installation guide trilogy with...

Doc. No. 370003.033, Issue 1 Published 31-May-13

Installation Guide

Trilogy with Smartpack2

Flatpack2 DC Power System

2 Installation Guide Trilogy with Smartpack2 ~ Doc. No. 370003.033, Issue 1, May 2013

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 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 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.

Copyright © 2013 Eltek

2925 E Plano Pkwy Plano, TX 75074

USA

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

Technical Support +1 (800) 435-4872

[email protected]

www.eltek.com

Doc. No. 370003.033, Issue 1, May 2013

Published 31 May 2013

Installation Guide Trilogy with Smartpack2 ~ Doc. No. 370003.033, Issue 1, May 2013 3

Table of Contents Safety Practices and Compliance ...................................................... 7

FCC Compliance Statement ............................................................................................. 10

1. Overview ....................................................................................... 11

Configurations ...................................................................................................................... 12 AC-DC Rectifier Specifications ........................................................................................ 14 DC-DC Converter Specifications ..................................................................................... 15 Input Junction Box .............................................................................................................. 16

Individual-Feed Configuration ................................................................................ 16 Dual-Feed Configuration .......................................................................................... 18

Protected DC Output .......................................................................................................... 20 Bulk DC Battery Output ..................................................................................................... 22 Ground .................................................................................................................................... 23 Control and Monitoring ...................................................................................................... 23 LVD Options .......................................................................................................................... 24 Two-Distribution Configuration ....................................................................................... 24 References ............................................................................................................................ 25

2. Installation .................................................................................... 26

Recommended Tools .......................................................................................................... 26 Torque Settings ................................................................................................................... 26 Power Module Ratings ....................................................................................................... 27 Unpacking .............................................................................................................................. 27 Mechanical Mounting ......................................................................................................... 28 Rack Mounting...................................................................................................................... 28 Grounding .............................................................................................................................. 28 AC Input Connections ......................................................................................................... 29

Individual-Feed AC Input .......................................................................................... 29 Dual-Feed AC Input .................................................................................................... 32

Protected DC Output Connections ................................................................................ 33 Two-Distribution Cable Routing............................................................................. 37

Bulk DC Battery Connections .......................................................................................... 37 Circuit Breaker/Fuse Installation .................................................................................... 38

Plug-in Breakers ......................................................................................................... 38 Plug-in Fuse Holders ................................................................................................. 38 Device Installation and Extraction........................................................................ 39

Alarm Connections .............................................................................................................. 40 Controller CAN Connections ............................................................................................ 40 Rectifier and Converter Module Installation ................................................................ 41


3. Startup .......................................................................................... 42

Rectifier Installation ........................................................................................................... 42 Connecting Batteries ......................................................................................................... 43 DC Breakers and Fuses ...................................................................................................... 43 Access Alarm Setup Menu................................................................................................ 43 Test and Reset Alarm Relays ........................................................................................... 44

Test alarm relays ....................................................................................................... 44 Reset alarm ................................................................................................................. 44

Set Charge Voltage ............................................................................................................ 45 Temperature Compensation ............................................................................................ 46 Smartpack2 Controller Menus......................................................................................... 46

4. Advanced Smartpack2 Features .................................................. 48

Connect to WebPower ....................................................................................................... 48 Set Float Voltage ................................................................................................................ 50 Change Alarm Settings ...................................................................................................... 51 Download Statistics ........................................................................................................... 52 Rectifier Alarm Silence ...................................................................................................... 54 Clearing a Rectifier Alarm ................................................................................................. 54 Battery Discharge Alarm ................................................................................................... 55 Upload Configuration Files ................................................................................................ 56 LED Test ................................................................................................................................. 59 Alarm Relay Tests ............................................................................................................... 59

5. Startup Checklist .......................................................................... 60

6. Basic Troubleshooting .................................................................. 62

7. Revision List .................................................................................. 63

Appendix – Power Shelf Configurations ........................................... 64

Appendix – Breaker Bus Configurations ........................................... 66


Table of Figures Figure 1 - Trilogy -48V, 600A System ....................................................................................................................... 11 Figure 2 - Trilogy with Distribution Door Open ........................................................................................................ 11 Figure 3 - Converter Shelf (bottom) ........................................................................................................................... 16 Figure 4 - Terminal Block (TB) Assignments, Individual-Feed AC....................................................................... 17 Figure 5 - Ground Connections, Individual-Feed Box ............................................................................................. 17 Figure 6 – Individual-feed AC Input Box (with 16 rectifier slots) ....................................................................... 18 Figure 7 - Terminal Block Assignments, Dual-Feed AC ......................................................................................... 19 Figure 8 - Ground Connections, Dual Feed Box ....................................................................................................... 19 Figure 9 - Dual-feed AC Input Box (with 10 rectifier slots) .................................................................................. 20 Figure 10 - Distribution with Adjustable Breaker Holders ................................................................................... 21 Figure 11 – Breaker Holders Assigned to Different Buses .................................................................................. 21 Figure 12 - Protected Distribution Connections ..................................................................................................... 22 Figure 13 - Breaker Holder ............................................................................................................................................ 22 Figure 14 - Battery Connections ................................................................................................................................. 23 Figure 15 - Ground Connections.................................................................................................................................. 23 Figure 16 – Alarm Monitor, LAN and CAN Ports ...................................................................................................... 24 Figure 17 - Two-Distribution Configuration.............................................................................................................. 25 Figure 18 - Division of Terminal Blocks by Shelf..................................................................................................... 30 Figure 19 - AC Terminal Jumper .................................................................................................................................. 32 Figure 20 - Terminal Blocks in Dual-Feed Configuration ...................................................................................... 33 Figure 21 - Return Connection ..................................................................................................................................... 36 Figure 22 - Hot (Breaker) and Return Connections ............................................................................................... 36 Figure 23 - Breaker Position Cable Routing for Two-Distribution System ...................................................... 37 Figure 24 - Smartpack2 Master Features ................................................................................................................ 44 Figure 25 - WebPower Welcome Page....................................................................................................................... 49 Figure 26 - Eltek Network Utility................................................................................................................................. 50 Figure 27 - "Web Interface" Button ............................................................................................................................ 50 Figure 28 - Main Page of WebPower Interface........................................................................................................ 50 Figure 29 - Modifying Alarm Outputs in WebPower ............................................................................................... 52 Figure 30 - Smartpack2 Master Unit Opened.......................................................................................................... 57 Figure 31 - Side View of Open Controller Display ................................................................................................... 57 Figure 32 - The “Enter” Key ........................................................................................................................................... 58 Figure 33 - Two Shelves for 24V/1800W 600A, 48V/2000W 300A, and 48V/3000W 400A................... 64 Figure 34 - Three Shelves for 48V/2000W 400A .................................................................................................. 64 Figure 35 - Three Shelves for 48V/3000W 600A .................................................................................................. 65 Figure 36 - Four Shelves for 48V/2000W 600A ..................................................................................................... 65 Figure 37 – Battery Shunt Only Configuration ........................................................................................................ 66 Figure 38 – Load LVD (LVLD) and Battery Shunt .................................................................................................... 66 Figure 39 - Battery Shunt and LVD (LVBD)............................................................................................................... 67 Figure 40 - Load and Battery LVDs............................................................................................................................. 67 Figure 41 - Two Distribution Panels, Battery Shunt Only .................................................................................... 68 Figure 42 - Two Distribution Panels, Load LVD and Battery Shunt ................................................................... 68 Figure 43 - Two Distribution Panels, Battery Shunt and LVD ............................................................................. 69 Figure 44 - Two Distribution Panels, Load LVD and Battery LVD....................................................................... 69 Figure 45 - Converter Shelf and Battery Shunt ...................................................................................................... 70 Figure 46 - Two Distribution Panels, Converter Shelf and Battery Shunt ...................................................... 70 Figure 47 - Converter Shelf and Battery LVD (LVBD) ............................................................................................ 71 Figure 48 - Two Distribution Panels, Converter Shelf and Battery LVD .......................................................... 71


