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3514
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Installation Guide
PRSB 9kW, 48VDC
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2 Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek Energy AS.
No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical, including photocopying and recording for any purpose without the explicit written permission of ELTEK Energy.
Copyright : Eltek Energy AS, Norway 2006 NS-EN ISO 9001:1994 Certificate no: 900005Q NS-EN ISO 14001:1996 Certificate no: 900005E This product holds a CE mark and satisfies all requirements covering relevant standards and directives. EMC EN61000-6-2 Industrial Environment EN61000-6-3 Residential, Commercial and Light Industry ETS 300386 v1.3.1 Telecommunication Equipment
LVD LVD73/23/EEC Low Voltage Directive EN60950 Safety of Technology Equipment UL60950,UL1801
Head Office: Eltek Energy AS P.O. Box 2340 Strms N-3003 Drammen NORWAY Phone: (+47) 32 20 32 00 Fax: (+47) 32 20 32 10 E-Mail: [email protected] Internet: http://www.eltekenergy.com
This product is made according to EU directive 2002/95/EC (RoHS) and 2002/96/EC (WEEE).
Art. No. 351434.033 Issue 3, 2006 July
Published 2006-07-18
Flatpack PRSB 9kW, 48VDC (Outdoor Site Power Cabinet, Fan Cooled) has part no. CF1017.001
POWER DISTRIBUTION CENTER FOR
COMMUNICATIONS EQUIPMENT
9N73
Certificate no: 900005E Certificate no: 900005Q
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 3
Table of Contents
1 DESCRIPTION OF FLATPACK PRSB 9KW, 48VDC 4 IMPORTANT NOTICE 4 OVERVIEW GENERAL ARRANGEMENT 4 INPUT AND DISTRIBUTION ARRANGEMENT 5 AC INPUT TERMINALS 5 MONITORING, CONTROL AND SIGNAL INTERAFCE 6 SYSTEM MONITORING 6 RECTIFIER INSTALLATION - MAINS SUPPLY BALANCING EFFECT 7 RECTIFIER INSTALLATION - HANDLES AND LOCKING MECHANISM 7 FAN & HEATER OPERATION 8 ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS 8 CONNECTIONS FOR INTERNAL SYSTEM WIRING 9 CUSTOMER CONNECTIONS 10 CONNECTIONS FOR GMT FUSES 10
2 INSTALLATION PRODECURES 12 SAFETY PRECAUTIONS 12 UNPACKING AND MECHANICAL INSTALLATION 12 ELECTRICAL INSTALLATION 13 COMMISSIONING 16 MAINTENANCE 16 REPLACEMENT OF FILTER, INTERVAL 16 REPLACEMENT OF DOOR FILTER 17 REPLACEMENT OF FAN FILTER 17
3 SPECIFICATIONS FLATPACK PRSB 9KW, 48VDC, FAN COOLED 19 SPECIFICATION 19
APPENDIX: SCHEMATICS, DRAWINGS, FIGURES ETC. 20 A1 - GENERAL ARRANGEMENT DRAWING 20 A2 - SYSTEM SCHEMATIC PRSB 9KW, 48VDC, OUTDOOR CABINET, FAN COOLED 21 A3 - DRILLING TEMPLATE 22 MCU DEFAULT SETTINGS PRSB 9 KW, 48 VDC 23
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 4
1 DESCRIPTION OF Flatpack PRSB 9kW, 48VDC
This Installation Guide contains information about how to install the Flatpack PRSB 9kW, 48VDC system1, for the outdoor site power cabinet, fan cooled. Please, refer to the systems Documentation Set (art. no 351405.003) for an overview of related user documentation.
IMPORTANT NOTICE 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 75C (167F). Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar. Use copper conductors only.
OVERVIEW GENERAL ARRANGEMENT The Flatpack PRSB 9kW, 48VDC is a DC power supply system based on the Flatpack 1500 48V rectifier. The system contains AC terminal blocks, DC distribution, Flatpack Power Rack, Flatpack 1500 rectifier modules and the Flatpack Monitoring and Control Unit (MCU). The system is designed for cable entry from top. The cabinet size is 770 (778 incl. cable entry) x 820 x 1300mm (30.3 (30.6) x 32.3 x 70.9) (WxDxH).
