Eltek PRS Manuale utente

Quick Start Guide

Installation, Operation, Commissioning and Maintenance

DC Power Supply System

With or without Batteries, Wall-mounted, Modular

Flat

ack PS S

stem

356803.103

PRS

PRSB PRSV

(with external

batteries)

(w/ without

internal batteries)

MPSU

Miscellaneous

Communication

oInstalling WinPower Silver – PC software ( 9)

AC Mains

oExternal AC Fuses, Recommended Rating (10 )

Earthing

oAbout AC, DC Earthing Systems ( 11)

Battery Monitoring

oBattery Terminology (12)

oBattery Symmetry – Connections (12 )

Alarms & Monitoring

oFail-Safe Operation ⎯Alarm Relays & Digital Inputs (13 )

oTerminals & Pin-out Location, Alarm Card 100350 (13 )

oTerminals & Pin-out Location, Front Access Alarm Card 101825 (14 )

Introduction

oThe Flatpack Product Range (2 )

oBrief System Description (2 )

Installation

oInstalling Rectifier Modules and MCU Controller ( 3)

oInstallation steps; mechanical, electrical (4-5)

Commissioning

oPre-start check (6 )

oCommissioning steps, Startup (6-7)

Operation

oFront keys and display ( 8)

oSoftware Menus ( 8)

Check Lists

pullout forms

oInstallation Check List

oCircuit Distribution List

oCommissioning Procedure

oMaintenance Procedure

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

The Flatpack Product Range

Eltek Energy's Flatpack product range utilizes the Flatpack rectifier and the MCU controller as

building blocks for implementing effective DC power systems, suitable for a wide range of

applications and power ratings.

MPSU systems consist of the power system, which includes rectifiers and controller(s), and the

distribution unit (1U or 4U high). MPSU systems are sold primarily for mounting in existing

cabinets.

In PRS systems, the cabinet contains the power system and the distribution unit. In addition, the

cabinet may also enclose battery banks, additional distribution and other dedicated equipment.

Brief System Description ⎯Flatpack

The Flatpack PS system is a compact, powerful and cost-effective DC power supply system,

specifically developed for the telecom industry.

Example of a typical Flatpack PS system for DC power supply of telecom equipment. The system is fed

from an external AC mains supply, and consists of rectifiers in power shelves, a control unit and DC

distribution unit. Battery banks, LVD contactors, etc. are typically also a part of the system.

Introduction

Flatpac

PRSB

Batte

y st

ing #1

Flatpack MCU

(Ctrl. Unit)

Flatpack

(rectifiers)

C mains

supply

selector

Symmetry

Alarm &

Temp. Senso

LVLD

LVBD

AC Supply

(Single- or

three-

hase

)

Fuse Alarm

DC Supply

(24V, 48V

or 60V

)

AC Fuses,

external

(230VAC or

400VAC

Telecom

equipment

larm Outputs NC-C-NO

Digital Inputs

distribution

Batte

Fuses

Load Fuses

& MCBs

Service

wit

h+/-

MPSU

Modular Power Supply Unit

PRSV

Power Rack System

Wall-mounted PRSB

Power Rack System

with or without Batteries

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

Installing Rectifier Modules and MCU Controller

Installation

Handel in locked position

Hole to release the

handle’s spring mechanism

Flatpac

rectifier

Handel in

unlocked

osition

Flatpac

rectifier

Device

hazard

CAUTION:

- The modules may be warm, but do not hand-carry them by their handles

- Open the handles before inserting them into the power shelves

Mounting Flatpack rectifier modules

1. Open the handles by

inserting a screwdriver into the holes to release the spring

mechanism

2. Insert the module fully into the power shelf, so that it makes

proper contact

3. Lock the handles by

pushing the handles up into their housings (locked position),

so that the module makes proper contact and is secured locked

Removing Flatpack rectifier modules

1. Open the handles by

inserting a screwdriver into the holes to release the spring

mechanism

2. Remove the module

using both handles to pull the module loose; support from

underneath

3. Lock the handles by

pushing the handles up into their housings (locked position). It

is then ready for transport

4. Mount blind panels in

unused module locations

Electric

shock

Mounting and Removing the MCU Controller

Note that cables are plugged to the MCU’s rear panel. When

mounting the controller, you must plug the cables before step 2.

When removing it, unplug the cables during step 2.