List of Tables Table 1 – Configuration Sizes by Rectifier Module and Number of Shelves .................................................. 12 Table 2 - Specifications for Trilogy Systems .......................................................................................................... 13 Table 3 – Flatpack2 Rectifier Specifications ........................................................................................................... 14 Table 4 – Flatpack2 Converter Specifications ........................................................................................................ 15 Table 5 - Recommended Torque Settings ............................................................................................................... 26 Table 6 - Flatpack2 Rectifier Ratings ........................................................................................................................ 27 Table 7 - Flatpack2 Converter Ratings ..................................................................................................................... 27 Table 8 – Individual-Feed Terminal Block Label Detail .......................................................................................... 30 Table 9 - Dual-Feed Terminal Block Label Detail .................................................................................................... 32


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 +50oC. 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 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: This product is intended to be protected by a surge protector that meets the applicable criteria of GR-974-CORE or GR-1361-CORE. Failure

to utilize this appropriate surge protector could result in susceptibility to lightning surges or create a potential hazard due to power faults.

WARNING: Flatpack2 AC-DC rectifiers and Flatpack2 DC-DC converters are not interchangeable. Do not combine AC-DC rectifiers and DC-DC

converters in the same power shelf!

WARNING: Do not use Flatpack2 48V/3000W HE and Flatpack2 48V/2000W HE rectifiers in the same system!

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 3, as well as national and local electric codes.

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. Follow national and local codes as well as company standards for wire sizing.

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 5.

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

WARNING: Protection of persons against electric shock:

Power cabling may be performed only by qualified personnel in accordance with local and national electric codes. Improper wiring can cause physical damage or injury. Input voltage from the power supply might be present. Improper connection may cause damage or serious injury. Ensure that the power supply source switch is in the OFF position. Use a voltmeter to check the presence of voltage from the supply. Ensure that all power switches are in the OFF position—in the system, devices, and at supply. Improper wiring may cause bodily injury and equipment damage. Before performing maintenance, either unplug or disconnect the equipment from the power supply source in order to reduce the risk of electric shock or other possible hazards.


When working on electrical equipment in and for applications in Germany, regulations for the prevention of electrical accidents—as stated in DIN VDE 0105—are summarized in the following five safety rules:

1. De-energize

2. Secure from re-energizing (“lockout”)

3. Verify that the equipment is de-energized

4. Ground and short-circuit

5. Insulate or cover any live or energized areas of nearby equipment

These five safety rules should be followed in order before starting work on electrical systems.

Only qualified electricians are to work on this equipment.

WARNUNG: Schutz von Personen gegen elektrischen Schlag:

Die Spannungsversorgungsleitung(en) darf nur durch qualifiziertes Personal in Abhängigkeit der örtlichen und nationalen elektrischen Bestimmungen ausgeführt werden. Unsachgemäße Verdrahtung kann körperliche Schäden und Verletzung verursachen. Eingangsspannungen von der Netzversorgung der Hausanlage können unter Spannung stehen beim Anschluss der Leitung(en). Versorgungsspannungen können bei unsachgemäßen Gebrauch gefährliche Verletzungen und Schäden verursachen. Sorgen Sie dafür, dass der/die Leistungsschalter in der AUS-Stellung ist/sind. Benutzen Sie ein Spannungsmesser um sicher zu sein das keine Netzspannung mehr vorhanden ist. Vergewissern Sie sich das alle Schalter an Ihrem Gerät/Anlage und in der Versorgungsleitung beim Anschluss abgeschaltet sind. Unsachgemäße Verdrahtung kann körperliche Verletzung und an der Anlage Schäden verursachen. Vor Wartungsarbeiten am Gerät sind alle Netzkabel vom Stromnetz zu trennen, um die Gefahr eines elektrischen Schlages oder andere mögliche Gefahren zu reduzieren.

Bei Arbeiten in und an elektrischen Anlagen gelten zur Vermeidung von Stromunfällen in Deutschland bestimmte Regeln, welche in den Fünf Sicherheitsregeln nach Normenreihe DIN VDE 0105 zusammengefasst sind:

1. Freischalten

2. Gegen Wiedereinschalten sichern

3. Spannungsfreiheit allpolig feststellen

4. Erden und kurzschließen

5. Benachbarte, unter Spannung stehende Teile abdecken oder abschranken

Diese fünf Sicherheitsregeln sollen vor den Arbeiten an elektrischen Anlagen in der oben genannten Reihenfolge angewandt werden. Diese Regeln werden bei jeder Elektrofachkraft als bekannt vorausgesetzt.


