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Installation Guide

PRSB 9kW, 48VDC


351434.033
Information in this document is subject to change without notice and does not represent a commitment on
the part of Eltek Energy AS.
No part of this document may be reproduced or transmitted in any form or by any means electronic or
mechanical, including photocopying and recording for any purpose without the explicit written
permission of ELTEK Energy.

Copyright : Eltek Energy AS, Norway 2006


NS-EN ISO 9001:1994 Certificate no: 900005Q
NS-EN ISO 14001:1996 Certificate no: 900005E
This product holds a CE mark and satisfies all requirements covering relevant standards and directives.

EMC LVD
EN61000-6-2 Industrial Environment LVD73/23/EEC Low Voltage Directive
EN61000-6-3 Residential, Commercial and Light Industry EN60950 Safety of Technology Equipment
ETS 300386 v1.3.1 Telecommunication Equipment UL60950,UL1801

Certificate no: 900005Q Certificate no: 900005E

Head Office:
Eltek Energy AS
P.O. Box 2340 Strms
N-3003 Drammen
NORWAY
Phone: (+47) 32 20 32 00
Fax: (+47) 32 20 32 10 POWER
E-Mail: eltek@eltekenergy.com DISTRIBUTION
Internet: http://www.eltekenergy.com
CENTER FOR
COMMUNICATIONS
EQUIPMENT
This product is made according to EU directive 2002/95/EC (RoHS) 9N73
and 2002/96/EC (WEEE).

Art. No. 351434.033 Issue 3, 2006 July


Published 2006-07-18

Flatpack PRSB 9kW, 48VDC (Outdoor Site Power Cabinet, Fan Cooled) has part no. CF1017.001

2 Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Table of Contents

1 DESCRIPTION OF FLATPACK PRSB 9KW, 48VDC 4


IMPORTANT NOTICE 4
OVERVIEW GENERAL ARRANGEMENT 4
INPUT AND DISTRIBUTION ARRANGEMENT 5
AC INPUT TERMINALS 5
MONITORING, CONTROL AND SIGNAL INTERAFCE 6
SYSTEM MONITORING 6
RECTIFIER INSTALLATION - MAINS SUPPLY BALANCING EFFECT 7
RECTIFIER INSTALLATION - HANDLES AND LOCKING MECHANISM 7
FAN & HEATER OPERATION 8
ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS 8
CONNECTIONS FOR INTERNAL SYSTEM WIRING 9
CUSTOMER CONNECTIONS 10
CONNECTIONS FOR GMT FUSES 10

2 INSTALLATION PRODECURES 12
SAFETY PRECAUTIONS 12
UNPACKING AND MECHANICAL INSTALLATION 12
ELECTRICAL INSTALLATION 13
COMMISSIONING 16
MAINTENANCE 16
REPLACEMENT OF FILTER, INTERVAL 16
REPLACEMENT OF DOOR FILTER 17
REPLACEMENT OF FAN FILTER 17

3 SPECIFICATIONS FLATPACK PRSB 9KW, 48VDC, FAN COOLED 19


SPECIFICATION 19

APPENDIX: SCHEMATICS, DRAWINGS, FIGURES ETC. 20


A1 - GENERAL ARRANGEMENT DRAWING 20
A2 - SYSTEM SCHEMATIC PRSB 9KW, 48VDC, OUTDOOR CABINET, FAN COOLED 21
A3 - DRILLING TEMPLATE 22
MCU DEFAULT SETTINGS PRSB 9 KW, 48 VDC 23

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07 3
1 DESCRIPTION OF Flatpack PRSB 9kW, 48VDC

This Installation Guide contains information about how to install the Flatpack PRSB 9kW, 48VDC system 1 ,
for the outdoor site power cabinet, fan cooled. Please, refer to the systems Documentation Set (art. no
351405.003) for an overview of related user documentation.

IMPORTANT NOTICE
To be installed only in restricted access areas or the like, in accordance with articles 110-16, 110-17, and
110-18 of the National Electrical Code, ANSI/NFPA 70.
For supply connectors use wires suitable for at least 75C (167F).
Type: FEPW, RH, RHW, THHW, THW, THWN, ZHHW, USE, ZX or similar.
Use copper conductors only.

