Quick Start Guide

Installation, Operation, Commissioning and Maintenance

Flatpack PS System
PRS, PRSB PRSV

DC Power Supply System

With or without Batteries, Wall-mounted, Modular

(with external
batteries)

MPSU

(w/ without
internal batteries)

Introduction
o The Flatpack Product Range (2 )
o Brief System Description (2 )

Installation
o Installing Rectifier Modules and MCU Controller ( 3)
o Installation steps; mechanical, electrical (4-5)

Commissioning
o Pre-start check (6 )
o Commissioning steps, Startup (6-7)

Operation
o Front keys and display ( 8)
o Software Menus ( 8)

Miscellaneous
Communication
o Installing WinPower Silver PC software ( 9)
AC Mains
o External AC Fuses, Recommended Rating (10 )
Earthing
o About AC, DC Earthing Systems ( 11)
Battery Monitoring
o Battery Terminology (12)
o Battery Symmetry Connections (12 )
Alarms & Monitoring
o Fail-Safe Operation Alarm Relays & Digital Inputs (13 )
o Terminals & Pin-out Location, Alarm Card 100350 (13 )
o Terminals & Pin-out Location, Front Access Alarm Card 101825 (14 )

Check Lists pullout forms

o Installation Check List
o Circuit Distribution List
o Commissioning Procedure
o Maintenance Procedure
356803.103
 Introduction

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
Modular Power Supply Unit

PRSV
Power Rack System
Wall-mounted PRSB
Power Rack System
with or without Batteries

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.

Alarm Outputs NC-C-NO

Digital Inputs

Flatpack Flatpack MCU

PRSB (Ctrl. Unit) Fuse Alarm

Flatpack
(rectifiers)

LVLD
Telecom
equipment
AC mains
supply LVBD
AC Fuses, selector
external Load Fuses
(230VAC or & MCBs
400VAC Service
Symmetry Switch
Alarm & +/- DC
Temp. Sensor distribution

AC Supply DC Supply
(Single- or Battery string #1 Battery (24V, 48V
three-phase) Fuses or 60V)

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.

Quick Start Guide Flatpack PS System

2 356803.103, v4-2006-10
 Installation

Installing Rectifier Modules and MCU Controller

CAUTION:
- The modules may be warm, but do not hand-carry them by their handles
Device - Open the handles before inserting them into the power shelves
hazard

Mounting Flatpack rectifier modules

Hole to release the
handles spring mechanism 1. Open the handles by
Flatpack
inserting a screwdriver into the holes to release the spring
rectifier mechanism
2. Insert the module fully into the power shelf, so that it makes
proper contact
Handel in locked position 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

Flatpack inserting a screwdriver into the holes to release the spring
rectifier
mechanism
2. Remove the module
using both handles to pull the module loose; support from
underneath
3. Lock the handles by
Handel in pushing the handles up into their housings (locked position). It
unlocked position
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 MCUs rear panel. When
mounting the controller, you must plug the cables before step 2.
When removing it, unplug the cables during step 2.

MCU Controller Handle 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
or
Fastening using both handles to pull the controller loose. Unplug the
holes 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

Quick Start Guide Flatpack PS System 356803.103, v4-2006-10

3
 Installation

Installation Steps
Check off in the Installation Check List, that you find in the pullout section of
this folder. Also, refer to the systems specific drawings.
200 mm Preparing the installation site
Begin preparing the following:
1 Organize the installation site
o Min. clearances for cabinet access: 60 cm in front, 20 cm on top
o Levelled surface able to support 600 kg (PRSB),100 kg (PRSV) EMC
regard
o Explosive atmospheres are to be avoided. Ensure suitable
ventilation
o 60V systems are only to be installed in Restricted Access
Locations (RAL)
600 mm 2 Prepare the installation tools
o Use insulated tools suitable for telecom installations
3 Prepare AC Supply: AC input cable(s) and fuses
o Correct type AC supply is available
o External AC fuses have correct rating
o AC input cable(s) are sized correctly

For external AC fuses and AC input cable ratings, refer to your sites 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.

Mechanical Installation Power is OFF!