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, Smartpack2 controller units, and a distribution section sized for either 19” or 23” racks (extension brackets are required for 23" racks). Maximum overall system depth is 16 inches (406 mm). It can be mounted in a standard 19” or 23” telecommunications equipment rack.

Figure 1 - Trilogy -48V, 600A System

Figure 2 - Trilogy with Distribution Door Open

Available systems are 48 VDC at total DC outputs of 300A, 400A, and 600A; and 24 VDC at a total DC output of 600A. Trilogy systems for 48 VDC output are specifically configured for either the 2000W or 3000W Flatpack2 HE rectifier models.

Distribution Section

Smartpack2 Controller

Flatpack2 HE Rectifiers

Smartpack2 Controller

DC Output (for breakers)

Alarm/control connections


Configurations Trilogy system configurations are primarily based on the Flatpack2 rectifier model used. See Table 1 for the available power shelf configurations. Note that there is a significant difference in output current between systems that employ the 48V/2000W rectifiers and those that use the 48V/3000W rectifiers. See Table 3 on page 14 for rectifier specifications.

Table 1 – Configuration Sizes by Rectifier Module and Number of Shelves

Drawings of rectifier shelf configurations can be found in "Appendix – Power Shelf Configurations" beginning on page 64.

A DC-DC converter shelf, which holds up to four Flatpack2 converter modules, is an option available for all Trilogy configurations. If ordered, the converter shelf is always installed below the rectifier shelves. Only one converter shelf can be configured for a Trilogy system. See Table 4 on page 15 for converter module specifications.

WARNING: Flatpack2 AC-DC rectifiers and Flatpack2 DC-DC converters are not interchangeable. Do not combine AC-DC rectifiers

and DC-DC converters in the same power shelf!

NOTICE: Converter shelves are not field-installable. They must be ordered along with the Trilogy system.

For available distribution configurations, please see "Appendix – Breaker Bus Configurations" beginning on page 66.

No. of Rectifier Shelves 24V/1800W 48V/2000W 48V/3000W

2 600A 300A 400A3 NA 400A 600A4 NA 600A NA

Rectifier Module Used

NOTICE: Configuration sizes are approximations of current output for the purposes of naming convention.


Table 2 - Specifications for Trilogy Systems

Mechanical

Dimensions

Distribution panel: 16.0”D x 17.3”W* x 7.0”H (4U) Rectifier shelf: 16.0"D x 17.3"W* x 1.75"H (1U) *Width is for a standard 19" rack For total system height, add the heights of all distribution

panels and all rectifier shelves installed

Weights

Approx. empty weight: 90 lbs. (one distribution panel, four rectifier shelves)

Rectifier (each): 4.3 lbs. Converter (each): 4.3 lbs

Clearances Front and rear clearance required for proper airflow.

Cable egress from top / rear. Vertical clearance required; dependent on load cable size.

Electrical Input

Rectifiers: See Table 3 on page 14 Converters: See Table 4 on page 15

Output Rectifiers: See Table 3 on page 14 Converters: See Table 4 on page 15

Connections

AC Input

Individual feed: One feed per rectifier, one-phase to terminal blocks; can be converted to dual-feed (one feed per two rectifiers, one-phase to terminal blocks), but for 48V/2000W rectifiers only

Dual feed: One feed per two rectifiers, one-phase to terminal blocks

DC Output

Front connections (circuit breakers) are for two-hole lugs with ¼" dia. On 5/8" centers.

Rear connections are for two-hole lugs with 3/8” dia. on 1” centers and max width of 2.25”.

CO Ground One connection to the return bus recommended, at least the size of the largest connected cable.

Environmental Operating Temperature -40°C to +50°C (-40°F to +122°F); rectifier derates above 45°C

Storage Temperature -40°C to +70°C (-40° to +158°F) Relative Humidity 0-95%, non-condensing

Interface TCP/IP 10/100BASE-T Ethernet

Alarm Relays Six (6) form-C dry contact output relays Six (6) auxiliary alarm inputs

Compliance NEBS Level 3 (GR-63-CORE, GR-1089-CORE)

Safety Standard: CSA UL 60950-1 (Canada and USA), 2nd Edition

Safety Standard: VDE EN 60950-1, 2nd Edition


AC-DC Rectifier Specifications The Flatpack2 HE rectifiers are high-efficiency modules that typically perform at a 96% conversion rate. Operational specifications are listed in Table 3.

Table 3 – Flatpack2 Rectifier Specifications

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.


WARNING: Do not combine AC-DC rectifiers and DC-DC converters in the same power shelf!

Flatpack2 Rectifier Model

48V/3000W HE(241119.105)

48V/2000W HE(241115.105)

24V/1800W HE(241115.205)

Operational Input Voltage Range

85 - 305 Vac 85 - 275 Vac 85 - 300 Vac

Full Power Input Voltage Range

176 - 277 Vac 185 - 275 Vac 185 - 275 Vac

AC Input Frequency

45 - 66 Hz 45 - 66 Hz 0 - 66 Hz

Maximum Input Current

19.2 A-rms 11.6 A-rms 11.25 A-rms

Default Output Voltage

53.5 Vdc 53.5 Vdc 26.7 Vdc

Adjustable Output Voltage Range

43.5 - 57.6 Vdc 43.5 - 57.6 Vdc 21.7 - 28.8 Vdc

Maximum Output Power

3000 W 2000 W 1800 W

Output Power @ 85 Vac Input

1380 W 750 W -

Maximum Output Current (@nominal input, full load)

62.5 A 41.7 A 75 A

Efficiency Up to 96.2% Up to 96.5%>95%

(@ 30 - 70% load)

DC OUTPUT

AC INPUT


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

DC-DC Converter Specifications The Flatpack2 HE converters provide DC-to-DC voltage conversion. If the Trilogy system is configured for converters, then one converter shelf (which holds up to four modules) is installed below the rectifier shelves. Input power is supplied by the internal system bus. Output is delivered to the top output power bus in the distribution. Operational specifications for the available Flatpack2 HE converters are listed in Table 4.