Figure 1: Flatpack Power Rack system General Arrangement. The system consists of 1 battery shelf.
1 PRSB = Power Rack System with Batteries
Air filter
DC Load Distribution: MCBs, Mains, Alarm and Signal Terminal Heater MCB (AC)
LTE Distribution, MCBs optional kit (not present on picture)
Battery strings, one shelf is optional kit
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 5
INPUT AND DISTRIBUTION ARRANGEMENT
-Ve DC Load Terminals (BTS MCBs) On top of each load breaker, 25mm2, 4AWG, 70mm2, 2/0AWG
-Ve Battery terminals Bus bar, 35mm2, 2AWG +Ve DC Load Terminals Common positive bus bar, 70 mm2, 2/0AWG
Figure 2
Figure 2: Location of components in The Powercore; contains Distribution and Power Racks
AC INPUT TERMINALS The AC terminal blocks are factory configured for mains supply type: 400VAC, 3 phase and N.
Figure 3: AC input terminal blocks for L1, L2, L3 & N
L2-bar
L1-bar
L3-bar
N-bar
L3 (Terminal for incoming wire)
L3 (neutral) (Terminal for incoming wire)
L2 (Terminal for
incoming wire)
Labels on internal wires (Wires may be reconnected to match the sites type of AC mains supply)
Cabinet main Protective Earth (PE) Connected to powercore PE. Positioned in the ceiling
+Ve Battery Terminals Common positive bus bar, 70mm2, 2/0AWG
DC Earth (TE) terminal M6
AC Earth (PE) terminal M6
AC Mains Terminals
Con 5, Alarm Terminals 1.5mm2, 16AWG (Front access)
MCU Ctrl.Unit, and CON 4, Monitoring Terminals (Back MCU)
Terminals for GMT 10A Load Fuses, 1.5mm2, 16AWG
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 6
It is possible to reconfigure the AC terminal block for connection of 230VAC, 3 phase supply. To do so, rewire the internal (blue) wires as described in the table below and connect the AC mains supply cable to terminals L1, L2 and L3.
To connect the system to 1 phase from a 230VAC-system or a 400VAC + N-system connect the input cables as illustrated in the table to the right.
MONITORING, CONTROL AND SIGNAL INTERAFCE The Flatpack PRSB 9kW, 48VDC is available with basic functionality for monitoring and control of the system. It is equipped with:
Relay outputs, 8 pcs Digital inputs, 5 pcs
One of the interface boards (Eltek p/n: 200920) is located behind the MCU (with rear access to the terminals), while the other board (Eltek p/n: 200958) is mounted on top of the MCU (with front access to the terminals). See Figure 8 Customer connections interface, page 10.
SYSTEM MONITORING The Flatpack MCU (Monitoring & Control Unit) monitors and controls the entire rectifier system including distribution and batteries, as well as other equipment on site. The unit also incorporates a communication port for connecting computers via the RS232C interface.
The Flatpack system can be operated and configured locally via the keypad on the MCU unit by selecting commands from set-up menus in a hierarchical menu system.
AC Terminal Block 400VAC, 3ph+N
Internal Wire Connections Internal Wire
(Labeled) Wire Color Connected to
Terminal Bar L1,1 Black L1-bar N1(L2) Blue N-bar L2,1 Black L2-bar N1(L3) Blue N-bar L3,1 Black L3-bar N1(L1) Blue N-bar
Factory configuration
AC Terminal Block 230VAC, 3ph
Internal Wire Connections Internal Wire
(Labeled) Wire Color Connected to
Terminal Bar L1,1 Black L1-bar N1(L2) Blue L2-bar L2,1 Black L2-bar N1(L3) Blue L3-bar L3,1 Black L3-bar N1(L1) Blue L1-bar
Customized configuration
An external breaker is required on all sites. This should be turned OFF during installation.