OVERVIEW GENERAL ARRANGEMENT


The Flatpack PRSB 9kW, 48VDC is a DC power supply system based on the Flatpack 1500 48V rectifier.
The system contains AC terminal blocks, DC distribution, Flatpack Power Rack, Flatpack 1500 rectifier
modules and the Flatpack Monitoring and Control Unit (MCU). The system is designed for cable entry from
top. The cabinet size is 770 (778 incl. cable entry) x 820 x 1300mm (30.3 (30.6) x 32.3 x 70.9) (WxDxH).

DC Load Distribution:
MCBs, Mains, Alarm
and Signal Terminal Heater MCB (AC)

Battery strings, one


shelf is optional kit
LTE Distribution,
MCBs optional kit (not
present on picture)

Air filter

Figure 1: Flatpack Power Rack system General Arrangement. The system consists of 1 battery shelf.

1
PRSB = Power Rack System with Batteries

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
4
INPUT AND DISTRIBUTION ARRANGEMENT

Cabinet main Protective Earth (PE)


Connected to powercore PE. Positioned in the ceiling

-Ve DC Load Terminals (BTS MCBs)


On top of each load breaker, 25mm2, 4AWG, 70mm2, 2/0AWG
-Ve Battery terminals
Bus bar, 35mm2, 2AWG +Ve DC Load Terminals
Common positive bus bar, 70 mm2, 2/0AWG
+Ve Battery Terminals
Common positive bus bar, 70mm2, 2/0AWG

DC Earth (TE) terminal M6


AC Earth (PE) terminal M6

AC Mains Terminals

Terminals for GMT 10A Load


Fuses, 1.5mm2, 16AWG

Con 5, Alarm Terminals


1.5mm2, 16AWG (Front access)
Figure 2

MCU Ctrl.Unit, and CON 4, Monitoring Terminals


(Back MCU)

Figure 2: Location of components in The Powercore; contains Distribution and Power Racks

AC INPUT TERMINALS
The AC terminal blocks are factory configured for mains supply type: 400VAC, 3 phase and N.

L2-bar L3-bar

L1-bar N-bar

L2
(Terminal for
L3
incoming wire)
(Terminal for incoming
wire)

L3 (neutral)
(Terminal for incoming
wire)
Labels on internal wires
(Wires may be reconnected to
match the sites type of AC
mains supply)

Figure 3: AC input terminal blocks for L1, L2, L3 & N

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
5
AC Input Feed Sizing
(Recommended AC Breaker Rating)
An external breaker VAC Input 9 kW Th/Mag 9 kW Hy/Mag
is required on all 400 VAC +N 25A C-char. 20A C2-char.
sites. This should be 3 ph
turned OFF during 230 VAC 3 32A C-char. 32A C2-char.
installation. ph
230 VAC 1 25A C-char. 20A C2-char.
ph

It is possible to reconfigure the AC terminal block for connection of 230VAC, 3 phase supply. To do so,
rewire the internal (blue) wires as described in the table below and connect the AC mains supply cable to
terminals L1, L2 and L3.

AC Terminal Block AC Terminal Block


400VAC, 3ph+N 230VAC, 3ph
Internal Wire Connections Internal Wire Connections
Internal Wire Wire Color Connected to Internal Wire Wire Color Connected to
(Labeled) Terminal Bar (Labeled) Terminal Bar
L1,1 Black L1-bar L1,1 Black L1-bar
N1(L2) Blue N-bar N1(L2) Blue L2-bar
L2,1 Black L2-bar L2,1 Black L2-bar
N1(L3) Blue N-bar N1(L3) Blue L3-bar
L3,1 Black L3-bar L3,1 Black L3-bar
N1(L1) Blue N-bar N1(L1) Blue L1-bar
Factory configuration Customized configuration

To connect the system to 1 AC Input Connection


phase from a 230VAC-system 1-phase
or a 400VAC + N-system External Wire Connections
connect the input cables as AC configuration in
illustrated in the table to the Terminal Block
right. 400 VAC + N 230 VAC
Input 400VAC + L1 L1-terminal L1-terminal
(230VAC, 3ph or N N N-terminal L2-terminal
400VAC, 3ph + 230VAC L1 L1-terminal L1-terminal
N) L2 N-terminal L2-terminal
1 phase configurations

MONITORING, CONTROL AND SIGNAL INTERAFCE


The Flatpack PRSB 9kW, 48VDC is available with basic functionality for monitoring and control of the
system. It is equipped with:
Relay outputs, 8 pcs
Digital inputs, 5 pcs

One of the interface boards (Eltek p/n: 200920) is located behind the MCU (with rear access to the
terminals), while the other board (Eltek p/n: 200958) is mounted on top of the MCU (with front access to the
terminals).
See Figure 8 Customer connections interface, page 10.