Table 4 – Flatpack2 Converter Specifications

Flatpack2 Converter Model

24V/1350W(241115.600)

48V/1350W(241115.602)

Operational Input Voltage Range

20 - 75 Vdc 20 - 75 Vdc

Maximum Input Current

70 Adc (85 Adc during boost*)

70 Adc (85 Adc during boost*)

Default Output Voltage

26 Vdc 53 Vdc

Adjustable Output Voltage Range

24 - 28 Vdc 48 - 58.5 Vdc

Maximum Output Power (Vin > 26 Vdc)

1350 W 1350 W

Maximum Output Power During Boost*

2000 W 2000 W

Output Power @ 18 Vdc Input

910 W 910 W

Maximum Output Current (@nominal input, full load)

56 A 28 A

Maximum Output Current During Boost*

84 A 42 A

Efficiency Up to 91.7% Up to 93.8%

INPUT

OUTPUT

*Boost mode supports a spike in output power for 15s with a 10 min recovery


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

Given the converter modules currently available (rated for 1350W output), a fully-populated converter shelf can output up to 216A at 24 VDC and 108A at 48 VDC.

NOTICE: If installed, the converter shelf is always the bottom-most shelf, and each converter slot is labeled "CONVERTER ONLY".

Figure 3 - Converter Shelf (bottom)

Input Junction Box The AC input junction box is located in the center-rear of the distribution section and is a top-access panel.

Individual-Feed Configuration Terminal blocks for individual-feed input can be fitted with jumpers (provided) for converting the box to dual-feed input. There are four knockouts on the box for 3/4” conduit.

NOTICE: Converting the individual-feed configuration to dual-feed is available for Flatpack2 HE 48V/2000W rectifier modules only.

Terminals 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”. The input lines are arranged in pairs to facilitate optional dual-feed input. See Figure 4 for the terminal block (TB) assignments for each rectifier slot.

Each terminal block accepts a maximum wire size of #10 AWG. Recommended torque is 7 – 8 in-lbs.

Converter Shelf


Figure 4 - Terminal Block (TB) Assignments, Individual-Feed AC

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

Figure 5 - Ground Connections, Individual-Feed Box

For AC mains input, the terminal designations are “L1” for “Line 1” and “L2” for “Line 2”. See Table 8 on page 30 for the full list of terminal designations.

Ground Studs (¼”-20)


Figure 6 – Individual-feed AC Input Box (with 16 rectifier slots)

Dual-Feed Configuration Terminal blocks for dual-feed input can be fitted with jumpers (provided) for converting the box to dual-feed input. There are four knockouts on the box for 1” conduit.

Terminals 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”. Each terminal feeds two neighboring rectifier slots. See Figure 7 for the terminal block (TB) assignments for each rectifier slot.

Each terminal block accepts a maximum wire size of #4 AWG. Recommended torque is 13 – 16 in-lbs.

Front of System

AC Input Box


Figure 7 - Terminal Block Assignments, Dual-Feed AC

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 8 - Ground Connections, Dual Feed Box



For AC mains input, the terminal designations are “L1” for “Line 1” and “L2” for “Line 2”. See Table 9 on page 32 for the full list of terminal designations.

Figure 9 - Dual-feed AC Input Box (with 10 rectifier slots)

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 of System

AC Input Box


Figure 10 - Distribution with Adjustable Breaker Holders

Figure 11 – Breaker Holders Assigned to Different Buses

Note the bus labels on the right side of the distribution panel to determine bus assignments. See "Appendix – Breaker Bus Configurations" beginning on page 66 for available distribution panel configurations.

Breaker Extraction Tool

Smartpack2 Basic

Smartpack2 Master


Figure 12 - Protected Distribution Connections

Figure 13 - 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. 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.

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

Insulator


Figure 14 - Battery Connections

Ground If the system is installed in a rack, the rack should be grounded. 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 to the system 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 15 - Ground Connections

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).

Next to the Ethernet port is a CAN connection for Eltek 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

Return Hot

CO Ground Connection



with each device for installation instructions. If the CAN port is not used, the CAN termination plug provided must remain in place.

Figure 16 – Alarm Monitor, LAN and CAN Ports

Alarm connections are made to the I/O Monitor2 unit that is mounted on the left side of the distribution wall. Maximum wire size is 16 AWG (1.5 mm2), strip length is 1/4”. Torque each connection to 3 in-lb. (0.2 N·m). There are six input alarms and six output relays.

LVD Options Trilogy systems can be ordered with low-voltage disconnect (LVD) contactors; there can be one load (LVLD) contactor, one battery (LVBD) contactor, or both. Contactor settings are configured through the Smartpack controller. See "Appendix – Breaker Bus Configurations" beginning on page 66 for available distribution panel configurations, which illustrate bus assignments for LVDs.

Two-Distribution Configuration Trilogy systems can be configured with up to two distribution panels, which provide a total of 40 breaker positions. Drawings of available configurations begin on page 68.

I/O Monitor2

LAN Port

CAN Port


Figure 17 - Two-Distribution Configuration

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 350020.013: User’s Guide—Smartpack2 Master Controller

o 350021.013: User's Guide—Smartpack2 Basic Controller

o 351509.003: Installation Guide—I/O Monitor2

Selected documentation and the Powersuite software for the Smartpack2 controller are located on the accompanying CD.

Additional product information is available online at eltek.sharefile.com.


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

Table 5 - 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 -- 4.25-115/16"-18 -- 8.33-213/8"-16 -- 15-38

Fuse Terminal 7.6-9.0


Power Module Ratings For installation considerations (e.g., sizing wire and circuit protection), the tables below provide the agency ratings of the Flatpack2 HE rectifier and converter modules.

Table 6 - Flatpack2 Rectifier Ratings

Table 7 - Flatpack2 Converter Ratings

Unpacking Rectifier modules and expansion options are packed in separate cartons from the Trilogy system. Exercise care when unpacking and setting the equipment in place.