AC Input Connection 1-phase
External Wire Connections AC configuration in
Terminal Block 400 VAC + N 230 VAC
L1 L1-terminal L1-terminal 400VAC + N N N-terminal L2-terminal
L1 L1-terminal L1-terminal
Input (230VAC, 3ph or
400VAC, 3ph + N)
230VAC L2 N-terminal L2-terminal
1 phase configurations
AC Input Feed Sizing (Recommended AC Breaker Rating)
VAC Input 9 kW Th/Mag 9 kW Hy/Mag 400 VAC +N
3 ph 25A C-char. 20A C2-char.
230 VAC 3 ph
32A C-char. 32A C2-char.
230 VAC 1 ph
25A C-char. 20A C2-char.
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 7
Please refer to the Flatpack MCU Operation Guide for detailed information about system monitoring.
Remote system monitoring and configuration may also be performed using WinPower Silver a Windows-based program that runs on a connected PC.
The following configuration tasks require the use of a PC:
Installation settings System calibration Battery configuration Alarm setup Alarm log retrieval Site information Site specific configuration
RECTIFIER INSTALLATION - Mains Supply Balancing Effect
The Flatpack PRSB system may be expanded to a maximum of 6 Flatpack 1500 rectifiers. In order to load the AC supply net evenly similar current load from the 3 phases of the mains supply it is advisable to mount the required number of rectifiers in the following order:
Figure 4: Rectifier mounting order to load the mains supply evenly
When possible, mount an equal number of rectifiers on each phase, L1, L2 and L3.
RECTIFIER INSTALLATION - Handles and Locking Mechanism The Flatpack 1500 rectifier module is equipped with handles that serve two purposes:
Locking the module into position
Open both handles, insert and plug the module into power shelf. Then lock it into position by rotating the handles upwards and pushing them firmly home. Failure to do so will prevent the module from making proper contact.
Figure 5: Module with released handles
Pulling the module out Unlock and release the handles by inserting a small flat screwdriver into the upper holes. Do not use excessive force. The handles will release and pop out. When both handles are released, use them to pull out the module.
Do not hold or carry the rectifier by its handles.
Figure 6: Releasing the modules handles
1st Pos (on L1)
2nd Pos (on L2) 3rd Pos (on L3)
4th Pos (on L1)
5th Pos (on L2) 6th Pos (on L3)
Rectifiers MCU
Handle in locked position
Upper hole which releases the spring
mechanism
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 8
FAN & HEATER OPERATION
The fan runs as soon as the temperature in the cabinet passes 25oC (77F). Hysteresis is 1C (1.8F).
The heater is controlled through a thermostat and the heater starts up at 5C (41F).
ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS
The digital inputs are configured as fail-safe, i.e. if the input is enabled, it will trigger an alarm when the input is open. If several external devices are to be connected to the same digital input, they must be connected in series.
The alarm relays are also operated in fail-safe, i.e. the relays are energized when there is no alarm. The description below describes the pin out in normal state, i.e. the REL output is closed to COM in normal operation and the REL output is open to COM in an alarm-state.
Alarm relay specifications:
Nominal switching capacity 2A/30VDC
Maximum switching power 60W (resistive load)
Maximum switching voltage 220VDC
Maximum switching current 2A DC
Interface Backwiring Connection Pin Out
Figure 7: Backwiring interface and internal terminals (max. 1.5 mm2, AWG 15). Art no. 200920
Terminal Description Terminal Description CON 2 Internal system connections CON 41 Customer connections (digital inputs, temp sense.) CON 3 Internal communication CON 42 Customer connections (Symmetry, etc.) CON 5 Customer connections (alarm relay outputs)
CON4 External device alarm state
Input 1 AGND
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 9
CON 41 Pin Assignment for basic PCB version, art. No. 200920
Pin Signal Function Pin Signal Function 1 2 3
Screen + -
Battery Temperature Sense
12 13
+ AGND
Digital Input 5 Door Open
4 5
+ AGND
Digital Input 1 (Programmable)
6 7
+ AGND
Digital Input 2 Phase 1
8 9