SYSTEM MONITORING
The Flatpack MCU (Monitoring & Control Unit) monitors and controls the entire rectifier system including
distribution and batteries, as well as other equipment on site. The unit also incorporates a communication
port for connecting computers via the RS232C interface.
The Flatpack system can be operated and configured locally via the keypad on the MCU unit by selecting
commands from set-up menus in a hierarchical menu system.

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
6
Please refer to the Flatpack MCU Operation Guide for detailed information about system monitoring.
Remote system monitoring and configuration may also be performed using WinPower Silver a Windows-
based program that runs on a connected PC.
The following configuration tasks require the use of a PC:
Installation settings
System calibration
Battery configuration
Alarm setup
Alarm log retrieval
Site information
Site specific configuration

RECTIFIER INSTALLATION - Mains Supply Balancing Effect


The Flatpack PRSB system may be expanded to a maximum of 6 Flatpack 1500 rectifiers. In order to load
the AC supply net evenly similar current load from the 3 phases of the mains supply it is advisable to
mount the required number of rectifiers in the following order:
MCU Rectifiers
st
4th Pos
1 Pos (on L1)
(on L1)
5th Pos
2nd Pos (on L2)
(on L2)
3rd Pos 6th Pos
(on L3) (on L3)

Figure 4: Rectifier mounting order to load the mains supply evenly


When possible, mount an equal number of rectifiers on each phase, L1, L2 and L3.

RECTIFIER INSTALLATION - Handles and Locking Mechanism


The Flatpack 1500 rectifier module is equipped with handles that serve two purposes:

Locking the module into position

Open both handles, insert and plug the module into power shelf. Then lock
it into position by rotating the handles upwards and pushing them firmly
home. Failure to do so will prevent the module from making proper contact.
Figure 5: Module with released handles

Pulling the module out


Unlock and release the handles by inserting a small
flat screwdriver into the upper holes. Do not use Upper hole which
excessive force. The handles will release and pop out. releases the spring
When both handles are released, use them to pull out mechanism
the module.
Do not hold or carry the rectifier by its handles.

Handle in locked position


Figure 6: Releasing the modules handles

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
7
FAN & HEATER OPERATION

The fan runs as soon as the temperature in the cabinet passes 25oC (77F). Hysteresis is 1C (1.8F).

The heater is controlled through a thermostat and the heater starts up at 5C (41F).

ALARM RELAY OUTPUTS AND SIGNAL CONNECTIONS

The digital inputs are configured as fail-safe, i.e. if the input is enabled,
Input 1
it will trigger an alarm when the input is open. If several external AGND
devices are to be connected to the same digital input, they must be
connected in series.
The alarm relays are also operated in fail-safe, i.e. the relays are
energized when there is no alarm. The description below describes the CON4
pin out in normal state, i.e. the REL output is closed to COM in normal External device
operation and the REL output is open to COM in an alarm-state. alarm state

Alarm relay specifications:


Nominal switching capacity 2A/30VDC
Maximum switching power 60W (resistive load)
Maximum switching voltage 220VDC
Maximum switching current 2A DC

Interface Backwiring Connection Pin Out

Figure 7: Backwiring interface and internal terminals (max. 1.5 mm2, AWG 15). Art no. 200920

Terminal Description Terminal Description


CON 2 Internal system connections CON 41 Customer connections (digital inputs, temp sense.)
CON 3 Internal communication CON 42 Customer connections (Symmetry, etc.)
CON 5 Customer connections (alarm relay outputs)

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
8
CON 41 Pin Assignment
for basic PCB version, art. No. 200920

Pin Signal Function Pin Signal Function


1 Screen Battery Temperature Sense 12 + Digital Input 5
2 + 13 AGND Door Open
3 -
4 + Digital Input 1
5 AGND (Programmable)
6 + Digital Input 2
7 AGND Phase 1
8 + Digital Input 3
9 AGND Phase 2
10 + Digital Input 4
11 AGND Phase 3

