installation guide trilogy - nps€¦ · installation guide trilogy ~ doc. no. 2074751, issue 3,...

Doc. No. 2074751, Issue 3

Published 21-Jan-11

Installation Guide

Trilogy

Flatpack2 DC Power System

2 Installation Guide Trilogy ~ Doc. No. 2074751, Issue 3, January 2011

DISCLAIMER

Information in this document is believed to be accurate as of the date of publication and is subject to change without notice. This document and the information contained herein do not represent either a commitment or any guarantee on the part of Eltek Valere regarding the reliability, fitness, or compatibility of the products and procedures described.

While every reasonable effort is made to ensure the accuracy and completeness of this document, Eltek Valere assumes no responsibility or liability for any damages that may be directly or indirectly attributed to the use of the information contained within or to any errors or omissions.

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 expressed consent of Eltek Valere.

Copyright © 2011 Eltek Valere

1303 E Arapaho Rd Richardson, TX 75081

USA

Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Technical Support +1 (866) 240-6614

[email protected]

www.eltekvalere.com/us

Doc. No. 2074751, Issue 3, January 2011

Published 21 January 2011

Installation Guide Trilogy ~ Doc. No. 2074751, Issue 3, January 2011 3

Table of Contents Safety Practices and Compliance ...................................................... 5

FCC Compliance Statement ................................................................................................ 7

1. Overview ......................................................................................... 8

Rectifier Specifications......................................................................................................... 9

Solar Charger Specifications ............................................................................................... 9

Input Junction Box .............................................................................................................. 11

AC Mains Input ......................................................................................................................... 12

Solar DC Input .......................................................................................................................... 12

AC Mains/Solar DC Input ...................................................................................................... 12

Protected DC Output .......................................................................................................... 13

Bulk DC Battery Output ..................................................................................................... 15

Ground .................................................................................................................................... 16

Control and Monitoring ...................................................................................................... 17

LVD Options .......................................................................................................................... 18

References ............................................................................................................................ 18

2. Installation .................................................................................... 19

Recommended Tools .......................................................................................................... 19

Torque Settings ................................................................................................................... 19

Unpacking .............................................................................................................................. 20

Mechanical Mounting ......................................................................................................... 20

Rack Mounting...................................................................................................................... 20

Grounding .............................................................................................................................. 20

Input Connections ............................................................................................................... 21

AC Mains Input Only ............................................................................................................... 23

Solar DC Input Only ................................................................................................................ 25

AC Mains / Solar DC Input .................................................................................................... 27

Protected DC Output Connections ................................................................................ 27

Bulk DC Battery Connections .......................................................................................... 30

Circuit Breaker/Fuse Installation .................................................................................... 31

Plug-in Breakers ...................................................................................................................... 31

Plug-in Fuse Holders .............................................................................................................. 31

Device Installation and Extraction..................................................................................... 32

Alarm Connections .............................................................................................................. 32

Controller CAN Connections ............................................................................................ 33

Controller, Rectifier, and Charger Installation............................................................. 33


3. Turn-Up ......................................................................................... 35

Rectifier Installation ........................................................................................................... 35

Solar Charger Installation.................................................................................................. 35

Connecting Batteries ......................................................................................................... 36

Smartpack Access .............................................................................................................. 37

DC Breakers and Fuses ...................................................................................................... 37

4. Turn-Up Checklist ......................................................................... 38

5. Basic Troubleshooting .................................................................. 40

6. Revision List .................................................................................. 41

Sample Solar DC Schematic.............................................................. 42

Sample AC Mains / Solar DC Schematic ........................................... 43


Safety Practices and Compliance

For use in restricted access locations only

Only suitable for mounting on concrete or other non-combustible surface

The Trilogy DC power system accepts a nominal, single-phase AC voltage between 100 V and 250 V (±10%), 50 to 60 Hz. It is capable of delivering a maximum DC output of 600 A (depending on the number of rectifiers deployed) at an ambient operating temperature range of -40°C to +65oC. Systems are powered by Flatpack2 HE rectifiers and available for either 24V or 48V DC output.

WARNING: HAZARDOUS VOLTAGE AND ENERGY LEVELS CAN PRODUCE SERIOUS SHOCKS AND BURNS. Only authorized, qualified, and trained personnel should attempt to work on this equipment. Refer to datasheets for full product

specifications.

WARNING: For safety, the power supply is required to be reliably connected to PROTECTIVE GROUND. The equipment is to be connected to supply mains by qualified personnel in accordance with local and national codes (e.g., NEC, CEC,

etc). Do not disconnect and reconnect I/O power connectors during lightning storms. Equipment meets GR-1089 Surge requirements and is intended for deployments where an external Surge Protective Device (SPD) is utilized. The output of the power supply is not intended to be accessible due to energy hazards. Rack mounting must be performed in accordance with instructions provided by the manufacturer to avoid potential hazards.

WARNING: Changes or modifications to this unit not expressly approved by the party responsible for the compliance could void the user's authority to operate this equipment.

WARNING: Do not combine rectifiers and solar chargers in the same power

shelf!

CAUTION: Flatpack2 HE rectifiers and Flatpack2 HE Solar chargers must have dedicated shelves with dedicated AC and DC input, respectively. Rectifiers and solar chargers cannot be mixed in the same power shelf!

CAUTION: The Flatpack2 HE rectifiers and Flatpack2 HE Solar chargers used must be rated for the same output voltage (i.e., either 48 VDC or 24 VDC).

CAUTION: All rectifiers employ internal double pole/neutral fusing. Fuses are not field-replaceable.

Observe all local and national electrical, environmental, and workplace codes.

Each power shelf should be fed from a dedicated AC branch circuit of a terra neutral (TN) or isolated terra (IT) power system.

A readily accessible disconnect device shall be incorporated in the building installation wiring for all AC connections. Select wall breakers according to national and local electric codes.


If the plug end of an AC line cord is considered to be the primary disconnection means, reasonable access must be given to the plug and receptacle area. The receptacle must be fed with a breaker or fuse according to input current specifications in Table 1.