+ AGND
Digital Input 3 Phase 2
10 11
+ AGND
Digital Input 4 Phase 3
CON 42 Pin Assignment for basic PCB version, art. No. 200920
Pin Signal Function Pin Signal Function 1 2
+ AGND
Digital input Battery symmetry
11 12
+
+21V Auxiliary Supply (for modem or ext.equipment) (not used)
3 4
+ -
Battery Symmetry 1 (analogue input))
5 6
+ -
Battery Symmetry 2 (analogue input)
7 8
+ -
Battery Symmetry 3 (analogue input)
9 10
+ -
Battery Symmetry 4 (analogue input)
CONNECTIONS FOR INTERNAL SYSTEM WIRING CON3 is used for rectifier and power shelf communication. CON2 is used for internal system wiring, which has been done at the factory. These connectors are not involved in the system installation and commissioning process. The table below shows the pin assignment for CON2:
CON 2 Pin Assignment for basic PCB version, art. No. 200920
Pin Signal Function Pin Signal Function 1 2
+
Shunt 2: Battery current measurement
9 + Battery Fuse State (digital input)
3 4
+
Shunt 1: Battery current measurement
10 + Load Fuse State (digital input)
5 6
+
Auxiliary Supply (for Flatpack MCU)
11 LVBD control (Battery Disconnect contactor)
7 8
VDC+ VDC
Voltage Sense (system signal reference)
12 LVLD control (Load Disconnect contactor)
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 10
Customer Connections
Figure 8: Customer connection, relay output (max. 1.5 mm2, AWG 15). PCB art.no: 200958
Relay Out Pin Assignment for basic PCB version, art. No. 200958
Pin Signal Function Pin Signal Function 3 4
REL 8 COM 8
Relay 8: Phase 3 Alarm
11 12
REL 4 COM 4
Relay 4: Load / Battery Fuse Alarm
5 6
REL 7 COM 7
Relay 7: Phase 2 Alarm
13 14
REL 3 COM 3
Relay 3: Low Battery Alarm
7 8
REL 6 COM 6
Relay 6: Phase 1 Alarm
15 16
REL 2 COM 2
Relay 2: High Battery Alarm
9 10
REL 5 COM 5
Relay 5: Module Alarm
17 18
REL 1 COM 1
Relay 1: In use for Fan High Temp Alarm/
CONNECTIONS FOR GMT FUSES
Figure 9: GMT fuse board (max. cable size 1.5mm2)
GMT fuses Max. 10A each
Pin 16 Pin 1
WARNING:
Do not connect external cables to relay 1 as this is used for fan control.
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 11
The table below shows the pin assignment for the GMT load fuse board:
Pin Assignment for GMT Fuse
Pin Signal Function Pin Signal Function 1 2
+
GMT fuse 1 (F5) 9 10
+
GMT fuse 5 (F9)
3 4
+
GMT fuse 2 (F6) 11 12
+
GMT fuse 6 (F10)
5 6
+
GMT fuse 3 (F7) 13 14
+
GMT fuse 7 (F11)
7 8
+
GMT fuse 4 (F8) 15 16
+
Fuse 8 (F12) 10A
In use for FAN
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 12
2 INSTALLATION PRODECURES
This section describes how to install the Flatpack PRSB 9kW, 48VDC. Step-by-step procedures will guide you through the installation.
For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and control unit, please refer to the Operation Guides for the respective modules.
SAFETY PRECAUTIONS
The equipment described in this manual must only be installed by authorized personnel and only operated by persons who have attended a suitable Eltek Energy training course.
The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty.
There are hazardous voltages inside the rectifier system. As the rectifier units incorporate large charged capacitors, you should show precaution when working inside the system even if the mains supply is disconnected.
Products into which our components are incorporated have to comply with a number of requirements. Installation is to be in accordance with the recommendations herein.
Please read the manual carefully before using the equipment.
UNPACKING AND MECHANICAL INSTALLATION
Step Comments OK
1. UNPACK THE FLATPACK POWER SYSTEM OUT OF THE PACKING
Take the Flatpack Power System out of the packing and inspect it for any physical or transit damage, and tighten the screws that connect conductors. Report any transit damage to Eltek Energy immediately.
2. DRILL HOLES IN THE GROUND
Drill holes in the ground according to the drilling template located on page 22, figure 12. Eltek recommends that the system isnt mounted directly to the ground without a plinth or similar structure.
3. POSITION THE CABINET Position the cabinet in the required location. The floor construction must be capable of supporting the equipment.