Flatpack2 Rectifier Model

48V/3000W HE(241119.105)

48V/2000W HE(241115.105)

24V/1800W HE(241115.205)

Rated Input Voltage Range

100 - 277 Vac 100 - 250 Vac 100 - 250 Vac

Rated Maximum Input Current

19.0 A-rms 12.5 A-rms 11.2 A-rms

Rated DC Output 53.5V / 56.1A 53.5V / 37.4A 26.7V / 67.5A

Maximum Output Voltage

57.9 Vdc 57.9 Vdc 29.0 Vdc

Maximum Output Current

62.6 Adc 42.2 Adc 73.7 Adc

Flatpack2 Converter Model

24V/1350W(241115.600)

48V/1350W(241115.602)

Rated Input Voltage Range

18 - 75 Vdc 18 - 75 Vdc

Rated Maximum Input Current

60A / 18Vdc 60A / 18Vdc

Rated DC Output 26.7V / 50.5A 53.5V / 25.2A

Maximum Output Voltage

28.2 Vdc 58.5 Vdc

Maximum Output Current

56.7 Adc 28.5 Adc


Mechanical Mounting Eltek 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 90mm (3.5”)

o A maximum bolt diameter of 13mm (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, connect a safety ground to one of the available locations in the junction box.

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 22). 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.

AC Input Connections AC connections differ depending on the configuration ordered from the factory. There are two primary options: Individual-feed and dual-feed. The individual-feed terminal configuration can be converted to a dual-feed configuration.

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.

Individual-Feed AC Input 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.

Table 8 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 17 to see which module slots are powered by which input terminals.


Table 8 – Individual-Feed 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

32 S4R4 L2 +31 S4R3 L2 +30 S4R4 L1 −29 S4R3 L1 −28 S4R2 L2 +27 S4R1 L2 +26 S4R2 L1 −25 S4R1 L1 −24 S3R4 L2 +23 S3R3 L2 +22 S3R4 L1 −21 S3R3 L1 −20 S3R2 L2 +19 S3R1 L2 +18 S3R2 L1 −17 S3R1 L1 −16 S2R4 L2 +15 S2R3 L2 +14 S2R4 L1 −13 S2R3 L1 −12 S2R2 L2 +11 S2R1 L2 +10 S2R2 L1 −

9 S2R1 L1 −8 S1R4 L2 +7 S1R3 L2 +6 S1R4 L1 −5 S1R3 L1 −4 S1R2 L2 +3 S1R1 L2 +2 S1R2 L1 −1 S1R1 L1 −

1 2 3 4

L1 L1 L2 L2

5 6 7 8 9 10 11 12 13 14 15 16

L1 L1 L2 L2

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

L1 L1 L2 L2 L1 L1 L2 L2 L1 L1 L2 L2 L1 L1 L2 L2 L1 L1 L2 L2 L1 L1 L2 L2

SHELF 1 SHELF 2 SHELF 3 SHELF 4


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 AC 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 S1R1, 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. Repeat in this manner for each remaining AC feed.

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




4. Locate terminals S1R1 L1 and S1R2 L1 (numbers “1” and “2”, respectively). Connect the terminals together by installing one jumper (Figure 19) in the input side of each terminal block.

5. Connect the first AC line of the feed to S1R1 L1 (terminal “1”).


6. Then, connect the terminals for S1R1 L2 and S1R2 L2 (numbers “3” and “4”, respectively) together by installing one jumper in the input side of each terminal block.

7. Connect the second AC line of the feed to S1R1 L2 (terminal “3”).

8. Repeat steps 1 to 7 for each remaining AC feed.

Figure 19 - AC Terminal Jumper

Dual-Feed AC Input 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 1” conduit.

Table 9 lists the designations for a dual-feed system, in this case, one with three rectifier shelves (two of which are unpowered in shelf #3). See Figure 20 for the division of terminal blocks by shelf. If necessary, refer to Figure 7 on page 19 to see which module slots are powered by which input terminals.

Table 9 - Dual-Feed Terminal Block Label Detail

Figure 20 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.

Terminal Block

Position Label

AC Designation

DC Designation

10 S3R1-2 L2 +9 S3R1-2 L1 −8 S2R3-4 L2 +7 S2R3-4 L1 −6 S2R1-2 L2 +5 S2R1-2 L1 −4 S1R3-4 L2 +3 S1R3-4 L1 −2 S1R1-2 L2 +1 S1R1-2 L1 −


Figure 20 - Terminal Blocks in Dual-Feed Configuration

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 #4 AWG. The recommended torque value is 13 – 16 in-lbs. Ground terminals are 1/4” studs and accept one-hole lugs.

To terminate AC feeds in a dual-feed configuration:




4. Beginning with the feed for S1R1-2 (shelf 1, rectifiers 1 and 2), 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 13 – 16 in-lbs.

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

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

1 2

L1 L2

3 4 5 6 7 8

L1 L2

9 10

L1 L2 L1 L2 L1 L2

SHELF 1 SHELF 2 SHELF 3

RECTIFIERS1, 2

RECTIFIERS3, 4

RECTIFIERS1, 2

RECTIFIERS3, 4

RECTIFIERS1, 2


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. The holder’s hooks correspond to each bus.

NOTICE: Holders set to higher buses sit higher than those at lower buses.

4. Ensure that the holder is firmly in place and sitting on the alignment

rail. Then, lower the holder into position against the bus and verify that the metal alarm tab goes into the alarm spring fingers between the buses.

Alarm Circuit Springs Alarm Tab


NOTICE: If the tab does not go into alarm spring fingers, then the breaker holder is not firmly on the alignment rail. Remove the holder and try again.

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 startup.

Hook for Bus 2

Aligned with Bus 2


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

Figure 21 - Return Connection

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

Figure 22 - 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.

Return Connection

Hot/Breaker Connection


Two-Distribution Cable Routing Trilogy systems with two distribution panels are designed to accommodate cabling to both panels. The breaker holders of the bottom panel (which houses the Smartpack2 controller) are set back farther than the breaker holders in the top panel. This allows cabling for the bottom panel to pass behind the breaker panel above. See Figure 23.

Figure 23 - Breaker Position Cable Routing for Two-Distribution System

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.


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

CAUTION: Do not connect batteries until system startup. It is required 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 startup, 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 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 Listed 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 startup.

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 make alarm connections:

1. Strip alarm wires back 0.25 in (6-7 mm).

2. Make input/output alarm connections. Maximum wire size is 16 AWG (1.5 mm2). Torque each connection to 3 in-lb. (0.2 N·m).

NOTICE: Each of the five terminal blocks can be removed from the I/O Monitor2 by pulling them straight up from the unit. This makes terminations easier to make. Simply plug the block back into the I/O Monitor2 after making alarm connections.