Use Underwriters Laboratories (UL)-listed, double-hole lugs for all DC connections to prevent lug rotation and inadvertent contact with other circuits. Terminal strip connections require only single-hole lugs.

Wire rated for 90°C is recommended for all DC connections. In practice, wires of a size larger than the minimum safe wire size are selected for loop voltage drop considerations.

Alarm contacts are rated for a maximum voltage of 60 V, SELV (Safety Extra Low Voltage) and a maximum continuous current of 1A. Connection and mounting torque requirements are listed in Table 4.

Heat dissipation greater than the objectives listed in GR-63-CORE may occur. Additional equipment room cooling may be required. To cope with high heat release, aisle spacing may be increased and high heat-dissipating equipment may be located adjacent to equipment generating less heat.

It is recommended practice to ensure that all circuit breakers (including those for DC distribution) are in the OFF position during both installation and removal.

Eltek Valere does not recommend shipping the power shelf with rectifiers installed. Rectifiers should be shipped in separate boxes provided by Eltek Valere.

WARNING: Protecting personnel against electrical shocks: The power system cabling must be done by qualified personnel in conformance with local and national electrical codes. Input voltages to rectifiers are at a dangerous level. Ensure that

circuit breakers are locked in the OFF position at the AC service panel before attempting to work on the power system. Dangerous voltages may still be present at the terminals even if the rectifiers are OFF. Use a voltmeter to verify the presence of such voltages. Do not switch circuit breakers to ON until the entire system has been assembled and you have been instructed to do so according to the appropriate procedure. Improper wiring can cause bodily harm and equipment damage. Turn off all power sources before servicing units.

WARNUNG: Schuetzen von Personal gegen elektrische Schocks. Die Spannungsversorgungs - Leitungen darf nur durch qualifiziertes Personal in Anpassung mit Oertlichen und nationalen elektrischen Codes ausgefuehrt werden.

Unsachgemaesse Verdrahtung kann koerperliche Verletzung und Schaeden verursachen. Eingangsspannungen von der Netzspannungs - Versorgung Ihrer Hausanlage koennen unter Spannung stehen beim Anschluss derLeitungen. Vesorgungsspannungen koennen bei unsachgemaessen Gebrauch gefeahrliche Schaeden verursachen. Sorgen Sie dafür, dass die Cirquite Breaker in der aus position sind. Benutzen Sie ein Spannungsmesser um sicher zu sein das keine Netzspannung mehr vorhanden ist. Vergwissern Sie sich das alle Schalter an Ihrem Gereat und in der Vesorgung beim Anschluss abgeschaltet sind. Unsachgemaesse Verdrahtung kann koerperliche Verletzung und an der Ausstattung Schaeden verursachen. Vor Wartungsarbeiten am Gerät sind alle Netzkabel vom Stromnetz zu trennen, um die Gefahr eines elektrischen Schlages oder andere mögliche Gefahren zu reduzieren.


FCC Compliance Statement

This device complies with Part 15 of FCC Rules. Operation is subject to the following two conditions:

1. This device may not cause harmful interference, and

2. This device must accept any interference received, including interference that may cause undesired operation.


1. Overview The Trilogy power system consists of 19” rectifier shelves, a Smartpack controller, and a distribution section sized for either 19” or 23” racks. Maximum overall system depth is 15 inches (381 mm). It can be mounted in a standard 19” or 23” telecommunications equipment rack. Available systems are 48 VDC at total DC outputs of 300A, 400A, and 600A; and 24 VDC at a total DC output of 600A.

Figure 1 - Trilogy -48V, 600A System

Figure 2 - Trilogy -48V, 300A System (door and rectifiers removed)

Distribution Section

Smartpack Controller

Flatpack2 HE Rectifiers

AC Input Box

Smartpack Controller

Power Shelf

DC Output (for breakers)

Alarm/control connections


Rectifier Specifications

The Flatpack2 HE rectifiers are high-efficiency modules that typically perform at a 96% conversion rate. Specifications are listed in Table 1.

Table 1 - Rectifier Operation

Flatpack2

Rectifier Model

Input Voltage

(Vac)

Input Current

(A-rms)

Operational

Output Voltage

Range (Vdc)

Operational

Output Current

Range (Adc)

120 11.59 43.5-57.6 0-23.6208 10.46 43.5-57.6 0-41.7240 8.98 43.5-57.6 0-41.7

120 10.8 21.7-28.8 0-44.2208 9.7 21.7-28.8 0-75240 8.3 21.7-28.8 0-75

48V/2000W HE(241115.105)

24V/1800W HE(241115.205)

NOTICE: Maximum current draw is 11.5 A(rms) at 176 Vac

NOTICE: Maximum current draw is 11.88 A(rms) at 185 Vac

The Trilogy system can also be powered by standard Flatpack2 rectifier models, but it will not yield the same energy efficiency. Flatpack2 rectifiers have an operating input voltage range of 85 to 300 VAC (rated for 100 – 250 VAC), with a frequency range between 45 and 66 Hz. See the User’s Guide—Flatpack2 Rectifier Modules (350002.013) for further details.

NOTICE: Flatpack2 rectifier modules are assigned a system ID based on order of installation. Therefore, it is recommended to install rectifiers AFTER system AC turn-up, in the order desired.

Solar Charger Specifications

WARNING: Do not combine rectifiers and solar chargers in the same power shelf!



The Flatpack2 power system supports Flatpack2 HE Solar chargers for integration of solar power without requiring the implementation of a separate DC power system. Rather, the Flatpack2 power system accommodates both Flatpack2 HE rectifiers and Flatpack2 HE Solar chargers within the same system. See Figure 3 below for an overview of the Flatpack2 Power System solar integration concept.


Figure 3 - Solar Integration Concept

NOTICE: Each Flatpack2 HE Solar charger must be fed by a dedicated solar array in order for the MPPT function to calculate peak power properly.