1. Unlock the controller by

unscrewing the two fastening screws on the front

2. Insert or remove the module by

sliding it fully into the power shelf

using both handles to pull the controller loose. Unplug the

cables, when removing the MCU module

3. Lock the controller by

screwing the two fastening screws on the front. It is then

securely locked in the shelf. Or ensure the screws do not fall

out of the holes, when removing the MCU module

Handle

Fastening

holes

MCU Controlle

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

Installation Steps

Check off in the Installation Check List, that you find in the pullout section o

this folder. Also, refer to the system’s specific drawings.

For external AC fuses and AC input cable ratings, refer to your site’s AC

supply specification. Read also our external AC fuse recommendations

in section “Miscellaneous”. In general, a site with better AC supply

quality (stable nominal voltage) may use smaller breakers.

200 mm

600 mm

Flatpack PRS, batteries, Doc.

Chart, Spec. Drawings, CD-ROM

Installation

Preparing the installation site

Begin preparing the following:

1 Organize the installation site

oMin. clearances for cabinet access: 60 cm in front, 20 cm on top

oLevelled surface able to support 600 kg (PRSB),100 kg (PRSV)

oExplosive atmospheres are to be avoided. Ensure suitable

ventilation

o60V systems are only to be installed in Restricted Access

Locations (RAL)

2 Prepare the installation tools

oUse insulated tools suitable for telecom installations

3 Prepare AC Supply: AC input cable(s) and fuses

oCorrect type AC supply is available

oExternal AC fuses have correct rating

oAC input cable(s) are sized correctly

EMC

regard

Electric

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Mechanical Installation

Power is OFF!

Carry out the following:

4 Remove packaging and check equipment

oCheck you have received all the parts, correct cabinet,

documentation, batteries (if applicable), etc.

oInspect the equipment for physical damage (report any damages)

oLeave rectifier modules in their packaging or in the selves, if

factory installed. To be installed under commissioning

5 Remove top cover and dummy front panels

oCable entry from the top. Connection terminals are located behind

the upper dummy panels

oBattery shelves (if any) are placed behind the lower panels

6 Position and fasten the cabinet or subassembly

oPRSB cabinets are floor-mounted on levelled surface. Adjust the

legs if necessary. If the cabinet must be fastened, unscrew the legs

and use suitable bolts to fasten it to the floor

oPRSV cabinets are wall-mounted; keyholes facilitate fixing

oMPSU subassemblies are fastened in existing 19” or in ETSI

cabinets, using brackets. Mount the support & heat deflecting

plate under the lower power shelf

7 Mount the batteries on the shelves

oStart (if applicable) placing the batteries on the lower shelf first,

and continue upwards

oDo not terminate the battery cables yet!

Device

hazard

Uppe

fastening hole

Ø 7 mm

Ø 13 mm

550 mm

Ø 7.3 mm

10 mm

736.7 mm

Lowe

fastening hole

Wall

mounting distances

PRSV cabinets

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

Electrical Installation

Power is OFF!

Carry out the following: (Refer to the system’s specific drawings)

8 Make the system completely voltage free

oSwitch OFF or remove all load fuses (MCB1, MCBx), battery

fuses (Fb1, Fbx) and the AC supply fuses, in external fuse

boards

9 AC Connections

oCheck AC configuration: the AC terminals are correct configured

to the external AC supply, otherwise reconfigure the terminals

oConnect the AC Earth wire (PE) to the terminals AC Earth (PE)

oConnect the AC input cable(s) to the terminals. Cable and

terminal block labeling are to correspond

10 DC Connections ⎯Load Circuits

oTerminate DC Earth (TE), and check that the common DC

Output Rail is connected to “Telecom Earth” (TE) at only one

place (at the cabinet or at a central distribution point). Se

chapter about AC, DC earthing systems

oFor each DC load, connect one of the cables to the common DC

output rail, and the other directly to the MCB or load fuse

11 DC Connections ⎯Alarm & Signal Circuits

oRefer to your system’s connection drawings and configuration

(Factory Settings), or to the “Miscellaneous, Alarms &

Monitoring” section

oTerminate Alarm Circuit cables to the relay output terminals

oTerminate Signal Circuit cables to the digital input/output

terminals

12 DC Connections ⎯Battery Cables

Careful! Use correct polarity.