Carry out the following:

4 Remove packaging and check equipment
o Check you have received all the parts, correct cabinet,
documentation, batteries (if applicable), etc. Device
o Inspect the equipment for physical damage (report any damages) hazard
Flatpack PRS, batteries, Doc. o Leave rectifier modules in their packaging or in the selves, if
Chart, Spec. Drawings, CD-ROM factory installed. To be installed under commissioning
5 Remove top cover and dummy front panels
o Cable entry from the top. Connection terminals are located behind
the upper dummy panels
Upper
fastening hole o Battery shelves (if any) are placed behind the lower panels
6 Position and fasten the cabinet or subassembly
7.3 mm
o PRSB 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
o PRSV cabinets are wall-mounted; keyholes facilitate fixing
736.7 mm

Lower o MPSU subassemblies are fastened in existing 19 or in ETSI

fastening hole
cabinets, using brackets. Mount the support & heat deflecting
plate under the lower power shelf
10 mm

7 mm 7 Mount the batteries on the shelves

o Start (if applicable) placing the batteries on the lower shelf first,
13 mm and continue upwards
o Do not terminate the battery cables yet! Electric
550 mm shock
Wall-mounting distances
PRSV cabinets

Quick Start Guide Flatpack PS System

4 356803.103, v4-2006-10
 Installation

Electrical Installation Power is OFF!

Carry out the following: (Refer to the systems specific drawings)

8 Make the system completely voltage free
o Switch OFF or remove all load fuses (MCB1, MCBx), battery
fuses (Fb1, Fbx) and the AC supply fuses, in external fuse
boards
9 AC Connections
o Check AC configuration: the AC terminals are correct configured
to the external AC supply, otherwise reconfigure the terminals
o Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
o Connect the AC input cable(s) to the terminals. Cable and
terminal block labeling are to correspond
10 DC Connections Load Circuits
o Terminate 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
o For each DC load, connect one of the cables to the common DC Electric
output rail, and the other directly to the MCB or load fuse shock
11 DC Connections Alarm & Signal Circuits
o Refer to your systems connection drawings and configuration
(Factory Settings), or to the Miscellaneous, Alarms &
Monitoring section
o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output
terminals
Link 2
Chassis
12 DC Connections Battery Cables
(DC Earth)
Common Careful! Use correct polarity.
Battery EG DC Rail
Fuse For each battery shelf: (refer to the figure in this page)
(In PRS systems, steps b, d and f are usually performed in factory)
Card Art.100986
CON4:11 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 shelfs outer terminals; black (+); blue (-)
and d-e Connect battery symmetry cables, if applicable, to the input
CON3:34-
35-36 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
Temp. Sensor cable

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

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

installed battery bank
Temp. sensor

Battery
Cable

- + - + - + - +
(-48V) Outer
Terminal Block1 Block3 Block4
+
Intercell Links 0V Outer
Terminal

Quick Start Guide Flatpack PS System 356803.103, v4-2006-10

5
 Commissioning

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

I 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

o Ensure a correctly performed system installation, with correct polarity on all
Device connections, has been carried out (Installation Check List filled in)
hazard
o All cabling and copper bars are securely terminated and supported
o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
2. Battery and load fuses are disconnected
o Verify that all battery and load MCBs/ fuses are switched OFF or removed
3. AC input cable(s) and AC Earth wire (PE) are terminated
o Make sure that the AC input cable(s) are connected to correctly configured AC terminals
o Verify that the AC input cable(s) and external AC fuses are sized and rated as specified
o Check that AC Earth (PE) is terminated, and electrically connected to chassis (Link 1)
4. Site specific parameters and settings are known
o Read the system specific drawings and documentation
5. AC supply and all MCBs, fuses are switched OFF
o Make 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:
II Startup and No-Load Adjustments Power is ON!

1. Disconnect all rectifier modules, without removing them

o Read how to install modules, on page 3 in this guide. and then
o If Flatpack rectifier modules are installed, unlock the handles and pull the modules
Device partially out (fan housing visible), but do NOT physically remove them from the
hazard
power shelves
o If Flatpack rectifier modules are not yet mounted, release their handles and insert
them partially into the shelves
2. Switch ON the system
o Switch ON the AC input supply (external AC fuses) to the PS cabinet
3. Measure and verify that the AC input voltage is correct
o Measure the AC input voltage at the cabinets mains connection box
o Verify the AC voltage is within range