Although the Flatpack2 HE rectifier and Flatpack2 HE Solar charger use different input power sources, both units supply 48VDC to the common DC bus of the Flatpack2 power system. This common bus then provides power to load and/or batteries.

To implement solar power input in the Flatpack2 DC power system, the following are required in addition to the typical AC power configuration:

o A dedicated photovoltaic array for each solar charger

o One feed from the array for a single Flatpack2 HE Solar charger

o Flatpack2 HE Solar chargers (one per PV array)

Table 2 - Solar Charger Specifications

~

SOLAR ARRAY

AC MAINSFLATPACK2 HE

RECTIFIER

FLATPACK2 HESOLAR CHARGER

LOAD

BATTERIES

CO

MM

ON

DC

BU

S

FLATPACK2POWER SYSTEM

Flatpack2 HE

Solar Charger

Input Voltage

(Vdc)

Input Current

(A-rms)

Operational

Output Voltage

Range (Vdc)

Operational

Output Current

Range (Adc)

Minimum: 85 10.0 43.5 - 57.6 0 - 15.6Nominal: 170 - 230 9.5 43.5 - 57.6 0 - 31.3

Minimum: 85 10.0 21.7 - 28.8 0 - 31.3Nominal: 170 - 230 9.5 21.7 - 28.8 0 - 62.5

48V/1500W HE(241115.650)

NOTICE: Startup voltage is 150 Vdc

24V/1500W HE

(241115.660)NOTICE: Startup voltage is 150 Vdc


NOTICE: Although the Flatpack2 HE Solar charger can operate on a minimum input voltage of 85 Vdc, initial startup does not occur until 150 Vdc is reached.

Input Junction Box

The junction box is located in the center-rear of the distribution section and is a top-access panel. The terminal blocks are designed for individual-feed input, but jumpers are provided for converting the box to dual-feed input. There are four knockouts on the box for 3/4” conduit.

Terminal blocks are labeled numerically and given a module slot assignment. The module slot is a 4-character code : “S” means “shelf” and “R” means “rectifier slot”. Because the leftmost slot of the top shelf (“S1R1”) houses the Smartpack controller, the terminal blocks begin with input lines 1 and 2 of the second slot in the top shelf (“S1R2”). Thereafter, the input lines are arranged in pairs to facilitate optional dual-feed input.

The terminal blocks accept a maximum wire size of #10 AWG. Recommended torque is 7 – 8 in-lbs.

Figure 4 - Terminal Block (TB) Assignments

There are four ¼”-20 studs provided for ground connections. Ground leads must be longer than the power leads. Always make ground connections first!

Figure 5 - Ground Connections

Ground Studs (¼”-20)


AC Mains Input

For AC mains input, the terminal designations are “L1” for “Line 1” and “L2” for “Line 2”. Always make ground connections first. See Table 5 on page 22 for the full list of terminal designations.

Figure 6 – AC Input Box (system with 7 rectifier slots)

Solar DC Input

For solar input, the junction box accepts DC input only. The terminal designations are “–” for negative and “+” for positive. See Table 5 on page 22 for the full list of terminal designations.

NOTICE: A DC-only system requires that an external ground wire be connected to one of the ¼”-20 ground studs in the junction box.

AC Mains/Solar DC Input

The junction box can also be used for both AC and DC input. If both types of input are to be used, then the two sides are divided and clearly marked as “AC Input – Rectifier” and “DC Input – Charger”. See Table 5 on page 22 for the full list of terminal designations.

The AC input always takes up the first terminals (which correspond to the top power shelves). The DC input begins thereafter for the shelves reserved for solar chargers.

Front

Rear

AC Input Box


Figure 7 - AC Mains / Solar DC Input Box (System with 2 Rectifier Shelves and 2 Solar Shelves)

NOTICE: Trilogy systems with AC Mains/Solar DC have a diagram on the lower left side of the front distribution panel that illustrates the power shelf designations. Modules with the yellow fan grilles represent solar chargers; the rest are rectifiers.

Figure 8 - Power Shelf Designation Label

Protected DC Output

The front-facing side of the distribution section features two buses for protected DC connections. There are either 20 (19” distribution) or 24 (23” distribution) moveable breaker holders provided for UL-approved, bullet-nose circuit breakers. The breaker holders can be removed and reassigned to either DC bus. Load and return landings accept up to #1 AWG cable with two-hole 1/4” lugs on 5/8” centers.

Front

Rear

AC/DC Divider

Rectifier Shelves

Solar Charger Shelves

AC Input Solar DC Input


Figure 9 - Distribution with Adjustable Breaker Holders

Figure 10 – Breaker Holders Assigned to Different Buses

The lower bus is labeled “CRITICAL” and is intended for load connections. The upper bus is labeled “BATTERY” and is intended for battery connections. If a low-voltage disconnect (LVD) is desired, one can be ordered for either bus (not both).


Figure 11 - Protected Distribution Connections

Figure 12 - Breaker Holder

Bulk DC Battery Output

The rear of the distribution section contains bulk battery connections. There are eight landings per polarity, as well as an extra set of studs on the return bus for a C.O. ground connection. Each landing consists of two, 3/8” studs with 1” spacing. Maximum wire gauge depends on the size of the distribution section.

Cable Landing

Top Bullet Receptacle

Bottom Bullet Receptacle

Alarm Contact

Bus Screw

Hooks for Battery Bus

Hooks for Load Bus

Return Landings

Breaker Holders

Bus Labels

Breaker Extraction Tool

Insulator


Figure 13 - Battery Connections

Ground

It is recommended that every system rack be grounded. Frame ground connection points are located along the top of each rack provided by Eltek Valere. Refer to the NEC, local codes, and customer specifications to determine the appropriate wire size. Use of paint-penetrating washers, abrasive compounds, or other means to achieve a reliable frame ground is recommended.

Always make safety or chassis ground connections before connecting any power. AC ground leads should be longer in length than the power leads.

NOTICE: A DC-only system requires that a ground wire from the photovoltaic combiner be connected to one of the ¼”-20 ground studs in the junction box.