For each battery shelf: (refer to the figure in this page)

(In PRS systems, steps b, d and f are usually performed in factory)

a Mount 3 intercell links to connect in series 4 battery blocks

b-c Connect battery cables to fuses and common DC rail, and to

the shelf’s outer terminals; black (+); blue (-)

d-e Connect battery symmetry cables, if applicable, to the input

terminals, and to the center terminal of the battery string

(+). Deviation from factory settings requires Symmetry

reconfiguration via WinPower Silver

f-g Connect the temperature sensor cable, if applicable, to the

input terminals, and fix the temperature sensor (at the end

of the cable) to a suitable place in the middle of the

installed battery bank

Electric

shock

Installation

Block1

- ++-+-+-

Block4Block3

—

(-48V) Oute

Terminal

0V Oute

Terminal

Link 2

(DC Earth) Common

DC Rail

Chassis

Batter

Fuse

Intercell Links

Batter

Cable

Symmetry cable

Tem

. senso

Card Art.100986

CON4:11

…and

CON3:34-

35-36

Temp. Sensor cable

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

The commissioning of a Flatpack PS System consists of following stages:

I. Perform a pre-start check before the PS system is switched ON

II. Switch ON the system with disconnected load; adjust output voltage

III. Adjust the nominal output voltage with connected batteries and load

Pre-Start Check

Power is OFF!

Check off in the Commissioning Procedure, that you find in the pullout section of this folder.

If you have just finished the system installation successfully and filled in the Installation

Check List, jump over the Pre-Start Check and continue with stage II.

Before you switch ON the Flatpack PS system, verify the following:

1. System installation is completed

oEnsure a correctly performed system installation, with correct polarity on all

connections, has been carried out (Installation Check List filled in)

oAll cabling and copper bars are securely terminated and supported

oAll components, terminal blocks, MCBs/ fuses, etc. are clearly labeled

2. Battery and load fuses are disconnected

oVerify that all battery and load MCBs/ fuses are switched OFF or removed

3. AC input cable(s) and AC Earth wire (PE) are terminated

oMake sure that the AC input cable(s) are connected to correctly configured AC terminals

oVerify that the AC input cable(s) and external AC fuses are sized and rated as specified

oCheck that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)

4. Site specific parameters and settings are known

oRead the system specific drawings and documentation

5. AC supply and all MCBs, fuses are switched OFF

oMake sure that all external AC fuses and internal MCBs/ fuses are switched OFF

Commissioning Steps, Startup

Check off in the Commissioning Procedure, that you find in the pullout section of this folder.

After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you

will switch ON the Flatpack PSS — while the batteries and load are disconnected ⎯then

measure the output voltage, and adjust it if required. Carry out the following:

Startup and No-Load Adjustments

Power is ON!

1. Disconnect all rectifier modules, without removing them

oRead how to install modules, on page 3 in this guide. and then

oIf Flatpack rectifier modules are installed, unlock the handles and pull the modules

partially out (fan housing visible), but do NOT physically remove them from the

power shelves

oIf Flatpack rectifier modules are not yet mounted, release their handles and insert

them partially into the shelves

2. Switch ON the system

oSwitch ON the AC input supply (external AC fuses) to the PS cabinet

3. Measure and verify that the AC input voltage is correct

oMeasure the AC input voltage at the cabinet’s mains connection box

oVerify the AC voltage is within range

Commissioning

Device

hazard

Device

hazard

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

4. Mount all Flatpack rectifier modules in the power shelves

oPush all rectifiers firmly inwards ⎯one module at a time, allowing a 2s delay ⎯

to plug them in the shelf. Lock their handles. Refer also to page 3 in this guide

oMount blanking panels over unused positions

5. Ensure that the MCU controller and all rectifier modules are working: LEDs are ON

oVerify correct operation, by monitoring the modules’ LED lamps and display:

No alarms are present on rectifiers; The MCU controller displays fuse alarms

6. Connect a PC to the PS system (to facilitate operation)

oPlug the correct serial cable between the PC and the MCU controller

oStart WinPower Silver on the PC (click on Start>All Programs>Eltek>WinPower Silver)

oConfigure equal communication parameters on the MCU and the PC.