4. BOLT THE CABINET Bolt the cabinet to the ground/plinth. Bolts are not included in the cabinet. If a plinth is used, refer to Installation Guide, Kit for Plinth, Doc. No. 351416.033.
5. REMOVE CONDENSATION STOPPER
The condensation stopper (yellow plastic) prevents humidity from entering the cabinet and must therefore not be removed before cabinet is powered up. Humidity before powering up the system may cause serious damage to the system.
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 13
ELECTRICAL INSTALLATION For location of components see Figure 2 - page 5, Figure 3 - page 5 and Figure 10 - page 20.
Step Comments OK 1. OPEN THE ROOF The cabinet roof is locked with 2 triangle locks with access from inside the system. Open these locks and lift up the roof. The key is located on the left
hand side of the cabinet. Secure the roof during installation with the rod on the left side under the roof.
2. CABLE ENTRY
DO NOT USE A KNIFE TO MAKE THE HOLE, USE A SCREW DRIVER OR EQUIVALENT!
Avoid placing cables on top of cable entry as this will block the filter entry
Cable (all phases in one cable) max 6mm2 each Single phase cable (one cable per phase) max 35mm2
Marcon 25 multigate The picture below show how to cut the grommets. The cut must be
smaller than the cable diameter:
Push cable(s) through the grommet(s):
Filter entry
WARNING:
Live bus bars underneath opening inner roof. You are operating in a live system. Precaution must be taken when working in this area.
Electric shock
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 14
Step Comments OK
Go back to the grommet and pull the cable back approx. 10mm. This
will lock the cable in the grommet and ensure full IP protection. Secure cables with cable tie to the cable bracket
3. EARTH CONNECTIONS
The AC Earth (PE) and DC Earth (TE) terminals are mechanically connected to the cabinet chassis. The Common Positive Bus bar is internally cabled to DC Earth (TE); therefore the positive output of the rectifiers is connected to ground (TE), and the negative output represents the 48VDC supply voltage. If required, remove the internal cable that connects the positive bus bar
to local PE
4. AC CONNECTIONS
Locate AC connections in the top area of the cabinet. Make sure that the cable(s) are long enough (+10mm).
AC-connections Switch OFF the AC input power (external MCBs), before connecting the
cable There are two pre-installed MC 25 Cable entries in the cabinet. These
can be mounted on rear, left and right side of the cabinet. To change position, remove MC 25 from existing position. Remove Blind
Panel from the position were you want the cable entry. Store all fixings in a safe place.
Then remount MC 25 in the preferable position and remount blind panel in the empty space
Connect the external AC ground wire to the protective earth (PE terminals)
If you are using double lug PE cable connect to the cabinets main PE terminal. See page 5.
Connect cables to L1-L2-L3-(N)
5. AC SOCKET The system is prepared for an AC socket located to the right side of the cabinet. This AC outlet is intended for optional equipment. Due to the many different socket types all over the world, no socket is delivered with
Cable bracket
PE terminal
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 15
Step Comments OK the system.
Turn off the AC breaker. Connect the cables L, N and PE to the preferred socket type and mount the socket to the bracket.
6. LOAD / BTS CONNECTIONS
3-pole link for CBI MCB
2-pole link for CBI MCB
Turn OFF the Load/BTS MCBs Turn OFF the PRS battery MCBs on the left side of the cabinet The kit includes two copper links; one for 100A (2-pole) and one for 150A
(3-pole). If the load current is larger than 50A, use the 2-pole copper link. Then the 3rd hole in the breaker cannot be used. If the load current is larger than 50A, use the 2-pole copper link. Mount the chosen copper link on to the top of the MCB.
Connect the orange alarm wire to the MCB Connect the positive cable(s), max 70mm2 (AWG 2/0), to the common
positive bus bar on the top of the power core2 Connect the negative (-48V) cables, max 25mm2 each (AWG 3), to the
top of the MCBs. By connection of a single cable to the 2- or 3-pole copper link max area is 70mm2 (AWG 2/0).