Alarm I/O can be configured through either the display or the Ethernet connection after startup. If making a change through the display (and a “Change” option is available), a PIN is required to execute a change. The default PIN for the display is “0003”. To access the alarm configuration menu in the Smartpack2 Master display, see the section “Access Alarm Setup Menu” on page 43.

To configure alarms through the Ethernet connection (using WebPower), see the section "Connect to WebPower", beginning on page 48.

Controller CAN Connections Connections for Eltek CAN monitoring devices are made to the CAN port of the I/O Monitor2 in the distribution panel (left wall). This provides a communication link to the Smartpack2 controller system.

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.


Rectifier and Converter Module Installation NOTICE: Flatpack2 rectifier and converter modules are assigned a system ID based on order of installation. Therefore, it is recommended to install rectifiers AFTER system startup, in the order desired.

The Flatpack2 family of power modules features 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 Flatpack2 modules by the handles, even if they are warm. The handles must be fully extended before installing or removing Flatpack2 modules to prevent damage to either the shelf or module.

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

To install 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 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.

Handle Release


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



CAUTION: Flatpack2 HE rectifiers and Flatpack2 HE converters have dedicated shelves. Rectifiers and converters cannot be mixed in the same power shelf!

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

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

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

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.

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

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.


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.

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

CAUTION: Do not connect batteries until system startup. 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 startup, 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.

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

Access Alarm Setup Menu To setup alarm parameters through the display:

1. Unlock the display by pressing the UP key, and then the DOWN key.

2. Press the ENTER key to access the menu.

3. Use the navigation keys to highlight the “Alarm Config.” symbol, and then press the ENTER key.

4. Use the navigation keys to highlight either the “Inputs” or the “Outputs” symbols, depending on which connections are to be configured. Press the ENTER key to select.


Figure 24 - Smartpack2 Master Features

To configure alarms through the Ethernet connection, see the instructions found in document #350020.013—Smartpack2 Master User’s Guide.

Test and Reset Alarm Relays This section describes the basic parameters that can be tested and reset using the Smartpack2 Master display. For other settings, use either PowerSuite or the built-in web interface called WebPower.

Test alarm relays 1. Press the following keys to enter the main menu: , , ,

2. Select the “Commands” menu, ,

3. Select the “Output Test” menu, ,

4. Select the relay to be tested,

5. Press and enter PIN 0003 by pressing three times; then press

6. Press the following keys to test the relay: ,

7. The alarm relay automatically returns to normal after 10 seconds.

Reset alarm 1. Press the following keys to enter the main menu: , , ,

2. Select the “Commands” menu, ,

Smartpack2 Master controller

Handle in locked position

”Enter” key

“Cancel” key

Arrow key

”Alarm” LED lamp (red)

“Warning” LED lamp (yellow)

“Power” LED lamp (green)

Graphical Color Display 3.2” TFT 32k, QGVA 320x240


3. Select the “System Commands” menu,

4. Select “Reset Manual Alarms”.


6. Press the following keys to reset the alarm relay, ,

Set Charge Voltage This section describes the basic parameters that can be set using the Smartpack2 Master display. For other settings, use either PowerSuite or the built-in web interface called WebPower.

1. Before adjusting the charge voltage, check if the Wallbox has a temperature sensor connected; this is required in order to regulate the charging voltage according to ambient temperature.

2. If the Wallbox has a connected temperature sensor, temperature compensation can be switched off as described below.

3. Press the following keys to enter the main menu: , , ,

4. Select the Sys Config menu, ,

5. Select the “Power Systems” menu,

6. Select “System Voltage Levels”, ,

7. Select “Reference Voltage”.


9. Adjust to the desired charging voltage with the arrow keys , ,

10. Confirm by pressing


Temperature Compensation 1. Press the following keys to enter the main menu: , , ,

2. Select the “General Sys Config” menu, ,

3. Select the “Battery” menu, ,

4. Select the “General Battery Config” menu,

5. Select“Temp Compensation On/Off”,


7. Press the following keys to shut off the temperature compensation: ,

8. After setting the charging voltage, repeat from 1 to activate again

Smartpack2 Controller Menus Press the following keys to enter the main menu: , , ,

System statusRead out system status, such as incoming AC, network, rectifier status, battery status, alarms, etc.

System ConfigurationSetting the charge voltage, temperature compensation, change the number of cells in the system, etc.

Alarm ConfigurationChange alarm limits, time delays, alarm groups, etc.


CommandsReset the alarm, test output relays, start boost charge, delete event list, start battery test, etc.

Event historyActive alarms, event log, battery test log, etc.

StatisticsStatistics about max, min DC voltage, max, min AC voltage, etc.


4. Advanced Smartpack2 Features The following sections describe how to use certain advanced features of the Smartpack2 control system.

NOTICE: Unless otherwise specified, all instructions assume that a connection with the controller is established and that the interface is through a web browser. The web browser interface is facilitated by Eltek’s WebPower.

NOTICE: Some web browsers may not support all features of WebPower. Microsoft© Internet Explorer 9 and Mozilla Firefox 15 (and later versions) are known to support all features of WebPower.

Default service-level login credentials

User name: admin

Password: admin

More comprehensive control and monitoring features can be accessed through the Ethernet connection using a PC. Consult the following Smartpack2 documentation for more details:

o 350020.013—Smartpack2 Master User’s Guide

o 350021.013—Smartpack2 Basic User’s Guide

o 351509.033—I/O Monitor2 Installation Guide

Documentation, software, and help files for the Smartpack2 controller are located on the accompanying CD.

Connect to WebPower WebPower is designed for interfacing with the controller through a desktop web browser. To establish a connection:

1. Open the Smartpack2 Master controller display.

2. Connect a PC to the Smartpack2 Master unit via Ethernet.

3. Open an Internet browser window.

To open, slide lever from right to left


NOTICE: Some web browsers may not support all features of WebPower. Microsoft© Internet Explorer 9 and Mozilla Firefox 15 (and later versions) are known to support all features of WebPower.

4. Enter the controller's IP address in the address bar.

NOTICE: A static IP address of 192.168.10.20 is programmed into Eltek controllers by default.

5. Enter the controller's IP address in the address bar.

6. Does the WebPower welcome page appear?

Figure 25 - WebPower Welcome Page

If YES, then type in the login credentials. The default user name and password are both "admin". Wait for the window to populate. Connection to WebPower is complete.

If NO, then continue to the next step.