Refer to chapter “Installing WinPower Silver ⎯PC Application”, page 9, if required

7. Measure and adjust DC output voltage

oRead the DC output voltage on the controller’s display

oWith a multi-meter, measure the DC output voltage at the most accessible point, e.g.

between the common DC rail and the lower connection of one of the priority load MCBs

oIf required, adjust the voltage using the controller’s front keys or via WinPower Silver

8. Verify the alarm relays are working correctly (alarm relay test)

oRun the alarm relay test using the controller’s front keys (refer to page 8) or via

WinPower Silver (click the “General Information” button; then the “Relay Test” tab)

9. Make sure the System Setup is in accordance with configuration

oVerify system settings using the controller’s front keys or via WinPower Silver

oUse the opportunity to enter site related information, type of batteries, etc. (Click

the “General Information” button; then the “Site Information” tab)

Load Adjustments

Power is ON!

Now, you can begin with stage III, where you will adjust again the output voltage to the

battery voltage, and connect the batteries and the load. Carry out the following:

10. Adjust DC output voltage to equal measured battery voltage

oMeasure the battery voltage is within range (check connections have correct polarity)

oAdjust DC output voltage — using the controller’s front keys (refer to page 8) or via

WinPower Silver— to equal the measured battery voltage.

(Important adjustment to avoid arcing when connecting the batteries)

11. Unplug all rectifiers but one, and connect the battery fuses /MCBs

(CAUTION: Have only one rectifier connected, when switching ON the battery fuses.

Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.)

oDisconnect all rectifiers but one, by unlocking the handles and pulling them partially

out (fan housing visible). Do NOT physically remove them from the power shelves

oSwitch ON all battery fuses or MCBs

12. Adjust DC output voltage again to equal the nominal battery voltage

oAdjust DC output voltage — using the MCU’s front keys or via WinPower Silver — to

equal the nominal battery voltage (or the nominal load voltage, when not using batteries)

13. Plug in again all rectifiers, and verify the rectifiers’ current sharing

oConnect all rectifiers again by pushing them firmly inwards ⎯Repeat step 4, in stage II

oWait for about 2 min., and check — reading the LED bar graph on the rectifiers’ font

panel — that each of the rectifiers delivers the same output current. A ±5 % deviation is

acceptable. (Each LED represents 3A approx.)

14. Connect the load breakers and verify that no alarms are displayed

oSwitch ON all load MCBs/ fuses

oVerify correct operation: rectifiers and controller display no alarms

Commissioning

Device

hazard

Device

hazard

III

Quick Start Guide Flatpack PS System

356803.103, v4-2006-10

Firmware 402080.009 5v1

Service menu <ServiceOption>

Password= 0003

lish

German

Norwe

ian

Lan

e Polish

French

anish

Comm

Protocol Trace *

Comli

9600

Set baud 1200

2400

4800

MODEM sense MODEM sense: ON

MODEM sense: OFF

* “Trace” is for internal factory use

Level 2 Level 3

Front Keys and display, menus, etc.

Flatpack rectifier module — front panel, left side

Power LED is OFF (mains unavailable) or ON

(powered). Alarm LED is ON (shutdown or similar

major alarm) or OFF (OK, no alarm)

Output voltage is factory adjusted on delivery. In

stand-alone operation (MCU ctrl. unit is not used),

you can use the potentiometer to adjust the output

voltage.

MCU Control Unit — front keys, display, etc

Display: is in Status Mode (displays the system’s

status) or in Menu Mode (displays the menu structure).

Operation: Press on the

key to change from

Status Mode to Menu Mode. Press the

keys to scroll up or down and navigate to find menu

options (function or parameter). Press then the

key to select the function.

Menus: When you “enter” Menu Mode, you access

the User Options. You may also scroll down to

password protected Service Options. Default password

<0000> and <0003> should be changed.

Software Menus

LED bar graph

Output current scale, 10 green LEDs (3A each)

0A scale mark

Alarm

LED Lamp (red)

Powe

LED Lamp (green)

30A scale mark

Potentiomete

Output voltage adjustment

Flatpack rectifie

RS232C

D-Sub 9 pins

female

LCD dis

Alarm

LED Lamp (red)

”Up” arrow key

”Down” arrow key

”Enter” key

MCU control unit

Service menu <ServiceOption>

Password= 0000

NomVolt

BoostVolt

LowBatt1

LowBatt2

oltAd

ustment Hi

hBatt1

hBatt2

LVD 1

LVD 2

LVD 3

Calibration VoltCal

SetDefaultCalib.