CON 42 Pin Assignment


for basic PCB version, art. No. 200920

Pin Signal Function Pin Signal Function


1 + Digital input 11 + +21V Auxiliary Supply
2 AGND Battery symmetry 12 (for modem or ext.equipment)
(not used)
3 + Battery Symmetry 1
4 - (analogue input))
5 + Battery Symmetry 2
6 - (analogue input)
7 + Battery Symmetry 3
8 - (analogue input)
9 + Battery Symmetry 4
10 - (analogue input)

CONNECTIONS FOR INTERNAL SYSTEM WIRING


CON3 is used for rectifier and power shelf communication. CON2 is used for internal system wiring, which
has been done at the factory. These connectors are not involved in the system installation and
commissioning process. The table below shows the pin assignment for CON2:
CON 2 Pin Assignment
for basic PCB version, art. No. 200920

Pin Signal Function Pin Signal Function


1 + Shunt 2: 9 + Battery Fuse State
2 Battery current measurement (digital input)
3 + Shunt 1: 10 + Load Fuse State
4 Battery current measurement (digital input)
5 + Auxiliary Supply 11 LVBD control
6 (for Flatpack MCU) (Battery Disconnect contactor)
7 VDC+ Voltage Sense 12 LVLD control
8 VDC (system signal reference) (Load Disconnect contactor)

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
9
Customer Connections

Figure 8: Customer connection, relay output (max. 1.5 mm2, AWG 15). PCB art.no: 200958

Relay Out Pin Assignment


for basic PCB version, art. No. 200958

Pin Signal Function Pin Signal Function


3 REL 8 Relay 8: 11 REL 4 Relay 4:
4 COM 8 Phase 3 Alarm 12 COM 4 Load / Battery Fuse Alarm
5 REL 7 Relay 7: 13 REL 3 Relay 3:
6 COM 7 Phase 2 Alarm 14 COM 3 Low Battery Alarm
7 REL 6 Relay 6: 15 REL 2 Relay 2:
8 COM 6 Phase 1 Alarm 16 COM 2 High Battery Alarm
9 REL 5 Relay 5: 17 REL 1 Relay 1: In use for Fan
10 COM 5 Module Alarm 18 COM 1 High Temp Alarm/

WARNING:
Do not connect external cables to relay 1 as this is used for fan control.

CONNECTIONS FOR GMT FUSES

Pin 16 Pin 1

GMT fuses
Max. 10A each

2
Figure 9: GMT fuse board (max. cable size 1.5mm )

10Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
The table below shows the pin assignment for the GMT load fuse board:

Pin Assignment for GMT Fuse


Pin Signal Function Pin Signal Function
1 + GMT fuse 1 (F5) 9 + GMT fuse 5 (F9)
2 10
3 + GMT fuse 2 (F6) 11 + GMT fuse 6 (F10)
4 12
5 + GMT fuse 3 (F7) 13 + GMT fuse 7 (F11)
6 14
7 + GMT fuse 4 (F8) 15 + Fuse 8 (F12) 10A
8 16
In use for FAN

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
11
2 INSTALLATION PRODECURES

This section describes how to install the Flatpack PRSB 9kW, 48VDC. Step-by-step procedures will guide
you through the installation.
For full description of the Flatpack Rectifier and the Flatpack MCU monitoring and control unit, please refer
to the Operation Guides for the respective modules.
SAFETY PRECAUTIONS
The equipment described in this manual must only be installed by authorized
personnel and only operated by persons who have attended a suitable Eltek Energy
training course.

The equipment represents an energy hazard and failure to observe this could cause
terminal injury and invalidate our warranty.

There are hazardous voltages inside the rectifier system. As the rectifier units
incorporate large charged capacitors, you should show precaution when working
inside the system even if the mains supply is disconnected.

Products into which our components are incorporated have to comply with a number
of requirements. Installation is to be in accordance with the recommendations herein.

Please read the manual carefully before using the equipment.

UNPACKING AND MECHANICAL INSTALLATION


Step Comments OK
Take the Flatpack Power System out of the packing and inspect it for
1. UNPACK THE FLATPACK
any physical or transit damage, and tighten the screws that connect
POWER SYSTEM OUT OF
conductors. Report any transit damage to Eltek Energy immediately.
THE PACKING

Drill holes in the ground according to the drilling template located on


2. DRILL HOLES IN THE
page 22, figure 12.
GROUND
Eltek recommends that the system isnt mounted directly to the ground
without a plinth or similar structure.
Position the cabinet in the required location. The floor construction
3. POSITION THE CABINET
must be capable of supporting the equipment.
Bolt the cabinet to the ground/plinth. Bolts are not included in the
4. BOLT THE CABINET
cabinet. If a plinth is used, refer to Installation Guide, Kit for Plinth,
Doc. No. 351416.033.