7. GMT FUSE CONNECTION
Connect the adequate cables, 1.5mm2 (AWG 16), to the GMT fuse board according to the table on page 11
8. BATTERY CONNECTIONS
The positive and negative (-48V) battery cables are connected from the factory to the common positive bus bar and to the battery MCBs (excluding additional battery string kits). The battery temperature sense cable is also pre-wired to CON4, and temporally fixed to the cabinets back wall. Connect the battery cables to the battery terminals; blue cable to the
negative terminal and black cable to the positive terminal Connect all battery inter-cell links Place the temperature sensor, located at the end of the battery
temperature sense cable, on top of the topmost battery string
9. CONNECT ALARM WIRES
You can now connect all external alarm wires to the front relay access card located above the MCU. See figure 2 page 5 for location.
10. PLUG IN RECTIFIERS Plug in the rectifiers and make sure you balance the rectifiers over the faces
11. POWER UP Please follow the chapters Pre-Start Check and Start-Up Procedure in the manual Commissioning Guide Flatpack 1500 DC Rectifier Plant, doc.no.
2 The bus bar is prepared for connection of stripped cables (app. 30mm) or with ferrules. Clamps are fitted at delivery.
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 16
Step Comments OK 360006.163
12. REMOVE CONDENSATION STOPPER
Remove the condensation stopper placed in front of both filters; inside door and in front of fan:
COMMISSIONING For information regarding system commissioning, please read manual Commissioning Guide Flatpack 1500 DC Rectifier Plant, art. no. 360006.163.
MAINTENANCE
Replacement of filter, interval
FOR DOOR Locations:
Pollution degrees: Car park/road side: City roof top: Non central:
Low 1 year 2 years 3-4 years
Medium 1 year 2 years 3-4 years
High 6 months 1 year 2 years
FOR FAN Locations:
Pollution degrees: Car park/road side: City roof top: Non central:
Low 4 year 8 years 12 years
Medium 4 year 8 years 12 years
High 2 years 4 year 8 years
WARNING:
You are operating in a live system. Precaution must be taken when changing filter in front of the fan. Electric
shock
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 17
Replacement of Door filter
Step Comments OK
1. REMOVE FILTER Remove the filter grid by pushing it slightly up and then pulling it towards you
2. EXCHANGE FILTER Exchange the old filter with a new. Make sure that the smooth side of the filter faces the inside of the cabinet (the rough side of filter should not be visible).
3. FASTEN FRAME Fasten the frame to the door again and push it slightly down when the hinges are in place.
Replacement of Fan filter
Step Comments OK
1. DISCONNECT FAN Remove fuse for fan, located at the GMT fuse card
2. OPEN TOP OF CABINET
The fan filter is located behind the power equipment and should be removed from the top of the cabinet
Air filter, fine side facing inside of cabinet
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 18
Step Comments OK
3. REMOVE FILTER GRID
Remove the filter grid by pushing it slightly up and then pulling it out and up towards you
4. EXCHANGE FILTER
Exchange the old filter with a new. Make sure that the smooth side of the filter faces the inside of the cabinet
5. FASTEN GRID
Fasten the filter grid by pushing it slightly down when the hinges are in place
6. CONNECT FAN Replace the fuse for fan and verify that the system is operating normally
7. CLOSE TOP Close the top of the cabinet and lock it with the key found on the left side
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 19
3 SPECIFICATIONS Flatpack PRSB 9kW, 48VDC, Fan Cooled
Site Power Outdoor cabinet
SPECIFICATION
Max. number of rectifiers
6
AC INPUT Voltage 1 phase 230VAC (max 4 rectifiers)
3 phase 208VAC ( D ) 3 phase 230VAC ( D ) 3 phase 400VAC+N ( Y )
Frequency 45 to 66Hz
Maximum Current See Flatpack 1500 48VDC datasheet (241114.100.DS3)
Protection Soft start Surge protection (varistors) Disconnect above 312VAC
MONITORING Monitoring Unit Flatpack MCU Local operation Menu driven software via keypads
and LCD or PC (WinPower) Remote operation WinPower via modem or Web
NMS via SNMP-agent Alarm relays 8 relays are standard
Visual indications Green LED System ON
Red LED Active alarm(s) LCD system status
Digital inputs 5 (for monitoring of external equipment)
Current measurements
Battery current Rectifier current Load fuse alarm Battery fuse alarm LVD operated Low output voltage alarms (2 individual alarm levels) High output voltage alarms (2 individual alarm levels) Battery capacity Temperature alarm Symmetry alarm Door switch alarm
Alarms
Individual Mains detect alarm
DC OUTPUT Voltage 48VDC Current Up to 9KW 180A CONNECTIONS Battery connections Battery cable, M8 bolts Load MCB connections
Negative distribution, Negative load cable, 70mm2 cable clamps. Common positive bus bar, 70mm2 cable clamps.