Quick Start Guide Flatpack PS System

6 356803.103, v4-2006-10
 Commissioning

4. Mount all Flatpack rectifier modules in the power shelves

o Push 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
o Mount blanking panels over unused positions
5. Ensure that the MCU controller and all rectifier modules are working: LEDs are ON
o Verify 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)
o Plug the correct serial cable between the PC and the MCU controller
o Start WinPower Silver on the PC (click on Start>All Programs>Eltek>WinPower Silver)
o Configure 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
o Read the DC output voltage on the controllers display
o With 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
o If required, adjust the voltage using the controllers front keys or via WinPower Silver
8. Verify the alarm relays are working correctly (alarm relay test)
o Run the alarm relay test using the controllers 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
o Verify system settings using the controllers front keys or via WinPower Silver
o Use 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! III

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
o Measure the battery voltage is within range (check connections have correct polarity) Device
o Adjust DC output voltage using the controllers front keys (refer to page 8) or via hazard
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.)
o Disconnect all rectifiers but one, by unlocking the handles and pulling them partially Device
hazard
out (fan housing visible). Do NOT physically remove them from the power shelves
o Switch ON all battery fuses or MCBs
12. Adjust DC output voltage again to equal the nominal battery voltage
o Adjust DC output voltage using the MCUs 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
o Connect all rectifiers again by pushing them firmly inwards Repeat step 4, in stage II
o Wait 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
o Switch ON all load MCBs/ fuses
o Verify correct operation: rectifiers and controller display no alarms

Quick Start Guide Flatpack PS System 356803.103, v4-2006-10

7
 Operation Keys & Menus

Front Keys and display, menus, etc.

0A scale mark
Down arrow key
LED bar graph
RS232C Up arrow key Output current scale, 10 green LEDs (3A each)
D-Sub 9 pins 30A scale mark
female
Enter key Alarm
LED Lamp (red)
LCD display
Alarm Power
LED Lamp (red) LED Lamp (green)
Potentiometer
Output voltage adjustment
MCU control unit Flatpack rectifier

MCU Control Unit front keys, display, etc Flatpack rectifier module front panel, left side
Display: is in Status Mode (displays the systems Power LED is OFF (mains unavailable) or ON
status) or in Menu Mode (displays the menu structure). (powered). Alarm LED is ON (shutdown or similar
Operation: Press on the key to change from major alarm) or OFF (OK, no alarm)
Status Mode to Menu Mode. Press the or Output voltage is factory adjusted on delivery. In
keys to scroll up or down and navigate to find menu stand-alone operation (MCU ctrl. unit is not used),
options (function or parameter). Press then the you can use the potentiometer to adjust the output
key to select the function. voltage.
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. Level 2 Level 3
Service menu <ServiceOption> Password= 0000
NomVolt
Level 2 Level 3 BoostVolt
User menu <UserOption> LowBatt1
LowBatt2
System ON/OFF Turn system ON/OFF * VoltAdjustment HighBatt1
Alarm Reset Alarm Reset HighBatt2
NomVolt LVD 1
LVD 2
Firmware 402080.009 5v1

BoostVolt
LowBatt1 LVD 3
LowBatt2 Calibration VoltCal
VoltageInfo HighBatt1 SetDefaultCalib.
HighBatt2 ChangePassword Password
LVD 1 SetBoostTime BoostTime
LVD 2 Start/StopBoost StartBoost/StopBoost
LVD 3 Auto Boost Cfg. Enable/Disable
DisplayMessages Display messages Threshold
Software Menus

Sw Info SwInfo
* The ON/OFF function may be disabled in some IntervalTest Date Time
Test End Volt
Firmware 402080.009 5v1

systems Batt Test Setup Max Test Duration

Test Interval
Test Delay Period
Level 2 Level 3 Start/Stop Test Start Test/Stop Test
Charge Curr Lim Enable/Disable
Service menu <ServiceOption> Password= 0003 Max Charge Curr
English Battery Setup Number of banks
German Number of rectifiers
Norwegian Capacity Al.Cfg. Current pr rectifier
Language Polish Alarm limit
French
Temp.Comp
Spanish
OutputControl Voltage Control
pComm Presat Rect.Volt
Protocol Trace *
Firmware 402080.009 5v1

Change Date/Time Date

Comli
Time
9600
Relay1
Set baud 1200 Relays 210
2400 Relay Test Relay 11
4800 LVD1 relay
MODEM sense MODEM sense: ON LVD2 relay
MODEM sense: OFF LVD3 relay
* Trace is for internal factory use