5. REMOVE
CONDENSATION STOPPER

The condensation stopper (yellow plastic)


prevents humidity from entering the cabinet and must therefore not be
removed before cabinet is powered up. Humidity before powering up
the system may cause serious damage to the system.

12Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
WARNING:
Live bus bars underneath opening inner roof. You are operating in a live
Electric
system. Precaution must be taken when working in this area. shock

ELECTRICAL INSTALLATION
For location of components see Figure 2 - page 5, Figure 3 - page 5 and Figure 10 - page 20.
Step Comments OK
The cabinet roof is locked with 2 triangle locks with access from inside the
1. OPEN THE ROOF
system. Open these locks and lift up the roof. The key is located on the left
hand side of the cabinet. Secure the roof during installation with the rod on
the left side under the roof.

Avoid placing cables on top of cable entry as this will block the filter
2. CABLE ENTRY
entry

Filter entry

DO NOT USE A KNIFE


TO MAKE THE HOLE,
USE A SCREW DRIVER
OR EQUIVALENT!

Cable (all phases in one cable) max 6mm2 each


Single phase cable (one cable per phase) max 35mm2

Marcon 25 multigate
The picture below show how to cut the grommets. The cut must be
smaller than the cable diameter:

Push cable(s) through the grommet(s):

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
13
Step Comments OK

Go back to the grommet and pull the cable back approx. 10mm. This
will lock the cable in the grommet and ensure full IP protection.
Secure cables with cable tie to the cable bracket

Cable bracket

The AC Earth (PE) and DC Earth (TE)


3. EARTH
terminals are mechanically connected to
CONNECTIONS
the cabinet chassis.
The Common Positive Bus bar is
internally cabled to DC Earth (TE);
therefore the positive output of the
rectifiers is connected to ground (TE),
and the negative output represents the
48VDC supply voltage.
If required, remove the internal cable that connects the positive bus bar
to local PE
Locate AC connections in the top area of the cabinet. Make sure that the
4. AC CONNECTIONS
cable(s) are long enough (+10mm).
PE terminal

AC-connections
Switch OFF the AC input power (external MCBs), before connecting the
cable
There are two pre-installed MC 25 Cable entries in the cabinet. These
can be mounted on rear, left and right side of the cabinet.
To change position, remove MC 25 from existing position. Remove Blind
Panel from the position were you want the cable entry. Store all fixings in
a safe place.
Then remount MC 25 in the preferable position and remount blind panel
in the empty space
Connect the external AC ground wire to the protective earth (PE
terminals)
If you are using double lug PE cable connect to the cabinets main PE
terminal. See page 5.
Connect cables to L1-L2-L3-(N)
The system is prepared for an AC socket located to the right side of the
5. AC SOCKET
cabinet. This AC outlet is intended for optional equipment. Due to the
many different socket types all over the world, no socket is delivered with

14Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Step Comments OK
the system.
Turn off the AC breaker. Connect the cables L, N and PE to the preferred
socket type and mount the socket to the bracket.

6. LOAD / BTS
CONNECTIONS

Turn OFF the Load/BTS MCBs


Turn OFF the PRS battery MCBs on the left side of the cabinet
The kit includes two copper links; one for 100A (2-pole) and one for 150A
(3-pole). If the load current is larger than 50A, use the 2-pole copper link.
Then the 3rd hole in the breaker cannot be used. If the load current is
larger than 50A, use the 2-pole copper link. Mount the chosen copper
3-pole link on to the top of the MCB.
link for CBI MCB
Connect the orange alarm wire to the MCB
Connect the positive cable(s), max 70mm2 (AWG 2/0), to the common
positive bus bar on the top of the power core 2
Connect the negative (-48V) cables, max 25mm2 each (AWG 3), to the
top of the MCBs. By connection of a single cable to the 2- or 3-pole
copper link max area is 70mm2 (AWG 2/0).