7. Launch the Eltek Network Utility program provided on the CD.

8. After the program launches, click on the magnifying glass icon in the upper left hand corner of the window. The controller list populates with all Eltek controllers on the network (see Figure 26).


Figure 26 - Eltek Network Utility

9. Locate the Smartpack2 controller and click on it.

10. Click on the “Web Interface” button in the lower left-hand corner.

Figure 27 - "Web Interface" Button

11. Login using “admin” for both the user name and password.

Figure 28 - Main Page of WebPower Interface

12. Wait for the window to populate. WebPower is now ready to use.

Set Float Voltage To set system float voltage:

1. In WebPower, select the “System Conf.” icon in the top menu bar.

2. Under “Power System” in the left menu bar select “System Voltages.


3. In the “Reference voltage” box, select a float voltage value for the

each battery cell. For example, if 54V is the desired float voltage, then enter “2.25” for the V/cell (volts per battery cell).

4. Click the save button (diskette icon) in the lower right-hand corner of the window.

Once the value is saved, then the voltage value in parentheses to the right of the “Reference voltage” value shows the float voltage. In this example, 2.25 V/cell equates to 54.00V.

Change Alarm Settings To change alarm settings in WebPower:

1. Click on “Alarm Conf.” in the top menu bar.

2. In the left menu bar, all supported alarm categories are listed. Click on a category to see the devices and parameters that can be modified.

For example, to change alarm input and output (I/O):

1. In the left menu bar, click on “Inputs” to modify input alarms; click on “Outputs” to modify output alarms.

2. After clicking either “Inputs” or “Outputs”, use the “Select Unit” drop-down menu to select the device where the alarm I/O are connected that are to be modified.

Reference voltage box


3. Each alarm can now be assigned to an alarm input or output channel of that device.

Figure 29 - Modifying Alarm Outputs in WebPower

Download Statistics Statistics collected by the Smartpack2 Master controller can be downloaded through two means: access via FTP or downloading directly from the SD card.

NOTICE: Statistics are stored in “CSV” files, which are delimited by tabs and semicolons. To view the data properly formatted in a spreadsheet program, the file must be imported as a delimited file, with “tabs” and “semicolons” specified as the delimiters.

To download statistics via FTP:

1. In the WebPower interface, click on the “Statistics” icon in the top bar.

2. A window appears showing the IP address of the controller. Write down this IP address.

3. Open a Windows Explorer window.

4. Type the following in the address bar:

ftp://192.168.10.20

NOTICE: The IP address given above is the default address assigned by Eltek manufacturing. Use the IP address recorded in step 2.


5. A window appears requesting login credentials. By default, the

credentials are the same as the default WebPower credentials:

User name: admin

Password: admin

Enter the credentials and click the “Log On” button.

6. At this point, all folders and statistics files can be copied.

To download statistics from the SD card:

1. Open the Smartpack2 Master controller display.

2. Remove the SD card by depressing it. When released, it pops out just

enough to extract.

3. Insert the card into an SD card reader on a computer. A file browsing window should automatically open.

4. At this point, all folders and statistics files can be copied.

5. When finished, put the SD card back in the Smartpack2 Master control display. Simply press it in the slot until a click is heard. The card is captured and properly reinstalled.

6. Close the Smartpack2 Master control display.



Rectifier Alarm Silence When a single rectifier alarm is triggered and immediate maintenance is not required, it may be desirable to silence the alarm.

To silence a rectifier alarm:

1. Check all alarms to ensure that no critical or major alarm has been triggered. If not, then proceed to the next step.

2. In WebPower, click on the “Commands” icon in the top bar.

3. Under the “System Commands” window, locate the “Reset Manual Alarm(s)/Silence Buzzer” line.

4. Click on the “Apply” button.

The rectifier alarm will then be silenced.

NOTICE: This "silence" only disables the alarm relay; the LEDs on the alarming rectifier remain illuminated.

Clearing a Rectifier Alarm Because a rectifier alarm is a latched alarm, it does not clear even if the failed rectifier is removed from the system. It must be cleared manually.

To clear a rectifier alarm:

1. Check all alarms to ensure that no critical or major alarm has been triggered. If not, then proceed to the next step.


2. Remove the failed rectifier.

3. Insert a replacement rectifier, or (if acceptable) leave the rectifier slot unpopulated (in the latter case, it is advisable to either reinstall the power blade cover or install a blank panel).

4. In WebPower, click on the “Commands” icon in the top bar.

5. Under the “System Commands” window, locate the “Reset Manual Alarm(s)/Silence Buzzer” line.

6. Click on the “Apply” button.

7. Locate the "Reset Number of Modules" button.

8. Click on the "Apply" button.

NOTICE: Resetting the number of modules will reassign rectifier ID numbers if the removed rectifier was not replaced.

Battery Discharge Alarm The battery discharge alarm issues an alarm if battery voltage drops to predetermined values. This section explains how to set the voltage values that trigger battery discharge alarms.

To set battery discharge alarm values:

1. In the WebPower interface, click on “Alarm Config.” icon in the top bar.

2. Click on "Battery" in the left bar.


3. Click on "Battery Alarm Configuration" to expand the battery alarms. Wait for the list to populate.

4. Click on the gears icon (next to the list number) to launch the edit window.

5. The edit window opens up under the “General” tab. At the very bottom, alarm thresholds can be set based on voltage values. There are four events for which to set battery voltage values: Major High, Minor High, Minor Low, and Major Low.

The alarm group assignments can also be changed under "Alarm Group."

6. If any changes are made, be sure to click the “Save” icon (diskette) in the

lower right hand corner.

Upload Configuration Files Controller configuration files can be uploaded from the SD card provided.

NOTICE: Power must be available on the control system in order upload the configuration to the controller.

1. Open the controller display by sliding the lever in the bottom right corner to the left. A pen or screwdriver may be needed in order to move the lever.


Figure 30 - Smartpack2 Master Unit Opened

2. Locate the SD card slot. It is directly behind the display, facing the open end of the controller when open, next to the Ethernet port. See Figure 31. There should be an SD card installed already.

Figure 31 - Side View of Open Controller Display

3. Is the current SD card to be used, or a new card?

3.1. If using the current SD card, then proceed to step 4.

NOTICE: If the current SD card is to be used but is not present in the controller, then contact site personnel. If the card cannot be located, please contact Eltek for a new one.