Quick Start Guide Flatpack PS System

8 356803.103, v4-2006-10
 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: OK
1. Organize the installation site
o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm
o Check that the levelled surface is able to support 600 kg (PRSB systems), 100 kg (PRSV systems)
EMC
regard o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas
2. Prepare the installation tools
o Check that insulated tools suitable for telecom installations are used
3. Prepare AC Supply: AC input cable(s) and fuses
o Check 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: OK
4. Remove packaging and check equipment
o Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc
Device o Inspect the equipment for physical damage (report any damages)
hazard
o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
5. Remove top cover and dummy front panels
o Check that cable entry from the top is possible
6. Position and fasten the cabinet or subassembly
o PRSB cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor
o PRSV cabinets are wall-mounted. Keyholes facilitate fixing
o MPSU subassemblies in existing 19 or in ETSI cabinets, using brackets. Mount support & heat deflecting plate
7. Mount the batteries on the shelves
Electric o Start (if applicable) on the lower shelf first, and continue upwards
shock o Do not terminate the battery cables yet!
Electrical Installation Power is OFF!
CARRY OUT FOLLOWING: OK
8. Make the system completely voltage free
o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses
9. AC Connections
o Check AC configuration: The AC terminals are correct configured to the external AC supply
o Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
10. DC Connections Load Circuits
o Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place
Electric
shock o For 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
o Refer to your systems connection drawings and configuration, or to the Factory Settings in the Quick Start Guide
o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output terminals
12. DC Connections Battery Cables Careful! Use correct polarity.
For each battery shelf,
o Mount 3 intercell links to connect in series 4 battery blocks
o Connect battery cables to fuses and common DC rail, and to the shelfs outer terminals; black (+); blue (-)
o Connect battery symmetry cables, if applicable, to the input terminals, and to the battery string
o Connect 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.:

Form XXX-gb-v1-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
 CIRCUIT DISTRIBUTION LIST
System Data
Flatpack Power Supply System, type: Article No.:
Site, name:
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
Fb1
Fb2
Fb3
Fb4
BATT.

Fb5
Fb6
F1
F2
F3
F4
F5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

LOAD
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Continue

Form 165-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
 CIRCUIT DISTRIBUTION LIST
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.

LOAD
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
Form 165-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
 MAINTENANCE PROCEDURE
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: Maintenance carried out by, name:
WARNING: Maintenance work on live equipment is only to be performed by authorized and
Electric qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.
shock
System Inspection Power is ON!
CARRY OUT FOLLOWING: OK
1. Site specific parameters and settings are known.
User manuals and site specific connection & arrangement drawings are available.
2. The battery bank has been fully charged in advance.
At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration
3. The equipment is free from damage, dust or dirt; verify.
Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.
4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.
5. The MCU & all rectifier modules are ON, no alarm present; verify.
Otherwise, correct and put the PS system in normal mode of operation.
6. All rectifiers functionality & MCUs keys and display work OK; verify
Correct possible abnormalities before continuing.
7. Connect the PS system to a PC (install the WinPower Silver application if required)
The WinPower Silver program in the PC enables system configuration from the PC.
8. Rectifiers load current sharing; verify.
The number of LEDs illuminated on every rectifier's bar graph should be equal (1 LED).

9. Display the stored log of Alarm Messages.
Using the keypad on the MCU controller or from the PC.
System Adjustment Activate the Service Switch, if installed
CARRY OUT FOLLOWING: OK
1. DC Output Voltage Calibration; ensure correct display readings.
If measured DC output voltage at the load terminals deviates more than 1% from the display reading, calibrate the

output voltage from the MCUs keypad or the PC.
2. Load & Battery Current Calibration; verify correct display readings.
Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery
current. If the calculated total values deviate more than 1% from the display readings, calibrate the current from the
PC (calibration value>50% of systems max. capacity)
3. DC Output Voltage Adjustment; measure and adjust.
Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery manufacturer.
(Voltage measurements to be done at the DC rail, with little load current)
4. Alarm Relay Test; verify all alarm relays are working correctly.
From the MCUs keypad or PC use the Relay Test function; verify activation of external equipment
5. Battery bank control; measure and verify battery specifications.
Follow the recommendations of the actual battery manufacturer.
Approval
Responsible of maintenance control, sign.: Date: Approved by customer, sign.:

