC mains feed, perform the following:

1. Switch OFF the AC supply fuses in external fuse boards

Terminals & Pin-out Location, GMT Fuses

Pin Assignment for GMT Fuse

Alarm Relays & Digital Inputs

Alarm Relays & Digital Inputs

Alarm Relay Specification

Digital Input X + Normal Mode

Terminals & Pin-out Location, Alarm Interface Card

Alarm Outputs & Digital Inputs

Card Art.105954 FUNCTION SIGNAL PIN-OUT

(To and from

CON2 Card, Art. 200576

(From external equipment)

(To external equipment)

Terminals & Pin-out Location, System Interface Card

Terminal Board, Art. 200625

(To Smartpack, CON5)

For Internal Use Only!

LVD Latching Contactors

Latching Contactors, LVD1 & LVD2

Flatpack2 PS System (internal)

Correct Use of Latching Contactors (example)

Monitoring, Control and Signal Interface

Following configuration tasks require the use of a PC:

Technical Specification DC OUTPUT

Rectifier Input Voltages

The equipment described in this manual must only be operated by

CAUTION: Even though the product incorporates protection circuitry and

The equipment represents an energy hazard and failure to observe this

Please read the manual carefully before using the equipment

Installing the Modules

Mounting or Removing Smartpack and Flatpack2 Modules

Hole to release the

1. Unlock the handles by

Mounting and Removing Blind Panels

To remove blind panels, carry out the following:

1. Release the panel’s upper left and right corners by

To mount blind panels, carry out the following:

1. Insert the panel’s upper edge by

Correct Rectifier Position in Power Shelves

Correct Rectifier Position in the Power Shelves

Start (if applicable) on the lower shelf first, and