2-pole
link for CBI MCB

Connect the adequate cables, 1.5mm2 (AWG 16), to the GMT fuse board
7. GMT FUSE
according to the table on page 11
CONNECTION

The positive and negative (-48V) battery cables are connected from the
8. BATTERY
factory to the common positive bus bar and to the battery MCBs (excluding
CONNECTIONS
additional battery string kits). The battery temperature sense cable is also
pre-wired to CON4, and temporally fixed to the cabinets back wall.
Connect the battery cables to the battery terminals; blue cable to the
negative terminal and black cable to the positive terminal
Connect all battery inter-cell links
Place the temperature sensor, located at the end of the battery
temperature sense cable, on top of the topmost battery string
9. CONNECT ALARM You can now connect all external alarm wires to the front relay access card
WIRES located above the MCU. See figure 2 page 5 for location.

10. PLUG IN Plug in the rectifiers and make sure you balance the rectifiers over the faces
RECTIFIERS

Please follow the chapters Pre-Start Check and Start-Up Procedure in the
11. POWER UP
manual Commissioning Guide Flatpack 1500 DC Rectifier Plant, doc.no.

2
The bus bar is prepared for connection of stripped cables (app. 30mm) or with ferrules. Clamps are fitted at delivery.

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
15
Step Comments OK
360006.163
Remove the condensation stopper placed in front of both filters; inside door
12. REMOVE
and in front of fan:
CONDENSATION
STOPPER

COMMISSIONING
For information regarding system commissioning, please read manual Commissioning Guide Flatpack 1500
DC Rectifier Plant, art. no. 360006.163.

MAINTENANCE

WARNING:
You are operating in a live system. Precaution must be taken when changing
filter in front of the fan. Electric
shock

Replacement of filter, interval


FOR DOOR Locations:
Pollution degrees: Car park/road side: City roof top: Non central:
Low 1 year 2 years 3-4 years
Medium 1 year 2 years 3-4 years
High 6 months 1 year 2 years

FOR FAN Locations:


Pollution degrees: Car park/road side: City roof top: Non central:
Low 4 year 8 years 12 years
Medium 4 year 8 years 12 years
High 2 years 4 year 8 years

16Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Replacement of Door filter
Step Comments OK
Remove the filter grid by pushing it slightly up and then pulling it towards you
1. REMOVE FILTER
Exchange the old filter with a new. Make sure that the smooth side of the
2. EXCHANGE FILTER
filter faces the inside of the cabinet (the rough side of filter should not be
visible).
Fasten the frame to the door again and push it slightly down when the hinges
3. FASTEN FRAME
are in place.

Air filter, fine side facing


inside of cabinet

Replacement of Fan filter


Step Comments OK
Remove fuse for fan, located at the GMT fuse card
1. DISCONNECT FAN

2. OPEN TOP OF
CABINET

The fan filter is located behind the power equipment and should be removed
from the top of the cabinet

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
17
Step Comments OK

3. REMOVE FILTER
GRID

Remove the filter grid by pushing it slightly up and then pulling it out and up
towards you

4. EXCHANGE FILTER

Exchange the old filter with a new. Make sure that the smooth side of the
filter faces the inside of the cabinet

5. FASTEN GRID

Fasten the filter grid by pushing it slightly down when the hinges are in place
Replace the fuse for fan and verify that the system is operating normally
6. CONNECT FAN
Close the top of the cabinet and lock it with the key found on the left side
7. CLOSE TOP

18Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
3 SPECIFICATIONS Flatpack PRSB 9kW, 48VDC, Fan Cooled