Form 166-gb-v2-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00
PULLOUT
 COMMISSIONING PROCEDURE
System Data Flatpack PS System
Suppliers Order No.: 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: Commissioning carried out by, name:
I Pre-Start Check Power is OFF!
CHECK FOLLOWING: OK
1. Flatpack system installation is completed; The Flatpack Installation Check List is filled in.
All cabling is securely terminated with correct polarity
Device
hazard 2. All battery and load MCBs/ fuses are disconnected

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

4. Site specific parameters and settings are known

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

Start-up, No-Load & Load Adjustments Power is ON!
II CARRY OUT FOLLOWING: OK
1. Disconnect all rectifier modules, without removing them

Device 2. Switch ON the system (external AC fuses ON)
hazard
3. AC input voltage is correct; Measure and verify

4. Insert all Flatpack rectifiers in their locations in the power shelves

5. The MCU and all rectifier modules are working, LEDs are ON; Verify

6. Connect a PC to the PS system Install the WinPower Silver program, if required

7. DC output voltage; Measure and adjust

8. Alarm relay test; Verify all alarm relays are working correctly

9. System Setup is in accordance with configuration Enter site spec. info in WinPower Silver

III 10. Adjust DC output voltage to equal measured battery voltage Check correct polarity!

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

Device
hazard 12. Adjust DC output voltage to equal nominal battery or load voltage

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

14. Connect all load MCBs/ fuses, and verify no alarms are displayed

Approval
Responsible of commissioning, sign.: Date: Approved by customer, sign.:
Eltek Energy AS Internet: www.eltekenergy.com E-Mail: eltek@eltekenergy.com
Tel. +47 32 20 32 00

Form 164-gb-v3-C01_356803-103_qstart_flatpack-pss.doc_mfm_2006-10-11
 Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
PULLOUT
 Communication Miscellaneous

Installing WinPower Silver PC Application

WinPower Silver software enables you to configure and operate the Flatpack PSS from a
personal computer.
Installation
1. Connect the MCUs D-Sub to one of the PCs COM port using an RS232C serial cable
2. Install WinPower Silver in the PC
3. Verify that MCU and PC have equal communication parameters,
e.g.: 9600 baud, 8b, P=N, Sb=1

RS232C serial cable, 99 pins

Flatpack PRS Max. 15m, RS232 driver protocol

1 1
RxD 2 2 RxD PC
9 pins (female)
COM1, D-Sub

COMx, D-Sub
9 pins (female)

9 pins (male)
9 pins (male)

TxD 3 3 TxD
MCU WinPower
4 4 DTR Silver
Control Unit GND 5 5 GND
6 6
7 7
CTS
D-Sub 8 8
9 9

D-Sub D-Sub
Technical Room Control Room

Quick Start Guide Flatpack PS System 356803.103, v4-2006-10

9
 Miscellaneous AC Mains

External AC Fuses Recommended Rating

The sites AC supply quality is of great importance. In general, a site with better AC supply
quality (stable nominal voltage) may use smaller breakers.
AC Mains No of Power Current Ext. Fuse
Type Shelves Max. (A) Type (Th/Mag)
1 16.2 25A-C
230VAC 2 32.4 40A-C

205VAC Inputs
1-phase
3 48.6 50A-C
For Flatpack 1500 sys- 1* 8.1 25A-C
tems use the recom- 230/400VAC
3-phase, TN network 2 or 3 16.2 25A-C
mendations in the
205VAC table, if you (5 wire system) 4,5 or 6 32.4 40A-C
are sure the available 1* 14.0 25A-C
Flatpack 1500

AC mains voltage will 230VAC 2 or 3 28.1 32A-C

not drop below 3-phase, IT network
4 42.9 50A-C
205VAC. (4 wire system)
5 or 6 56.1 63A-C
OR AC Mains No of Power Current Ext. Fuse
If you are unsure or Type Shelves Max. (A) Type (Th/Mag)
know that the voltage 1 18.1 25A-C
may drop below 230VAC 2 36.1 40A-C
185VAC Inputs

205VAC use the 1-phase

3 54.2 63A-C
185VAC table recom-
230/400VAC 1* 9.0 25A-C
mendations.
Doc 2014385, v2 3-phase, TN network 2 or 3 18.1 25A-C
(5 wire system) 4,5 or 6 36.1 40A-C
1* 15.6 25A-C
230VAC 2 or 3 31.3 32A-C
3-phase, IT network 47.8
(4 wire system) 4 50A-C
5 or 6 62.6 63A-C

