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Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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Table of Contents
2 INSTALLATION PROCEDURES 7
SAFETY PRECAUTIONS 7
UNPACKING AND MECHANICAL INSTALLATION 7
ELECTRICAL INSTALLATION 8
RECTIFIER INSTALLATION — MAINS SUPPLY BALANCING EFFECT 10
RECTIFIER INSTALLATION — HANDLES AND LOCKING MECHANISM 10
COMMISSIONING 10
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12 3
1 Description of Flatpack PRSB 15kW, 48VDC
This Installation Guide contains information about how to install the Flatpack PRSB 15kW,
48VDC system 1 , for outdoor site power cabinet, Air Conditioned. Please, refer to the
system’s Documentation Set (art. 351406.003) for an overview of related user
documentation.
DC Load Distribution:
MCBs, Mains, Alarm and
Signal Terminals
MCU, Monitoring & Control Unit
AC Mains Terminals
Terminals for 2GMT 10A Load
Fuses, 1.5 mm
1
PRSB = Power Rack System with Batteries
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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AC Input Terminals
The AC terminal block is factory configured for mains supply type: 400VAC, 3 phase and N.
L1-bar L2-bar
N-bar L3-bar
N (neutral)
L1 (Terminal for
(Terminal for incoming wire)
incoming wire)
L2
(Terminal for
incoming wire)
L3
(Terminal for
incoming wire)
You may 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.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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To connect your system to 1
phase from a 230 VAC- AC Input Connection
system or a 400 VAC + N- 1-phase
External Wire Connections
system connect the input AC configuration in
cables as illustrated in the Terminal Block
table to the right. With one 400 VAC + N 230 VAC
phase the maximum amount Input 400VAC + L1 L1-terminal L1-terminal
of rectifiers is 4. These have (230 VAC, 3ph or N N N-terminal L2-terminal
to be placed in position 1,4,7 400 VAC, 3ph + 230VAC L1 L1-terminal L1-terminal
and 9 in Figure 4, page 10. N)
The other positions will not be L2 N-terminal L2-terminal
1 phase configurations
usable.
One of the interface boards (104649) is located behind the MCU (with rear access to the
terminals), while the other board (104648) is mounted on top of the MCU (with front access
to the terminals).
Se “Figure 7 Customer connections interface”, page 11.
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.
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.
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
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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2 Installation Procedures
This section describes how to install the Flatpack PRSB 15kW, 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 parts.
Safety Precautions
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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Warning!
The cabinet has to stand upright (vertical position) for at least 2 hours before the Air-
Condition devise is started.
Electrical Installation
For location of components, see “Figure 2”, page 4, Figure 3, page 5, and Figure 9, page 15.
2. AC CONNECTIONS
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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• Turn OFF the Load/BTS MCBs.
3. LOAD CONNECTIONS
• Turn OFF the PRS battery MCBs on the left side of the
Alarm cabinet.
connection
• Loosen the screws and pull the black cable gland back to
draw the load cables down to the powercore.
• The kit includes two copper bridges. One for 100 A (two
pins) and one for 150 A. If the load current is larger than
100A 150A 50 A use the two pin copper bridge. Then the 3rd hole in
the breaker cannot be used. If the load current is larger
than 100 A, use the three pin copper bridge. Insert the
chosen copper bridge on to the top of the MCB.
• Connect the orange alarm cable to the copper bridges
Cable gland with a screw if the bridges are used.
• Connect the positive cable(s), max 70 mm sq (AWG 2/0), to
the common positive bus bar on the top of the power
core. 2
• Connect the negative (-48V) cables, max 25 mm sq each
(AWG 3), to the top of the MCBs or the copper bridges.
Connect the negative (-48V) cables to the MCBs.
Connect the adequate cables, 1,5 mm sq (AWG 15), to the
4. GMT FUSE CONNECTION
GMT fuse card according to the table in section 3 – page 13
The positive and negative (-48V) battery cables are
5. BATTERY CONNECTIONS
connected from factory to the common positive bus bar and
to the battery MCBs. (Excluding additional battery string
kits) The battery temperature sense cable is also pre-wired
Right Corner to CON4, and temporally fixed to the cabinet’s wall.
• Connect the loose end of the battery cables to the
battery terminals; blue cable to the negative terminal
Battery ventilation and black cable to the positive terminal.
hole with gland • Connect all battery intercell links
removed
• Place the temperature sensor, located at the end of the
battery temperature sense cable, on top of the topmost
battery string.
• Connect and fasten the ventilation hose kit (follows the
Battery ventilation batteries) to every battery block, guiding the exhaust
hole with gland end of the hose out of the cabinet through the upper
whole on the side of the cabinet. Fasten the exhaust host
to the cabinet with strips. Make sure that the fixings do
not limit the airflow in the hose.
Please follow chapters “Pre Start Check” and “Start Up
Procedure” in manual “Commissioning Guide Flatpack 1500
6. POWER UP DC Rectifier Plant”, Doc. No. 360006.163.
2
The bus bar is prepared for connection of cables with lugs or ferrules. M8 bolts are fitted
at delivery.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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Rectifier Installation — Mains Supply Balancing Effect
The Flatpack PRSB system may be expanded to a maximum of 10 Flatpack 1500 rectifiers.