Figure 14 - Ground Connections

The bulk DC return bus has an extra landing for a central office (CO) ground connection. A dedicated CO Ground conductor connection is recommended. This conductor should be of the same or larger gauge than the largest system conductor so that it can discharge total system current in a fault condition. A THHN-style cable is recommended. Install this cable between the DC system point and the critical site ground bar.

Return Hot

CO Ground Connection

Ground Studs (¼”-20)


Control and Monitoring

An Ethernet port for LAN connection is provided inside the front of the distribution section, on the left wall (below the alarm board). Use the Powersuite software provided with the system to access the Smartpack controller through a LAN connection.

Documentation and the Powersuite software for the Smartpack controller are located on the accompanying CD.

Next to the Ethernet port is a CAN connection for Eltek Valere CAN nodes, which are devices that extend controller monitoring. These devices include a battery monitor unit, battery symmetry, I/O monitor, load monitor, and CAN power device (each sold separately). Please refer to the documentation provided with each device for installation instructions. If the CAN port is not used, the CAN termination plug provided must remain in place.

Figure 15 – Alarm Board, LAN and CAN Ports

Alarm connections are made to a front-access alarm board that is mounted on the left side of the distribution wall. Alarm wires must be between #26 AWG and #18 AWG; strip length is 3/8”. There are six input alarms and six output relays.

Alarm Board

LAN Port

CAN Port

Cable Access


Table 3 - Alarm Relay Assignments

Relay Description

1 Common Alarm

2 AC Main Alarm

3 Distribution Alarm

4 High Voltage Alarm

5 Low Voltage Alarm

6 Rectifier Fail Alarm

Figure 16 - Terminal Assignments

LVD Options

Trilogy systems can be ordered with a low-voltage disconnect (LVD) contactor—either load (LVLD) or battery (LVBD). Contactor settings are configured through the Smartpack controller. If an LVLD is ordered, it is connected in line with the lower (“critical”) breaker bus. If an LVBD is ordered, it is connected in line with the upper (“battery”) breaker bus.

References

This manual provides a comprehensive overview of and installation guidelines for Trilogy power systems with DC output totals of 300A to 600A. Additional information regarding system components is found in the following documents:

o 350002.013: User’s Guide—Flatpack2 Rectifiers

o 350003.013: User’s Guide—Smartpack Monitoring & Control Unit


2. Installation NOTICE: The system is to be mounted over a non-combustible surface only and installed in Restricted Access Locations (RAL). Access must be limited by use of tool, e.g. lock and key.

NOTICE: Use of fully insulated tools is required when working with any powered AC or DC circuits.

Recommended Tools

The following tools are recommended for installation:

o Standard wrench and/or socket set (1/4” to 1”)

o Torque wrench, 10-40 Ft-lb range.

o Torque screwdriver, 5-10 in-lb range.

o Small flat blade screwdriver (3/32” wide)

o Standard blade screwdriver and Phillips tip screwdriver

o Wire cutters / strippers

o Fork-lift truck or similar heavy equipment handling transport

o Hoist with lifting straps

o Electric drill and appropriate bits (a hammer drill may be required for concrete flooring)

o Multimeter

Torque Settings

Table 4 shows recommended torque settings for mechanical and electrical connections according to screw or nut size. Not all screw sizes listed are necessarily present.

Table 4 - Recommended Torque Settings

Screw or Nut Size Torque

(in-lb)

Torque

(ft-lb)

#10-32 21-31.2 --

#12-24 36-42 --

1/4"-20 -- 4.25-11

5/16"-18 -- 8.33-21

3/8"-16 -- 15-38

Fuse Terminal 7.6-9.0


Unpacking

A Trilogy unit is typically pre-installed in a cabinet or rack, wrapped with a shroud of high-strength plastic, and bolted to a wooden pallet with four anchors. Rectifier modules and expansion options are packed in separate cartons. Exercise care when unpacking and setting the equipment in place.

Mechanical Mounting

Eltek Valere recommends mounting the system on a floor made of a non-combustible material and of sufficient strength to withstand an earthquake. There should be adequate clearance above the system for the AC feeds, as well as adequate free space in front of and behind the rack for air flow.

Concrete expansion anchors should meet the following requirements:

o A maximum embedment depth of 90 mm (3.5”)

o A maximum bolt diameter of 13 mm (0.5”)

o Use steel construction

o Be suitable for earthquake zones

Use the following generic steps for rack installation:

1. Inspect the floor for compliance.

2. Drill holes 5/8” in diameter.

3. Place anchors into holes.

4. Place the rack over the anchors.

Rack Mounting

CAUTION: Never install a power system without capable assistance. Use capable assistance when lifting and mounting the system.

If the Trilogy system is ordered without a rack or enclosure, use the following instructions for rack installation:

1. Use proper lifting equipment to position the Trilogy system so that the holes in the support bracket are aligned with the correct mounting holes in the rack.

2. Use #12-24 screws to mount the system and tightened each to a torque of 36 – 42 in-lbs.

Grounding

For electrical safety, it is recommended to connect a safety ground to one of the available locations in the junction box. For systems powered by solar


energy only, there should be a ground wire run from the photovoltaic (PV) combiner box to the Trilogy system.

Figure 17 - Grounding for Solar Input Only

A central office (CO) ground connection is also recommended. Use the following steps to connect CO ground:

1. Connect the lugged wire designated for a CO ground to the ground position on the battery return bus bar (see “Bulk DC Battery Output” on page 15). Connections are made on double 3/8” holes with 1” centers.

2. Secure the connection with the supplied hardware (screw, washer, and nut).

NOTICE: The CO ground wire must be the same size or larger than the largest wire used in the system.

Input Connections

Input connections are made to the junction box, which is located in the center-rear of the distribution section and is a top-access panel. There are four knockouts on the box for 3/4” conduit. The terminal blocks accept a maximum wire size of #10 AWG. Recommended torque is 7 – 8 in-lbs.