AC Mains No of Power Current Ext. Fuse

Type Shelves Max. (A) Type (Th/Mag)
1 19.5 25A-D
230VAC 2 39.0 40A-C
205VAC Inputs

1-phase
3 58.5 63A-C
For Flatpack 1800 sys- 1* 9.8 25A-D
tems use the recom- 230/400VAC
3-phase, TN network 2 or 3 19.5 25A-D
mendations in the
205VAC table, if you (5 wire system) 4,5 or 6 39.0 40A-C
are sure the available 1* 16.9 25A-D
Flatpack 1800

AC mains voltage will 230VAC 2 or 3 33.8 40A-C

not drop below 3-phase, IT network
205VAC. 4 51.6 63A-C
(4 wire system)
5 or 6 67.6 80A-C
OR AC Mains No of Power Current Ext. Fuse
If you are unsure or Type Shelves Max. (A) Type (Th/Mag)
know that the voltage 1 21.7 25A-D
may drop below 230VAC 2 43.5 50A-C
185VAC Inputs

205VAC use the 1-phase

3 65.2 80A-C
185VAC table recom-
230/400VAC 1* 10.9 25A-D
mendations.
Doc 2014386, v2 3-phase, TN network 2 or 3 21.7 25A-D
(5 wire system) 4,5 or 6 43.5 50A-C
1* 18.8 25A-D
230VAC 2 or 3 37.7 40A-C
3-phase, IT network 57.5
(4 wire system) 4 63A-C
5 or 6 75.3 80A-C

* The calculation for single sub-rack configuration requires separate AC feed to each module position

Note: The above recommendations apply for use of Thermal magnetic circuit breaker, type Siemens 5SX or 5SY series, MG C60H
series or similar. For more information regarding External AC fuses and other types of fuses, please read the article 2014385 for
Flatpack 1500 systems or the article 2014386 for Flatpack 1800 systems on the CD, 356802.CD3.

Quick Start Guide Flatpack PS System

10 356803.103, v4-2006-10
 Earthing Miscellaneous

About AC, DC Earthing Systems

To prevent the risk of electric shock, all cabinets chassis are to be electrically connected to AC
Earth (PE). Also, it is a common practice for telecom equipment to have its common DC output
rail (+ or -) connected to a separate Telecom Earth (TE) or DC Earth.
Earth connections are in particular important where frequent lightning might induce high
voltage levels in AC supply and in battery and load cables.
PE (Protective Earth)
TE (Telecom Earth) Link 2
EG (Exchange Ground) AC Mains Input
(L1,L2,L3,N) (DC Earth) Chassis
Common
AC Mains EG DC Rail
TE

Link 1 . DC Load
PE (AC Earth) Circuit
Cabinet
Chassis

AC Earth (PE) and DC Earth (TE) are usually connected to chassis via Link 1 and Link 2.
Remove the links (floating earth) for compliance with other local earthing systems. Refer to
your systems specific drawings to identify how these links are implemented in your DC power
system.

Common Positive DC Output Rail is usual in 48 and 60V DC supply systems: Negative DC
Distribution. Common Negative DC Output Rail is usual in 24V systems: Positive DC
Distribution.
Common DC Rail + Common DC Rail

DC Load
DC Load

+ wires
wires

+
+
+
Negative DC Positive DC
Distribution Distribution

Quick Start Guide Flatpack PS System 356803.103, v4-2006-10

11
 Miscellaneous Battery Monitoring

Battery Terminology
Refer to your systems specific drawings for the exact connection points.

Symmetry measurement is a battery monitoring method of automatically detecting

unbalanced battery blocks. Symmetry monitoring of a battery string may be performed by
measuring each battery block (block measurement method), or by only measuring the mid-
point of the battery string (mid-point measurement method).
The mid-point measurement method requires one symmetry cable per battery string, while the
block measurement method requires 3 symmetry cables per battery string.
Flatpack PRSB systems are delivered with the symmetry measurement method and the
number measurement points already preprogrammed in the MCU module. Any deviation from
factory settings requires Symmetry reconfiguration via PC and WinPower Silver.