In order to load the 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
9th Pos
7th Pos (on L1)
(on L1)
8th Pos 10th Pos
(on L2) (on L2)
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
Commissioning
For information regarding system commissioning, please read manual “Commissioning
Guide Flatpack 1500 Dc Rectifier Plant”, art. No. 360006.163.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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3 Alarm Relay Outputs and Signal Connections
The digital inputs are configured as fail-safe, i.e. if the input is Input 1
enabled, it will trig an alarm if the input is open. If several AGND
external devices are going 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 CON4
describes the pin out in normal state, i.e. the NO output is External device
alarm state
open in normal operation and shorts to the COM output in the
alarm-state.
Pin 11
Pin 20
Pin 12
Pin 1
CON2
CON5
CON3 CON4
Pin 1
Pin 10 Pin 20
Pin 1
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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CON 5 Pin Assignment
for basic PCB version, art. No. 104648
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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Connections for GMT fuses
Pin 16 Pin 1
GMT fuses
Max. 10 A each
The table below shows the pin assignment for the GMT load fuse card.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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4 Specifications Flatpack PRSB 15kW, 48VDC, Air Conditioned
SPECIFICATION CONNECTIONS
Battery Battery cable, M8 bolts
Max. number of rectifiers 10 connections
AC INPUT Load MCB Negative distribution, Load
Voltage 1 phase 230 VAC (max. 4 connections cable, M8 bolts. Common
positive bus bar, M8 bolts
rectifiers)
3 phase 208 VAC ( ∆ ) Alarm Plug-in wire connectors front
3 phase 230 VAC ( ∆ ) connections access
3 phase 400 VAC+N ( Y ) DISTRIBUTION OPTIONS
Frequency 45 to 66Hz No. of DC 3 x 50 Amps -150Amps MCBs
Load breakers
Maximum See Flatpack 1500 48VDC No. of Battery Up to 3 x 150 Amps MCBs mount
Current datasheet (241114.100.DS3) fuses next to each battery shelves
Protection Soft start No. of Aux. 8 x 10 Amps GMT type
Surge protection (varistors) fuses
Disconnect above 312 VAC Programmable Standard: 1 LVBD (max. 400 Amps)
LVD
MONITORING OTHER SPECIFICATIONS
Isolation 3.0 KVAC – input and output
Monitoring Unit Flatpack MCU
1.5 KVAC – input earth
Local operation Menu driven software via
1.0 KVDC – output earth
keypads and LCD or PC
Operating temp -40 to +50°C (-40 to +122°F)
(WinPower)
Storage temp -40 to +85°C (-40 to +185°F)
Remote WinPower via modem or Web
Dimensions 770 x 910 x 2000mm (WxDxH)
operation NMS via SNMP-agent
(30.3 x 35.8 x 78.7”)
Alarm relays 6 relays are standard
Weight Approx. 235kg excl. rectifiers and
batteries
Visual indications Green LED – System ON
Max. 250kg per battery shelf
Red LED – Active alarm(s)
LCD – system status APPLICABLE STANDARDS
Digital inputs 5 (for monitoring of external Electrical safety EN 60950
equipment) UL 60950
Current Battery current EMC ETSI EN 300 386 V.1.3.1
measurements tifier current (telecommunication network)
Alarms Load fuse alarm EN 61000-6-3
Battery fuse alarm (emission, light industry)
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
(2 individual alarm levels)
Battery capacity
Temperature alarm
Symmetry alarm
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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5 Appendix: Schematics, Drawings, Figures, etc.
DC Distribution, Alarm,
AC Terminals, etc.
Rectifiers
LTE Fuses
MCBs
Battery MCB
FB4
Battery MCB
FB3
Battery MCB
FB2
Battery MCB
FB1
Figure 9 General Arrangement drawing, PRSB 15kW, 48VDC Outdoor Cabinet, Air Conditioned
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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System Schematic — PRSB 15kW, 48VDC, Outdoor Cabinet, Air Conditioned
Figure 10 Schematic
drawing, PRSB 15kW, 48VDC
system
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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On Site Door Removal — Outdoor Cabinet, Air Conditioned
Step Description Ok
1 Switch OFF AC
supply to Air Air
Condition Condition
AC supply
2 Remove the AC cable.
supply cables from
the door terminals.
Make sure the AC
cable is completely
freed from the door.
3 Disconnect the earth Air
connection cable on Condition
the bottom of the AC supply
door cable
4 Lift the door off the connection
hinges. This might terminal
require two or more
persons, since the
door is heavy.
5 When the door is
mounted back on,
lift the door back on
to its hinges
6 Reconnect the earth Eart
and AC supply connection
cable. cable
7 Fasten the AC
supply cable to the
door.
8 Switch the AC
supply back ON.
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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Drilling Template
Figure 11 Top
view of the
cabinet’s bottom
plate.
700x700 mm
external
dimensions Holes for mounting
the cabinet to the
ground without a Holes for the
plinth. plinth.
The cabinet
overhangs by 35
mm outside the
plinth on the rear,
on the left hand
and on the right
hand side
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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Air Condition unit schematic drawing
Installation Guide Flatpack PRSB 15kW, 48VDC, Outdoor Cab., Air Conditioned — Art. No. 351406.033, v4—2004-12
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Main Office:
Eltek Energy AS
P.O. Box 2340 Strømsø
N-3003 DRAMMEN
Norway
Phone: 47 32 20 32 00
Fax: 47 32 20 32 10
Art. No. 351406.033
E-Mail: eltek@eltek.no
Issue 4, 2004 December
Internet: www.eltekenergy.com
Published 2004-12-06