3.2. If using a new SD card for the software upload, push down on the card (into the display) and release in order to remove it. Then Install the new SD card. Make sure the contacts are oriented toward the front of the display, and the label is oriented to the inside of the bay.

4. With the SD card installed, go to the display screen to begin download (the display can be closed now).

5. Press the up key and then the down key to unlock the display screen.

6. Press the “Enter” key (center of keypad) to enter the menu.


SD Card slot (card present)

Ethernet


Figure 32 - The “Enter” Key

7. Navigate to the “Up/Dwnload” icon in the lower right corner and press the Enter key.

8. Navigate to the “Save/Load Config” line and press the Enter key.

9. Navigate to “Load Config from File” and press the Enter key.

10. The next page shows all of the control modules installed. Navigate

to one of the controllers to be upgraded and press the Enter key.

11. The controller requests a PIN. The default is 0003.

If the default PIN does not work, it has been changed on site. Contact site personnel for the current PIN.

12. Hit the Enter key twice to start the software upload. The screen will display “Programming…” at the bottom. This process takes about 90


seconds to complete. Wait until the screen indicates that programming is complete.

13. Repeat steps 11-13 for the remaining controllers.

14. OPTION: If desired, all controllers may be updated in order to ensure that the latest firmware is present on all units in the list.

LED Test LEDs can be tested on the controllers and rectifiers from the display panel of the Smartpack2 Master controller, as follows:



3. Highlight and select the "Commands" icon.

4. Highlight and select the "System Commands" line.

5. Highlight and select the "LED Test" line.

6. Enter the PIN-code (default is "0003").

7. The following prompt appears: "Enter – Execute / (X) – Cancel". Press the ENTER key to execute the LED test.

LEDs on all controllers (including the I/O Monitors) and rectifiers illuminate immediately and sustain for at least 3 seconds.

Alarm Relay Tests Alarm output relays can be tested from the display panel of the Smartpack2 Master controller, as follows:



3. Highlight and select the "Commands" icon.

4. Highlight and select the "System Commands" line.

5. Highlight and select the "Output Test" line.

6. Select the relay to test.

7. Enter the PIN-code (default is "0003"). The selected relay changes state.


5. Startup Checklist Quick Start Startup 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

Rack anchored to suitable location

Distribution circuits open

o Circuit breaker actuators switched OFF o Fuses REMOVED

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

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

Startup Procedure Turn on AC breakers and verify proper input voltage

Insert rectifiers in the desired order; system will power up

Insert converters (if applicable) in the desired order

Verify system startup 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 testsBattery 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


Quick Start Startup Checklist

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


6. 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 350020.013: User’s Guide—Smartpack2 Master Controller

o 350021.013: User's Guide—Smartpack2 Basic Controller

o 351509.003: Installation Guide—I/O Monitor2

Selected documentation and the Powersuite software for the Smartpack2 controller are located on the accompanying CD.

Additional product information is available online at eltek.sharefile.com.

For further assistance, please contact Eltek Technical Support at +1 (800) 435-4872 or [email protected].


7. Revision List Revision Published Description CO

1 05/31/13 First release. NA


Appendix – Power Shelf Configurations The following drawings illustrate the power (rectifier) shelf configurations that are available for the Trilogy power system.

NOTICE: All drawings depict just one distribution panel for reference.

NOTICE: All configurations can have one converter shelf installed at the very bottom. Converter shelves have the same mechanical dimensions as rectifier shelves and are labeled as converter shelves. See Figure 3 on page 16.

Figure 33 - Two Shelves for 24V/1800W 600A, 48V/2000W 300A, and 48V/3000W 400A

Figure 34 - Three Shelves for 48V/2000W 400A

Two Rectifier Shelves

Distribution Panel


Figure 35 - Three Shelves for 48V/3000W 600A

NOTICE: The 600A system for 48V/3000W rectifiers does not use the two right rectifier positions in the bottom rectifier shelf.

Figure 36 - Four Shelves for 48V/2000W 600A

NOT USED


Appendix – Breaker Bus Configurations The following drawings illustrate breaker bus configurations that are available for the Trilogy power system. The first four configurations use one distribution panel:

Figure 37 – Battery Shunt Only Configuration

Figure 38 – Load LVD (LVLD) and Battery Shunt

Battery breakers

CRITICAL load breakers

Rectifier Battery

SH1

‐ +

Y X

LVLD

Battery breakers

LVLD Load breakers

Rectifier Battery

SH1

‐ +


Figure 39 - Battery Shunt and LVD (LVBD)

Figure 40 - Load and Battery LVDs

Battery


Rectifier Battery

Y X

LVBDSH1

‐ +

LVLD


Rectifier Battery

Y X

LVBDSH1

‐ +

Y X

LVLD


The next four configurations use two distribution panels:

Figure 41 - Two Distribution Panels, Battery Shunt Only

Figure 42 - Two Distribution Panels, Load LVD and Battery Shunt

Battery breakers


Rectifier Battery

SH1

‐ +

BATTERY


BATTERY

LVLD Load breakers

Y X

LVLD

Battery breakers

LVLD Load breakers

Rectifier Battery

SH1

‐ +


Figure 43 - Two Distribution Panels, Battery Shunt and LVD

Figure 44 - Two Distribution Panels, Load LVD and Battery LVD

Battery


RectifierBattery

Y X

LVBDSH1

‐ +

Battery



The remaining four configurations include DC-to-DC converter shelves:

Figure 45 - Converter Shelf and Battery Shunt

Figure 46 - Two Distribution Panels, Converter Shelf and Battery Shunt

Converter


Rectifier Battery

SH1

‐ +

Converter

Converter


Rectifier Battery

SH1‐ +

Converter


Converter


Figure 47 - Converter Shelf and Battery LVD (LVBD)

Figure 48 - Two Distribution Panels, Converter Shelf and Battery LVD

Converter


Rectifier Battery

Y X

LVBDSH1

‐ +

Converter

Converter


Rectifier Battery

Y X

LVBDSH1

‐ +

Converter


Converter

Doc. No. 370003.033, Issue 1 Published 31-May-13

www.eltek.comUS Office: Eltek, Inc. 2925 E Plano Pkwy, Plano, TX 75074, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

International: Eltek AS

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

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