Table 5 lists the designations for the maximum number of slots that can be present in the largest size of Trilogy system. The designations are the same for smaller systems (i.e., those with fewer shelves). See Figure 18 for the division of terminal blocks by shelf. If necessary, refer to Figure 4 on page 11 to see which module slots are powered by which input terminals.

NOTICE: For ease of installation, it is recommended to work on the junction box from the front of the system, and prior to making DC output connections. In this orientation, connections are terminated to the near end of the block, with the far end already wired to the shelves.

PHOTOVOLTAIC (PV)

COMBINER BOX

GROUND

ELECTRODEGROUND BAR

TRILOGY SYSTEM


Table 5 - Terminal Block Label Detail

Figure 18 groups the terminals by shelf. Shelf 1 is the topmost. The presence of the rest of the shelves depends on the size of the system.

Figure 18 - Division of Terminal Blocks by Shelf

Terminal

Block

Position

Label

AC

Designation

DC

Designation

30 S4R4 L2 +

29 S4R3 L2 +

28 S4R4 L1 −

27 S4R3 L1 −

26 S4R2 L2 +

25 S4R1 L2 +

24 S4R2 L1 −

23 S4R1 L1 −

22 S3R4 L2 +

21 S3R3 L2 +

20 S3R4 L1 −

19 S3R3 L1 −

18 S3R2 L2 +

17 S3R1 L2 +

16 S3R2 L1 −

15 S3R1 L1 −

14 S2R4 L2 +

13 S2R3 L2 +

12 S2R4 L1 −

11 S2R3 L1 −

10 S2R2 L2 +

9 S2R1 L2 +

8 S2R2 L1 −

7 S2R1 L1 −

6 S1R4 L2 +

5 S1R3 L2 +

4 S1R4 L1 −

3 S1R3 L1 −

2 S1R2 L2 +

1 S1R2 L1 −

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

SHELF 1 SHELF 2 SHELF 3 SHELF 4


AC Mains Input Only

WARNING: Each AC feed must be grounded. For safety, make ground leads longer than the lines, and always terminate the

ground wire before connecting the lines to the terminal block.

CAUTION: Ensure that all AC feeds are not energized (i.e., breakers are in the OFF position, or fuses are removed). Do not apply AC power until all electrical connections are terminated and verified.

AC terminal blocks accept a maximum wire size of #10 AWG. The recommended torque value is 7 – 8 in-lbs. Ground terminals are 1/4” studs and accept one-hole lugs.

To terminate AC feeds in an individual-feed configuration:

1. Use a small Philips screwdriver to remove the four screws holding the clear Lexan cover in place. Remove the cover.

2. Attach one-hole lugs for 1/4” studs to the ground wire of each AC feed and connect them to any of the four 1/4” ground studs in the junction box (on the side of the terminal block where the AC lines will be terminated).

3. Cut the AC lines of each feed shorter than their respective ground wires.

4. Beginning with the feed for S1R2, connect line 1 of the first AC feed to the terminal block labeled “1”, and connect line 2/neutral to the block labeled “2”. Tighten each connection to a torque of 7 – 8 in-lbs.

5. Next, connect line 1 of the AC feed for S1R3 to the terminal block labeled “3”; then, connect line 2/neutral for S1R3 to the terminal block labeled “5”.

6. Next, connect line 1 for S1R4 to terminal block “4”, and line 2 to terminal block “6”.

7. Repeat in this manner for each remaining AC feed.

To convert to dual-feed input and install AC feeds:


2. Attach one-hole lugs for 1/4” studs to the ground wire of each AC feed and connect them to any of the four 1/4” ground studs in the junction box (on the side of the terminal block where the AC lines will be terminated).


3. Cut the AC lines of each feed shorter than their respective ground wires.

4. Position S1R2 must be configured for single-feed input. Beginning with the feed for S1R2, connect line 1 of the first AC feed to the terminal block labeled “1”, and connect line 2/neutral to the block labeled “2”. Tighten each connection to a torque of 7 – 8 in-lbs.

NOTICE: Only terminals 1 and 2 require single-feed input. Subsequent terminals, including those on following shelves, are to be configured for dual-feed input.

5. Next, locate terminals S1R3 L1 and S1R4 L1 (numbers “3” and “4”, respectively). Connect the terminals together by installing one jumper (Figure 19) in the input side of each terminal block.

6. Connect the first AC line of the feed to S1R3 L1 (terminal “3”).

7. Then, connect the terminals for S1R3 L2 and S1R4 L2 (numbers “5” and “6”, respectively) together by installing one jumper in the input side of each terminal block.

8. Connect the second AC line of the feed to S1R3 L2 (terminal “5”). See Figure 20 and Figure 21 for a depiction of the results.

9. Repeat steps 1 to 8 for each remaining AC feed.

Figure 19 - AC Terminal Jumper

Figure 20 - Dual-feed Configuration with Jumpers (Second Feed)

Line 1 Jumper, Terminals 3 and 4

Line 2 Jumper, Terminals 5 and 6

Line 1 connected to terminal 3

Line 2 connected to terminal 5

Ground


Figure 21 - Proper Dual-Feed Configuration of Terminals 1 – 6

Solar DC Input Only

WARNING: Always check polarity symbols for DC connections! Improper connections can cause permanent damage to electrical

equipment.

WARNING: Do not mix AC and DC input! Improper connections can cause permanent damage to electrical equipment.

WARNING: Each DC feed must be grounded. For safety, make ground leads longer than the lines, and always terminate the

ground wire before connecting the lines to the terminal block.

CAUTION: Ensure that all DC feeds coming from the PV arrays are not energized (i.e., breakers are in the OFF position, or fuses are removed). Do not apply power until all electrical connections are terminated and verified.

NOTICE: Each Flatpack2 HE Solar charger requires an input voltage of at least 150 VDC to start up. It is recommended that each charger be powered by a dedicated photovoltaic array.

The method for DC input is essentially identical to AC input. However, take careful note of polarity markings.