Chan

ePassword ÆPassword

SetBoostTime ÆBoostTime

Start

Sto

Boost ÆStartBoost/Sto

Boost

Auto Boost Cfg. Enable/Disable

Threshold

IntervalTest Date Time

Test End Volt

Batt Test Setu

Max Test Duration

Test Interval

Test Dela

Period

Start

Sto

Test ÆStart Test/Sto

Test

Charge Curr Lim Enable/Disable

Max Char

e Cur

Batter

Setu

ÆNumber of banks

Number of rectifiers

Capacity Al.Cfg. Current pr rectifier

Alarm limit

Temp.Comp

Out

utControl Volta

e Control

Presat Rect.Volt

Chan

e Date/Time Date

Time

Rela

s 2…10

Rela

Test Rela

LVD1 rela

LVD2 rela

LVD3 rela

Level 2 Level 3

Firmware 402080.009 5v1

User menu <UserOption>

System ON/OFF ÆTurn system ON/OFF *

Alarm Reset ÆAlarm Reset

NomVolt

BoostVolt

LowBatt1

LowBatt2

VoltageInfo HighBatt1

HighBatt2

LVD 1

LVD 2

LVD 3

DisplayMessages ÆDisplay messages

Sw Info ÆSwInfo

* The ON/OFF function may be disabled in some

systems

Level 2 Level 3

Firmware 402080.009 5v1

Operation

Keys & Menus

PULLOUT

Check Lists Pullout

Pull out the pages with the gray outer band,

and use them as check lists

INSTALLATION CHECK LIST

System Data

Flatpack PS System

Flatpack Power Supply System, type: Article No.:

Site, name:

Serial No.: Software, version No.: Rectifiers, type & number of:

AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:

Site Preparations

CARRY OUT FOLLOWING

1. Organize the installation site

oCheck min. clearances for cabinet access: front access, 60cm, top access, 20cm

oCheck that the levelled surface is able to support 600 kg (PRSB systems), 100 kg (PRSV systems)

oEnsure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas



2. Prepare the installation tools

oCheck that insulated tools suitable for telecom installations are used



3. Prepare AC Supply: AC input cable(s) and fuses

oCheck the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated



Mechanical Installation

Power is OFF!

CARRY OUT FOLLOWING

4. Remove packaging and check equipment

oCheck you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc

oInspect the equipment for physical damage (report any damages)

oLeave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)



5. Remove top cover and dummy front panels

oCheck that cable entry from the top is possible



6. Position and fasten the cabinet or subassembly

oPRSB cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor

oPRSV cabinets are wall-mounted. Keyholes facilitate fixing

oMPSU subassemblies in existing 19” or in ETSI cabinets, using brackets. Mount support & heat deflecting plate



7. Mount the batteries on the shelves

oStart (if applicable) on the lower shelf first, and continue upwards

oDo not terminate the battery cables yet!



Electrical Installation

Power is OFF!

CARRY OUT FOLLOWING

8. Make the system completely voltage free

oSwitch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses



9. AC Connections

oCheck AC configuration: The AC terminals are correct configured to the external AC supply

oConnect the AC Earth wire (PE) to the terminals AC Earth (PE)

oConnect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond



10. DC Connections ⎯Load Circuits

oTerminate DC Earth (TE):

Common DC Output Rail is connected to TE at only one place

oFor each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB



11. DC Connections ⎯Alarm & Signal Circuits

oRefer to your system’s connection drawings and configuration, or to the Factory Settings in the Quick Start Guide

oTerminate Alarm Circuit cables to the relay output terminals

oTerminate Signal Circuit cables to the digital input/output terminals



12. DC Connections ⎯Battery Cables Careful! Use correct polarity.

For each battery shelf,

oMount 3 intercell links to connect in series 4 battery blocks

oConnect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; black (+); blue (-)

oConnect battery symmetry cables, if applicable, to the input terminals, and to the battery string

oConnect the temperature sensor cable, if applicable, to the input terminal, and fix the sensor (at the end of the

cable) to a suitable place in the middle of the installed battery bank



Approval

Responsible of installation, sign.: Date: Approved by customer, sign.:

EMC

regard

Electric

shock

Device

hazard

Electric

shock

Form XXX-gb-v1-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11

Eltek Energy AS

Tel. +47 32 20 32 00

Internet: www.eltekenergy.com E-Mail: [email protected]

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