Battery Terminology

Battery Block, Battery String and Battery Bank

Battery Example of a 48V battery bank implemented
Block (12V) with two 48V battery strings; each string
consists of four 12V battery blocks.
Normally, battery banks are implemented
Battery by connecting in parallel several battery
String #1
(48V) strings; each string is formed by battery
blocks connected in series.
Battery
48V Battery Bank String #2
(48V)

Battery Symmetry Connections

The examples below show battery symmetry connections for 48V DC supply systems.

Battery Symmetry Battery Symmetry

Mid-point Measurement Block Measurement
One measurement per string Three measurements per string
Front access
circuit card
12

11
13
11

100986
Front access CON4 CON4
circuit card Symmetry Symmetry
100986 cable 3 cable 1
Symmetry
cable 1
+ + + +

(-48V) Outer (-48V) Outer
Terminal Terminal
+ +
Intercell Links 0V Outer Intercell Links 0V Outer
Terminal Terminal

Quick Start Guide Flatpack PS System

12 356803.103, v4-2006-10
 Alarms & Monitoring Miscellaneous

Fail-Safe Operation Alarm Relays & Digital Inputs

Standard Relays & Digital Inputs

The alarm outputs in Flatpack systems use the Fail-

Normal Mode NO
Com +
Safe Operation Mode (relay coils energized in the
Relay X
(Energized coil) NC systems normal operation mode). When the system is
in alarm mode, the alarm relay coils are de-energized.
NOAlarm Mode
Relay X Com +
(De-energized coil) NC The figure shows the position of the relay contacts

Flatpack PS System when the relay coils are de-energized (PS system in
Correct Use of Alarm Outputs (example) alarm mode)

Digital Input X + Normal Mode

(Normal mode) External Relay Y
(Energized coil)

Digital Input X + Alarm Mode

External Relay Y
In order to implement monitored fail-safe digital
(Activated)
(De-energized coil) inputs circuits, the external relay coil must be
energized and the contacts closed in the systems
Flatpack PS System normal mode of operation.
Correct Use of Digital Inputs (example)

Terminals & Pin-out Location, Alarm Card 100350

DC power systems using the Alarm & Signal Interface Card Art. 100350, basic version
have following alarm outputs and monitoring inputs available: 6 alarm relay outputs, 4 digital
inputs, 3 symmetry alarm inputs and 1 temperature sense input.
For detailed information about the cards pin-out location and terminal block connections,
refer to the figure in this section.
Terminals & Pin-out Location
Alarm & Signal Card, Art. 100350
The figure shows the position of the relay
contacts when the PS system is in its alarm
mode of operation. The relay coils are then 12
de-energized (fail-safe mode). The relay CON2*
outputs are preprogrammed from factory 1
(Factory Settings).
CON3*
FUNCTION SIGNAL PIN-OUT CON4 CON5
11 20
CON4 CON2*
(From external equipment)
Digital & Analogue Inputs (circuit card 100350)

+ 1 1 10 1 18
AGND 2
+ 3 FUNCTION SIGNAL PIN-OUT
Monitoring Input Signals

Digital Input 2
4
**

+ 5 CON5
Digital Input 3 AGND 6 Relay 6 NC 1
+ 7 Common Alarm NO 2 Alarm Circuit 6
Voltage free (circuit card 100350)

Digital Input 4 AGND 8 Com 3

Alarm Relay Outputs

+ 9 Relay 5 NC 4
1.5 mm , max. wire section

Symmetry Alarm 2
(digital input) AGND 10 (From external Symmetry Module Alarm NO 5 Alarm Circuit 5
Alarm circuit card, art. 26851) Com 6
+ 11
Analogue

Symmetry Alarm 1 Relay 4 NC 7

Inputs

12
batteries)

Fuse Alarm, NO 8
internal
(From

Symmetry Alarm 3 + 13
14 Load & Battery Com 9
Alarm Circuit 4

+21V Auxiliary Supply + 15 Relay 3 NC 10

200mA (for external equipment) 16
(To Modem) Low Battery Alarm NO 11 Alarm Circuit 3
Com 12
2

(Not used) 17
+ 18 Relay 2 NC 13
internal batteries)

Temperature Sense
(From area with

(for internal battery bank) 19 High Battery Alarm NO 14 Alarm Circuit 2

screen 20 Com 15
Relay 1 NC 16
2
1.5 mm , max.
wire section Temperature Mains Alarm NO 17 Alarm Circuit 1
sensor Com 18

* CON2 & CON3 are used for internal connections (connected from factory)
** For correct use of digital inputs, see the Fail-Safe Operation chapter
Quick Start Guide Flatpack PS System 356803.103, v4-2006-10
13
 Miscellaneous Alarms & Monitoring

Terminals & Pin-out Location, Alarm Card 101825

DC power systems using the front access Alarm & Signal Interface Card (Art. 101825) have
following alarm outputs and monitoring inputs available: 11 alarm relay outputs, 5 digital
inputs, 5 symmetry alarm inputs and 1 temperature sense input.
For detailed information about the cards pin-out location and terminal block connections,
refer to the figure in this section.