Site Power Outdoor cabinet DC OUTPUT


Voltage 48VDC
SPECIFICATION Current Up to 9KW 180A
CONNECTIONS
Max. number of 6 Battery connections Battery cable, M8 bolts
rectifiers Load MCB Negative distribution, Negative load
AC INPUT connections cable, 70mm2 cable clamps. Common
positive bus bar, 70mm2 cable
Voltage 1 phase 230VAC (max 4 rectifiers)
clamps.
3 phase 208VAC ( )
Alarm connections Front access screw terminals
3 phase 230VAC ( )
3 phase 400VAC+N ( Y )
DISTRIBUTION OPTIONS
No. of DC Load Up to 4 x 3pole 150A
Frequency 45 to 66Hz breakers
No. of Battery Up to 2 x 150A MCBs mount next to
Maximum Current See Flatpack 1500 48VDC breakers each battery shelf
datasheet (241114.100.DS3) No. of Aux. fuses 8 x 10A GMT type
Protection Soft start Programmable LVD Standard: 1 LVBD (max. 300A)
Surge protection (varistors)
Disconnect above 312VAC OTHER SPECIFICATIONS
Isolation 3.0 KVAC input and output
MONITORING
1.5 KVAC input earth
Monitoring Unit Flatpack MCU 1.0 KVDC output earth
Local operation Menu driven software via keypads Operating temp -10 to +45C (14 to +113F)
and LCD or PC (WinPower) Storage temp -40 to +85C (-40 to +185F)
Remote operation WinPower via modem or Web Dimensions 770 (778) x 820 x 1300mm (WxDxH)
NMS via SNMP-agent (30.3 (30.6) x 32.3 x 70.9)
Alarm relays 8 relays are standard Weight Approx. 143 kg excl. rectifiers and
batteries
Visual indications Green LED System ON Max. 250kg load per battery shelf
Red LED Active alarm(s) APPLICABLE STANDARDS
LCD system status
Electrical safety EN 60950
Digital inputs 5 (for monitoring of external
UL 60950
equipment)
EMC ETSI EN 300 386 V.1.3.1
Current Battery current
(telecommunication network)
measurements Rectifier current
EN 61000-6-3
Alarms Load fuse alarm (emission, light industry)
Battery fuse alarm EN 61000-6-2
LVD operated (immunity, industry)
Low output voltage alarms Environment ETSI EN 300 019-2
(2 individual alarm levels) ETSI EN 300 132-2
High output voltage alarms RoHS Compliant
(2 individual alarm levels)
Battery capacity
Temperature alarm
Symmetry alarm
Door switch alarm
Individual Mains detect alarm

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
19
APPENDIX: SCHEMATICS, DRAWINGS, FIGURES etc.

A1 - General Arrangement drawing


See also Figure 2, page 5, for more detailed information about DC distribution.

Door switch
Main Protective
Earth (PE)

DC Distribution,
Alarm, AC
Terminals, etc.
Heater MCB
(AC)
Rectifiers
AC socket

Battery MCB
FB2

Battery MCB
FB1

Figure 10: General Arrangement drawing, PRSB 9kW, 48VDC Outdoor Cabinet, Fan Cooled

20Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
A2 - System Schematic PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled

LTE Distribution
Load
L3 L2 L1 N PE *OPTIONS F13 F14 F15 F16 F17 F18 F19 F20 F21 F22 *
OVP kit F1
*

F2
204144 204144

F3*
First p.shelf
2xFlatpack 1500
A
PE + CU-bar common + F4*
N
SH1 Fan
B
L -
- +

Second p.shelf GMT Load Fuse Board


2xFlatpack 1500

Load Alarm
- 16
PE + F12 15
N
SH2 REL1 COM1
14
F11
AC Detection

+ 13
L - CON 5
12
F10 11
Third p.shelf 10
-

203929
2xFlatpack 1500 F9 9
LVBD NO
PE + 8
+ F8 7
N
6
- F7

Load Alarm
L
5
4
F6 3
2
10
11
12
1
2
3
4
5
6
7
8
9
F5 1
CU-bar Battery -
MCU
Monitoring / Interface Board
Controller Unit Con41

Con3
10
12
13
6
8

Batt.string 1 Batt.string 2*
AC socket Battery Heater*
PE
N Date Design Draw Approved Scale Projection
13,02.2006 OLHUNO OLHUNO N/A
L
AC MCB
Heater
Door Switch
Schematic PRSB 9 kW OD
Eltek
Co pyright A/S Eltek. All rig hts reserved
Replace for Replaced by
- -
Consultant Format Page Draw. No. Rev.
Sym. Alteration Date/Sign
- A4 1 of 1 2011671 1

Figure 11: Schematic drawing, PRSB 9kW, 48VDC system

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
21
A3 - Drilling Template

Holes for mounting


the cabinet to the
Holes for the
ground without a
plinth. Factory
plinth.
drilled.
Holes for the
plinth. Factory
drilled.

Figure 12: Top view of the cabinets bottom plate. 700x700mm external dimensions
The cabinet overhangs by 35 mm outside the plinth in the rear, on the left hand and on the right hand
side. The Fan box builds an extra 80mm in the front.

22Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
MCU Default Settings PRSB 9 kW, 48 VDC
CF1032.001
SITE INFO Default System Setup
Customer
Location
Max. Current Rectifier 33
Rectifier Installed 0
Battery Type Marathon M12V 155FT
SET LEVELS Setup
High Battery Alarm 1 58 V
Low Battery Alarm 1 45 V
High Battery Alarm 2 59 V
Low Battery Alarm 2 43 V
Battery Voltage 54,5 V (at 25 C)
Boost Voltage 56,4 V
Alarm Delay 0s
High Temperature Alarm Level 1 25
High Temperature Alarm Level 2 (LVBD
disconnects) 50
Disconnect Voltage LVD1 40 V
Reconnect Voltage LVD1 47 V
Disconnect Delay Time LVD1 0
Disconnect Voltage LVD2 NA
Reconnect Voltage LVD2 NA
Disconnect Delay Time LVD2 NA
Disconnect Voltage LVD3 NA
Reconnect Voltage LVD3 NA
Disconnect Delay Time LVD3 NA
ALARM SETUP (which relay output is wanted
on each alarm) Setup
High Battery 1 No alarm relay
Low Battery 1 No alarm relay
High Battery 2 Relay 2
Low Battery 2 Relay 3
LVD1 No alarm relay
LVD2 No alarm relay
Battery Fuse Relay 4
Rectifier Relay 5
Critical Rectifier Relay 5
Mains No alarm relay
Battery Test No alarm relay
Battery Pre No alarm relay
Battery Fault No alarm relay
Common Relay 5
Load Fuse Relay 4
Symmetry1 No alarm relay
Symmetry2 No alarm relay
High Temperature 1 Relay 1
High Temperature 2 No alarm relay
Conf. Input 1 / Heat management No alarm relay
Conf. Input 2 Relay 6
Conf. Input 3 Relay 7
Conf. Input 4 Relay 8
Conf. Input 5 No alarm relay
LVD3 NA
SYSTEM CONFIGURATION Setup
Nom. Voltage 48V
Enable Function:
ON/OFF OFF
Battery Fuse ON
Symmetry 1 (SW) OFF
Symmetry 2 (HW) OFF

Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
23
Auto Boost OFF
Setup LVD1 Battery contactor
Type LVD1 Normally Open
Setup LVD2 No contactor
Type LVD2 NA
Setup LVD3 No contactor
Type LVD3 NA
OUTPUT CONTROL Setup
Temp. Comp.
BATTERY CONFIGURATION Setup
Battery Test Setup
End Voltage* 1.85 V/cell
Max test duration 300 min
Test interval 270 days
Test delay period 3 days
Battery Type
Battery Type User defined, type:
Marathon M12V 155FT
Number of battery modules (strings) 1
Battery cable resistance 0
Charge Current Limit
Charge Current Limitaion Active
Max. Charge Current 0.2C10 (18.4A)
Battery Setup User Def.
Battery Name
Battery test end voltage 1.85 V/cell (44.4 V)
Temp. Compensation (voltage at 20) 2.29 V/cell
Slope of temperature comp. equation 5,5 (mV/cell)/deg
Battery table (see next sheet for table) Marathon M12V 155FT
CONFIGURABLE INPUTS Setup
Conf.Inp. 1 Disable
Conf.Inp. 2 Phase 1
Conf.Inp. 3 Phase 2
Conf.Inp. 4 Phase 3
Conf.Inp. 5 Door Open
TEMPERATURE COMP. CHARGING Setup
Voltage at 20 C 2.29 V/cell
Slope 5,5 (mV/cell)/deg
Max. Compensation Voltage 2.4 V/cell
Min. Compensation Voltage 2.21 V/cell (53 V)
MODEM
Modem Callback NA
Baud Rate NA
RELAY SETTINGS(Jumper settings) Setup
Relay 1 NO
Relay 2 NO
Relay 3 NO
Relay 4 NO
Relay 5 NO
Relay 6 NO
Relay 7 NO
Relay 8 NO

*Parameter not used when User Defined Battery setup is enabled

24Installation Guide Flatpack PRSB 9kW, 48VDC, Outdoor Cabinet, Fan Cooled Art. no. 351434.033, v32006-07
Head Office:

Eltek Energy AS
P.O. Box 2340 Strms
N-3003 DRAMMEN
Norway
Phone: 47 32 20 32 00
Fax: 47 32 20 32 10
E-Mail: eltek@eltek.no Art. No. 351434.033
Issue 3, 2006-July
Internet: www.eltekenergy.com
Published 2006-07-18