To terminate solar DC feeds:


AC Feed 1 (single), Terminals 1 and 2

AC Feed 2 (dual), Terminals 3/4 and 5/6


2. Attach a one-hole lug for a 1/4” stud to a ground wire from the PV combiner box. Connect it to any of the four 1/4” ground studs in the junction box (on the side of the terminal block where the power lines will be terminated). This is necessary to bond the system shelves and chassis.

3. Beginning with the feed for S1R2, connect the negative (–) line of the first feed to the terminal block labeled “1”, and connect the positive (+) line to the block labeled “2”. Tighten each connection to a torque of 7 – 8 in-lbs.

4. Next, connect the negative (–) line of the feed for S1R3 to the terminal block labeled “3”; then, connect the positive (+) line for S1R3 to the terminal block labeled “5”.

5. Next, connect the negative (–) line for S1R4 to terminal block “4”, and the positive (+) line to terminal block “6”.

6. Repeat in this manner for each remaining solar DC feed.

To convert to dual-feed input and install solar DC feeds:


2. Attach a one-hole lug for a 1/4” stud to a ground wire from the PV combiner box. Connect it to any of the four 1/4” ground studs in the junction box (on the side of the terminal block where the power lines will be terminated). This is necessary to bond the system shelves and chassis.

3. Position S1R2 must be configured for single-feed input. Beginning with the feed for S1R2, connect the negative (–) line of the first feed to the terminal block labeled “1”, and connect the positive (+) line to the block labeled “2”. Tighten each connection to a torque of 7 – 8 in-lbs.

NOTICE: Only terminals 1 and 2 require single-feed input. Subsequent terminals, including those on following shelves, are to be configured for dual-feed input.

4. Next, locate terminals S1R3 L1 and S1R4 L1 (numbers “3” and “4”, respectively). Connect the terminals together by installing one jumper (Figure 19) in the input side of each terminal block.

5. Connect the negative line of the feed to S1R3 L1 (terminal “3”).

6. Then, connect the terminals for S1R3 L2 and S1R4 L2 (numbers “5” and “6”, respectively) together by installing one jumper in the input side of each terminal block.


7. Connect the positive line of the feed to S1R3 L2 (terminal “5”). See Figure 20 and Figure 21 for a depiction of the results (in an AC box, which is similar).

8. Repeat steps 1 to 8 for each remaining solar DC feed.

AC Mains / Solar DC Input

If the Trilogy system has a combination of AC and DC input (for rectifiers and solar chargers, respectively), then take care to connect AC to the first sets of terminals blocks, which are designated and marked for AC input. The remaining blocks are marked for DC input. An insulated divider separates the AC and DC sides.

For AC connections, follow the instructions in the section “AC Mains Input Only” beginning on page 23. For DC connections, follow the instructions in the section “Solar DC Input Only” beginning on page 25.

NOTICE: In a system with AC and DC input, the AC ground connections serve as the safety ground; disregard the ground connection instructions in the DC instructions.

Protected DC Output Connections

WARNING: Shock hazard! Use insulated tools, especially when working on live systems.

CAUTION: Significant extraction force is required to remove distribution devices due to the contact pressure required for proper connections. Do not use any type of clamps, pliers, or similar tools as the housing can be cracked by excessive force. Damaged devices represent an operational hazard and should never be used. Use the breaker extraction tool provided inside the distribution door.

By default, breaker holders are connected to the bottom bus (labeled “Critical”). Each can be individually removed and assigned to the top bus (labeled “Battery”). To change the bus assignment of a breaker holder:

1. Loosen the bottom bullet receptacle with an insulated 7/16” or 11mm nut driver.


2. Select the appropriate bus for the holder. Bus labels are on the right wall of the distribution section.

3. Hook the device holder into the position that lines up with the bus selected.

4. Lower the holder into position against the bus. The bus screw should align with a hole in the bus.

5. Screw the receptacle into the bus using an insulated 7/16” or 11 mm nut driver. Torque between 20 – 25 in-lbs.


To make cable connections:

1. Make the return connection first to the position on the return bus (directly above the breaker holders) corresponding to the desired breaker position. Use a maximum #1 AWG cable with two-hole lugs having 1/4” diameter holes on 5/8” centers; 1/4”-20 fastening hardware is provided. Do not connect batteries until system turn-up.

2. Torque connections to 51-58 in-lbs.

Figure 22 - Return Connection

3. Make connection to the corresponding breaker position in the same manner as the return position.

Return Connection


Figure 23 - Hot (Breaker) and Return Connections

4. Make a note for each position on the label provided on the distribution door.

NOTICE: The distribution device holders must be installed in the desired bus before plugging over-current protection devices into the holders.

NOTICE: The distribution alarm circuit requires the use of breakers provided by Eltek Valere.

Bulk DC Battery Connections

DANGER: Improper battery connections can cause permanent

damage to electrical equipment, serious personal injury, and/or

death. Always check polarity before making battery connections.


CAUTION: Do not connect batteries until system turn-up. It is strongly recommended that inline circuit breakers or fuses be used with bulk/battery connections.

Batteries should be connected after making AC connections and activating rectifiers. The system must be powered to check polarity on the battery bus. Then, power off the system to connect batteries.


1. After successful system turn-up, remove the screws holding the rear cover in place.

2. Make connections using two-hole, 3/8”-16 lugs on 1” centers. Fastening hardware is provided.

Hot/Breaker Connection


3. Torque connections from 15 to 23 ft.-lbs.

4. Replace the cover.

Circuit Breaker/Fuse Installation

CAUTION: Significant extraction force is required to remove distribution devices due to the contact pressure required for highly-reliable, low-temperature rise connections. DO NOT use pliers or tools other than the breaker extraction tool provided.

CAUTION: Circuit breakers (both load and battery) should be in the “OFF” position when installed in the system.

Plug-in Breakers

Auxiliary contact circuit breakers are the standard over-current protection devices used in the distribution section. Breakers are connected to system alarming through the holder so that an open breaker (whether tripped or manually placed in the OFF position) triggers a “Load Distribution Alarm” in the Smartpack controller. Breakers should be removed from any unused positions to prevent nuisance alarms. Single-pole circuit breakers rated up to 100A can be installed. Straps are available to make use of two-pole breakers rated up to 175A and three-pole breakers rated up to 250A.