Alarm connections Front access screw terminals DISTRIBUTION OPTIONS No. of DC Load breakers
Up to 4 x 3pole 150A
No. of Battery breakers
Up to 2 x 150A MCBs mount next to each battery shelf
No. of Aux. fuses 8 x 10A GMT type Programmable LVD Standard: 1 LVBD (max. 300A)
OTHER SPECIFICATIONS Isolation 3.0 KVAC input and output
1.5 KVAC input earth 1.0 KVDC output earth
Operating temp -10 to +45C (14 to +113F) Storage temp -40 to +85C (-40 to +185F) Dimensions 770 (778) x 820 x 1300mm (WxDxH)
(30.3 (30.6) x 32.3 x 70.9) Weight Approx. 143 kg excl. rectifiers and
batteries Max. 250kg load per battery shelf
APPLICABLE STANDARDS Electrical safety
EN 60950 UL 60950
EMC
ETSI EN 300 386 V.1.3.1 (telecommunication network) EN 61000-6-3 (emission, light industry) EN 61000-6-2 (immunity, industry)
Environment
ETSI EN 300 019-2 ETSI EN 300 132-2 RoHS Compliant
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 20
APPENDIX: SCHEMATICS, DRAWINGS, FIGURES etc.
A1 - General Arrangement drawing See also Figure 2, page 5, for more detailed information about DC distribution.
Figure 10: General Arrangement drawing, PRSB 9kW, 48VDC Outdoor Cabinet, Fan Cooled
Door switch
AC socket
Heater MCB (AC)
DC Distribution, Alarm, AC
Terminals, etc.
Rectifiers
Battery MCB FB2
Battery MCB FB1
Main Protective Earth (PE)
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 21
A2 - System Schematic PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled
Rev.Draw. No.PageFormatConsultant
Replace for Replaced byCopyright A/S Eltek. All rights reserved
Eltek
2011671Sym. Date/SignAlteration
1 of 1
ProjectionScaleApprovedDrawDesignDate
1
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- A4
Schematic PRSB 9 kW OD
13,02.2006 OLHUNO OLHUNO N/A
PENL1L2L3
*
Interface Board
CU-bar common +PE
L
N
+
-
PE
L
N
+
-
PE
L
N
+
-
F13 F14 F15 F16 F17 F18 F19 F20 F21 F22
204144 204144
**OPTIONSOVP kit
LTE Distribution
203929
16151413121110987654321
+
-
Load Alarm
F1
F2
F3*
F4*
F12
F11
F10
F9
F8
F7
F6
F5
GMT Load Fuse Board
CU-bar Battery -
Load Alarm
121110987654321
MCUMonitoring /
Controller Unit
SH1
SH2
- +
-
+
NOLVBD
Load
Batt.string 1 Batt.string 2*AC socket
AC MCB Heater
PENL
Battery Heater*
Fan
First p.shelf2xFlatpack 1500
Second p.shelf2xFlatpack 1500
Third p.shelf2xFlatpack 1500
A
B
106 8 12 13
Con41
Con3
Door Switch
REL1 COM1
CON 5
AC
Detection
Figure 11: Schematic drawing, PRSB 9kW, 48VDC system
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 22
Holes for mounting the cabinet to the ground without a plinth.
Holes for the plinth. Factory drilled.
Holes for the plinth. Factory drilled.
A3 - Drilling Template
Figure 12: Top view of the cabinets bottom plate. 700x700mm external dimensions
The cabinet overhangs by 35 mm outside the plinth in the rear, on the left hand and on the right hand side. The Fan box builds an extra 80mm in the front.