Terminals & Pin-out Location The figure shows the position of the
Alarm & Signal Front Access Kit, Art. 101825 relay contacts when the PS system
Circuit Card 100985 is in its alarm mode of operation.
The relay coils are then de-
Internal System

1
Connections,

energized (fail-safe mode). The

relay outputs are preprogrammed
CON1

from factory (Factory Settings).

FUNCTION SIGNAL PIN-OUT

10 1 18 1
CON3
1 Com 1
Relay 1 NO 2
2
Mains Alarm Alarm Circuit 1
CON5 NC 3
20 CON4 11 36 CON3 19 Com 4
Relay 2NO 5
Customer Connections (front access, circuit card 100986) High Battery Alarm Alarm Circuit 2
NC 6
Com
Relay 3 7
Voltage free (Front access circuit card 100986)

FUNCTION SIGNAL PIN-OUT

Low Battery Alarm NO 8 Alarm Circuit 3
CON4 NC 9
+ 1 Com
Relay 4 10
Digital Input 1 Fuse Alarm, NO

1.5 mm , max. wire section

(From external equipment)

11
(Front access circuit card 100986)

2 Alarm Circuit 4
Monitoring Input Signals

AGND
Alarm Relay Outputs

3+ Load & Battery NC 12

Digital Input 2 Com 13
Digital & Analogue Inputs

AGND 4
Relay 5NO
Digital Input 3 AGND 5
+ Module Alarm
14 Alarm Circuit 5
**

6 NC 15
Com 16
Digital Input 4 AGND + 7 Relay 6
NO 17
8 Common Alarm Alarm Circuit 6
NC 18
Digital Input 5 AGND + 9

2
10 Com 19
Relay 7 20
Symmetry Alarm 1 + 11 NO
Analogue

(not programmed) Alarm Circuit 7

Inputs

NC 21
batteries)

Symmetry Alarm 2 + 12
external
(From

Symmetry Alarm 3 + 13 Com 22

Relay 8 23
Symmetry Alarm 4 + 14 (not programmed) NO Alarm Circuit 8
Symmetry Alarm 5 + 15 NC 24
(digital input) AGND 16 (From external Com 25
Relay 9 26
(Not used) 17 Symmetry Alarm circuit
(not programmed) NO Alarm Circuit 9
card, art. 26851) 27
(Not used) 18 NC
+21V Auxiliary Supply + 19 Com 28
Relay 10 29
200mA (for external equipment) 20
(not programmed) NO Alarm Circuit 10
(To Modem)
2
1.5 mm , max. wire section NC 30
Com 31
Relay 11
CON5 (not programmed) NO 32 Alarm Circuit 11
NC 33
Auxiliary Supply 1
+ 34
sensor
Temperature

System output voltage + 2 (To external Temperature Sense

(for external equipment)
equipment) (for external battery bank) 35 (From area
1.5 mm , max.
2
screen 36 with external
batteries)
wire section
* CON1 is used for internal connections (connected from factory)
** For correct use of digital inputs, see the Fail-Safe Operation chapter

Quick Start Guide Flatpack PS System

14 356803.103, v4-2006-10
Quick Start Guide Flatpack PS System 356803.103, v4-2006-10
15
 This product is CE marked and
complies with all current requirements
for relevant standards and directives.

Head Office
Eltek Energy AS
PO Box 2340 Strms; N-3003 Drammen; Norway
Tel:+47 32 20 32 00 Fax:+47 32 20 32 10
E-mail: eltek@eltekenergy.com Internet: www.eltekenergy.com
Copyright Eltek Energy AS, Norway 2006
This document may be changed without notice
Doc. No. 356803.103, Issue 4, 2006 Oct
Published 2006-10-11