Plug-in Fuse Holders

Plug-in fuse modules may also be installed. The same considerations regarding insertion and removal of breakers should be observed.

A plug-in fuse assembly consists of three main parts: A fuse, an alarm fuse indicator, and a plug-in module. If the main fuse element opens, the alarming fuse also opens, giving a visible indication of a fault condition; a signal is then sent via the Smartpack alarm board that activates the remote system monitor. The alarming fuse must be replaced whenever a new main fuse is required. A fuse holder may be removed and inserted into the plug-in module at any time; it is not necessary to remove the plug-in module to replace the fuse.


Device Installation and Extraction

To install plug-in breakers or fuse-holders in device holder:

1. Remove fuses and turn breaker actuators OFF until system turn-up.

2. Orient the device correctly to the device holder (line is the bottom receptacle, load is the top); securely insert device into the receptacles.

A distribution device extraction tool is installed on the distribution door. It is shaped like a handle and has two Phillips-head screws. This item is provided for convenience and should not be necessary for all extractions.

To remove plug-in breakers or fuse-holders:

1. Align the extraction tool to the device to be removed.

2. Use a Phillips screwdriver to secure the device.

3. Firmly pull the device out from the holder. Avoid using excessive force or motion to extract an over-current protection device.

Alarm Connections

To install an alarm wire to the board:

1. Strip the alarm wire end 3/8”.

2. Press the white terminal clamp above the desired wire location.

3. Insert the alarm wire, and release the terminal clamp.

Alarm terminals are designed to accept a wire range of #26 AWG solid or stranded to #18 AWG. The Form-C contacts provided in the system have a rating of 1A at 60 VDC. Please refer to the User’s Guide—Smartpack Monitoring & Ctrl Unit for further details of alarm relay designations and assignment procedures.


Controller CAN Connections

Connections for Eltek Valere CAN monitoring devices are made to the CAN port inside the distribution panel (left wall, below the Ethernet port). This provides a direct link to the Smartpack controller.

To install a CAN device:

1. Remove the CAN termination plug from the port.

2. Install one end of the communication cable into the port.

3. Install the other end of the cable into one of the CAN ports on the device.

4. Install the CAN termination plug in the unused CAN port on the device.

5. For multiple CAN devices, simply daisy-chain them together using the two ports provided on each device. The last device in the chain MUST have the CAN termination plug installed in the unused port.

For installation and operation details for each CAN device, consult the documentation provided with it.

Controller, Rectifier, and Charger Installation

NOTICE: Flatpack2 rectifier and solar charger modules are assigned a system ID based on order of installation. Therefore, it is recommended to install rectifiers AFTER system turn-up, in the order desired.

Both the Smartpack controller and Flatpack2 family of power modules feature a locking mechanism for security in the shelf. The controller is already installed and secured in the leftmost slot of the top shelf.

CAUTION: Never carry Smartpack or Flatpack2 modules by the handles, even if they are warm. The handles must be fully extended before installing or removing Smartpack and Flatpack2 modules to prevent damage to either the shelf or module.

CAUTION: Flatpack2 power modules employ double-pole/neutral fusing.

To install the Smartpack controller and Flatpack2 modules:

1. Release the handles by inserting a small flat-blade screwdriver into the release slots and pressing the tip upward; extend each handle.

2. Slide the module firmly into the shelf.

3. Latch the handles to lock the rectifier in place.

4. Allow a 2 second delay before inserting the next module.


To remove the Smartpack controller and Flatpack2 modules:

1. Release the handles by inserting a small flat-blade screwdriver into the release slots and pressing up.

2. Use the handles to pull the module out just far enough to where the body can be gripped.

3. Slide the module out the rest of the way. Do not carry it by the handles. Flatpack2 modules weigh just over 4 lbs (1.9 kg) each.

NOTICE: If the Smartpack controller must be removed for any reason, be aware that there are cables plugged into the rear of the device. Unlock the controller using the instructions below and carefully extract the module until the cables are accessible.

Handle Release


3. Turn-Up Ensure that all AC and DC cable connections are properly sized and secure. Then, activate all AC input breakers.

WARNING: Do not combine rectifiers and solar chargers in the same power shelf!



Rectifier Installation

CAUTION: Never carry Smartpack or Flatpack2 modules by the handles, even if they are warm. The handles must be fully extended before installing or removing Smartpack and Flatpack2 modules to prevent damage to either the shelf or module.


Once AC power is activated, install each module as follows:

1. Release the latches by inserting a small flat-blade screwdriver into the release slots and pressing the tip upward; extend each handle.

2. Beginning with the first rectifier position (as determined by site policy), slide the first rectifier firmly into the shelf.

3. Close the latches to lock the rectifier in place.


5. Continue installing rectifiers in the order desired.

6. Repeat steps 1 to 5 until all rectifiers to be used are installed.

Once the first rectifier is properly installed and powered, the controller starts up.

NOTICE: Any DC circuit breakers left in the off position may trigger a distribution alarm after the first rectifier is installed. If the load device can be powered at this point, simply switch the breaker ON to clear the alarm.

Solar Charger Installation

CAUTION: Never carry Smartpack or Flatpack2 modules by the handles, even if they are warm. The handles must be fully extended before installing or


removing Smartpack and Flatpack2 modules to prevent damage to either the shelf or module.


Once solar power is activated, install each module as follows:

1. Release the latches by inserting a small flat-blade screwdriver into the release slots and pressing the tip upward; extend each handle.

2. Beginning with the first charger position (as determined by site policy), slide the first charger firmly into the shelf.

3. Close the latches to lock the rectifier in place.


5. Continue installing chargers in the order desired.

6. Repeat steps 1 to 5 until all chargers to be used are installed.

If this is a solar charger-only system, then the controller starts up once the first charger is properly installed and powered.