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 23
MCU Default Settings PRSB 9 kW, 48 VDC
CF1032.001 SITE INFO Default System Setup Customer Location Max. Current Rectifier 33 Rectifier Installed 0 Battery Type Marathon M12V 155FT SET LEVELS Setup High Battery Alarm 1 58 V Low Battery Alarm 1 45 V High Battery Alarm 2 59 V Low Battery Alarm 2 43 V Battery Voltage 54,5 V (at 25 C) Boost Voltage 56,4 V Alarm Delay 0 s High Temperature Alarm Level 1 25 High Temperature Alarm Level 2 (LVBD disconnects) 50 Disconnect Voltage LVD1 40 V Reconnect Voltage LVD1 47 V Disconnect Delay Time LVD1 0 Disconnect Voltage LVD2 NA Reconnect Voltage LVD2 NA Disconnect Delay Time LVD2 NA Disconnect Voltage LVD3 NA Reconnect Voltage LVD3 NA Disconnect Delay Time LVD3 NA
ALARM SETUP (which relay output is wanted on each alarm) Setup High Battery 1 No alarm relay Low Battery 1 No alarm relay High Battery 2 Relay 2 Low Battery 2 Relay 3 LVD1 No alarm relay LVD2 No alarm relay Battery Fuse Relay 4 Rectifier Relay 5 Critical Rectifier Relay 5 Mains No alarm relay Battery Test No alarm relay Battery Pre No alarm relay Battery Fault No alarm relay Common Relay 5 Load Fuse Relay 4 Symmetry1 No alarm relay Symmetry2 No alarm relay High Temperature 1 Relay 1 High Temperature 2 No alarm relay Conf. Input 1 / Heat management No alarm relay Conf. Input 2 Relay 6 Conf. Input 3 Relay 7 Conf. Input 4 Relay 8 Conf. Input 5 No alarm relay LVD3 NA SYSTEM CONFIGURATION Setup Nom. Voltage 48V Enable Function: ON/OFF OFF Battery Fuse ON Symmetry 1 (SW) OFF Symmetry 2 (HW) OFF
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Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 24
Auto Boost OFF Setup LVD1 Battery contactor Type LVD1 Normally Open Setup LVD2 No contactor Type LVD2 NA Setup LVD3 No contactor Type LVD3 NA
OUTPUT CONTROL Setup Temp. Comp. BATTERY CONFIGURATION Setup Battery Test Setup End Voltage* 1.85 V/cell Max test duration 300 min Test interval 270 days Test delay period 3 days Battery Type Battery Type User defined, type: Marathon M12V 155FT Number of battery modules (strings) 1 Battery cable resistance 0 Charge Current Limit Charge Current Limitaion Active Max. Charge Current 0.2C10 (18.4A) Battery Setup User Def. Battery Name Battery test end voltage 1.85 V/cell (44.4 V) Temp. Compensation (voltage at 20) 2.29 V/cell Slope of temperature comp. equation 5,5 (mV/cell)/deg Battery table (see next sheet for table) Marathon M12V 155FT CONFIGURABLE INPUTS Setup Conf.Inp. 1 Disable Conf.Inp. 2 Phase 1 Conf.Inp. 3 Phase 2 Conf.Inp. 4 Phase 3 Conf.Inp. 5 Door Open TEMPERATURE COMP. CHARGING Setup Voltage at 20 C 2.29 V/cell Slope 5,5 (mV/cell)/deg Max. Compensation Voltage 2.4 V/cell Min. Compensation Voltage 2.21 V/cell (53 V) MODEM Modem Callback NA Baud Rate NA RELAY SETTINGS(Jumper settings) Setup
Relay 1 NO Relay 2 NO Relay 3 NO
Relay 4 NO Relay 5 NO Relay 6 NO Relay 7 NO Relay 8 NO *Parameter not used when User Defined Battery setup is enabled
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Head Office:
Eltek Energy AS P.O. Box 2340 Strms N-3003 DRAMMEN Norway Phone: 47 32 20 32 00 Fax: 47 32 20 32 10 E-Mail: [email protected]
Internet: www.eltekenergy.com
Art. No. 351434.033 Issue 3, 2006-July
Published 2006-07-18