NOTICE: Any DC output circuit breakers left in the off position may trigger a distribution alarm after the first rectifier is installed. If the load device can be powered at this point, simply switch the breaker ON to clear the alarm.

Connecting Batteries

DANGER: Improper battery connections can cause permanent

damage to electrical equipment, serious personal injury, and/or

death. Always check polarity before making battery connections.


CAUTION: Do not connect batteries until system turn-up. It is strongly recommended that inline circuit breakers or fuses be used with bulk/battery connections.

Batteries should be connected after making AC connections and activating rectifiers. The system must be powered to check polarity on the battery bus. Then, power off the system to connect batteries.


1. After successful system turn-up, remove the screws holding the rear cover in place.

2. Make connections using two-hole, 3/8”-16 lugs on 1” centers. Fastening hardware is provided.

3. Torque connections from 15 to 23 ft.-lbs.


4. Replace the rear cover.

Smartpack Access

The Smartpack controller can be accessed through the front keypad, USB port, and LAN port. Consult document #350003.013, entitled “User’s Guide—Smartpack Monitoring & Control Unit”, for controller access and operation.

Documentation and the Powersuite software for the Smartpack controller are located on the accompanying CD.

DC Breakers and Fuses

Once the system and the controller power up properly, the DC load breakers can be activated and fuses installed.


4. Turn-Up Checklist Quick Start Turn-up Checklist

Pre-start Check (Power is OFF)

��

Installation site prepared o Mounting location is well-ventilated and provides adequate room for airflow o Floor is level and capable of supporting the system (Individual system weights vary;

see product flyer for more information) o Suitable insulated tools available

�� AC input supply prepared

o AC supply is compatible with rectifier shelves o Supply fuses and/or circuit breakers and wires are properly rated

�� System components inspected

o All parts, equipment, documentation, etc. accounted for o Components checked for damage; if damaged, contact Eltek Valere

�� Rack anchored to suitable location

�� Distribution circuits open

o Circuit breaker actuators switched OFF o Fuses REMOVED

��

If applicable, make AC input connections (power is OFF) o Circuit breaker actuators switched off or fuses removed o AC ground connections terminated (always connect ground first) o AC supply lines are correctly configured to the rectifier shelf terminals

��

If applicable, make solar DC input connections (power is OFF) o Circuit breaker actuators switched off or fuses removed o Ground connection terminated (always connect ground first) o DC supply lines are correctly configured to the solar charger shelf terminals

�� DC load connections made (EXCEPT BATTERIES)

o Load cables properly connected to system output and return busbars

�� System alarm cable connected to “Alarm” port on controller

��

External devices connected to controller (if applicable) o PM device(s) (use provided terminators in any open CAN ports) o Battery thermal probe cables o Auxiliary alarms terminated

Turn-up Procedure

�� If applicable, turn on AC breakers and verify proper input voltage

�� If applicable, turn on DC input breakers and verify proper input voltage

�� Insert rectifiers (if applicable) in the desired order; system will power up

�� Insert solar chargers (if applicable) in the desired order

��

Verify system turn-up o Controller display turns on o Controller and rectifier LEDs turn on o Rectifier fans activate

��

Check controller interface o Check display functionality o Connect PC to controller o Insert provided CD into laptop (program will automatically start) o Verify controller appears in LAN Configuration Utility (no need to log in at this time)

�� Once alarms are cleared, run relay/alarm tests


Quick Start Turn-up Checklist Battery Connections (if applicable)

�� Measure battery string voltage; adjust system DC output voltage to equal battery voltage �� Disconnect (but do not remove from shelves) all but one rectifier

�� CHECK POLARITY and attach batteries to system

o Terminate cable connections to designated battery landings o Switch battery circuit breaker actuators ON and/or insert battery fuses (if applicable)

�� Reconnect all rectifiers �� Adjust DC output voltage to equal required battery float voltage

��

Configure battery settings (if desired) via front display or graphical interface o Battery boost o Thermal compensation o Battery current limit

Load Distribution

�� Once battery management is configured, activate load distribution circuits

o Switch circuit breaker actuators to the ON position o Insert fuses


5. Basic Troubleshooting In case of alarm conditions, verify the following:

o All AC and DC connections are secured properly.

o All rectifiers are installed and seated properly.

o The controller is installed and seated properly.

o Distribution breakers are in the ON position.

Specific rectifier and controller alarm conditions can be found in the following documents:

o 350002.013: User’s Guide—Flatpack2 Rectifiers

o 350003.013: User’s Guide—Smartpack Monitoring & Control Unit

For further assistance, please contact Eltek Valere Technical Support at +1 (866) 240-6614 or [email protected].


6. Revision List Revision Published Description CO

1 04/28/10 First release NA 2 09/14/10 Added reference to documentation CD;

removed cord grip reference; corrected surge protection information.

100826UC

3 01/21/11 24V rectifier modules added. Solar chargers and system designs added. Terminal block labels added to describe AC and DC connections. Grounding information updated to explain procedure for DC-only systems. Dual-feed AC connection instructions updated to include grounding.

101207UB


Sample Solar DC Schematic

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+

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24V BATTERY BANK

LOAD230Vdc

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+

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24Vdc

200Ah

230Vdc

24Vdc

24Vdc

DISCONNECT

CONTROLLER

CAN BUS

PV ARRAY 1

PV ARRAY 2

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+

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Sample AC Mains / Solar DC Schematic

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48V BATTERY BANK

LOAD

230Vdc

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48Vdc

200Ah

230Vdc

48Vdc

48Vdc

DISCONNECT

CONTROLLER

CAN BUS

PV ARRAY 1

PV ARRAY 2

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+

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48Vdc

A B C

AC terminalConnections

230Vac

A B C

UTILITY SERVICE

ENGINE GENERATOR

230 VAC

Transfer SW

CAN BUS

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Doc. No. 2074751, Issue 3

Published 21-Jan-11

www.eltekvalere.com/us Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Eltek Valere

Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

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