Eltek FP2 IandC Manual

Installation & Commissioning,

Operation & Maintenance Manual

TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS

MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x

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Eltek Valere Australia Pty Ltd Unit 1, 22 Narabang Way, Belrose, NSW, 2085, Australia Telephone: +61 2 9479 4200 Facsimile: +61 2 9450 1661

INSTALLATION, COMMISSIONING

AND OPERATIONS MANUAL FOR FLATPACK2 OPTUS SYSTEM

REVISION CONTROL

Rev Date Revision Description Orig Check App

A 28/08/09 Modified from TG6340H SW

B 27/11/09 Add New Model A111223.001 SW

C 11/01/10 Update images SW

D 24/01/10 Insert New Optus Part Number Table SW

E 25/05/10 Temperature probe position RB

F 20/11/10 Change of MCB line up and position and minor edit

RB/RZ

G 07/02/11 Included: AG12V100F battery, manual battery test. Updated: packing list, scope.

RZ

DOCUMENT DISTRIBUTION CONTROL

Copy No: 1 Controlled: X Uncontrolled:





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Eltek Valere Australia Pty Ltd ACN072 645 446 ABN 90 072 645 446

Unit 1, 22 Narabang Way

Belrose NSW 2085

Phone: (02) 9479 4200

E-Mail (Sales Dept.): [email protected]

E-Mail (Service Dept.): [email protected] E-Mail (all departments): [email protected]





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TABLE OF CONTENTS

1. SCOPE .......................................................................................................................................... 5 2. SYSTEM OVERVIEW ................................................................................................................ 6 3. REQUIREMENTS ..................................................................................................................... 11

3.1 INSTALLATION REQUIREMENTS .....................................................................................................................11 3.2 FOR COMMUNICATION WITH THE CONTROLLER: ...........................................................................................11 3.3 WARNINGS ...................................................................................................................................................12

4. PACKING LIST ......................................................................................................................... 14 5. SYSTEM CONFIGURATION .................................................................................................. 14 6. UNPACKING ............................................................................................................................. 15 7. CABINET ASSEMBLY ............................................................................................................. 16 8. FLOOR FIXING ........................................................................................................................ 17 9. EARTH CABLING .................................................................................................................... 17 10. CONNECTING THE BATTERIES ...................................................................................... 18

10.1 SYMMETRY CONNECTIONS ..........................................................................................................................19 10.2 CONTROLLER SETUP ...................................................................................................................................20

11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS. ............... 25 12. EXPANSION RACK ALARM CONFIGURATION .......................................................... 25 13. BATTERY VOLTAGES ........................................................................................................ 26

13.1 REFRESHING OF BATTERIES ........................................................................................................................26 13.2 LOW VOLTAGE BATTERY DISCONNECT (LVBD)........................................................................................26 13.3 TEMPERATURE COMPENSATION ..................................................................................................................26

14. EXPANSION RACK INSTALLATION CHECK LIST ..................................................... 28 15. INSTALLATION AND OPERATION OF RECTIFIER MODULES .............................. 29

15.1 VISUAL INDICATIONS..................................................................................................................................30 15.2 PLUGGING IN RECTIFIERS ...........................................................................................................................31 15.3 REPLACING AND INSTALLING RECTIFIER MODULES .....................................................................................31 15.4 RECTIFIER EFFICIENCY MANAGEMENT / LOAD SHEDDING ..........................................................................32

16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER ....................... 33 17. OPERATION OF THE SMARTPACK CONTROLLER .................................................. 35

17.1 FRONT PANEL OPERATION ..........................................................................................................................35 17.2 OPERATING MENUS, (MENU MODE) ...........................................................................................................37 17.3 FRONT KEYPAD MENU TREE FOR SMARTPACK CONTROLLER: .....................................................................38

18. ALARM MONITORING ....................................................................................................... 39 18.1 ALARM PCBS .............................................................................................................................................39 18.2 ALARM OUTPUTS ........................................................................................................................................40 18.3 ALARM CONNECTIONS ................................................................................................................................40 18.4 ALARM LEVELS SETUP ................................................................................................................................41 18.5 DIGITAL INPUT POSITIONS. ..........................................................................................................................42

19. AC MAIN SUPPLY INSTALLATION ................................................................................. 43 20. DC DISTRIBUTION INSTALLATION ............................................................................... 46 21. INSTALLATION CHECKLIST ........................................................................................... 47 22. COMMISSIONING CHECKLIST ....................................................................................... 47

22.1 PRE-START / INITIAL CHECKS .....................................................................................................................47 22.1 SYSTEM START-UP .....................................................................................................................................47 22.3 CHECKING THE ALARMS .............................................................................................................................48 22.4 OTHER COMMISSIONING CHECKS................................................................................................................53 22.6 DEFAULT -48V SYSTEM SETTINGS .............................................................................................................54

23. ON-GOING MAINTENANCE PROCEDURES ................................................................. 55 23.1 GENERAL CHECKS .......................................................................................................................................55 23.2 MODULE MAINTENANCE .............................................................................................................................55 23.3 GENERAL ONGOING MAINTENANCE PROCEDURES ......................................................................................55 23.4 SYSTEM COMPONENTS MINIMUM OPERATING LIFE ....................................................................................56

24. USING POWER SUITE SOFTWARE ................................................................................. 57 24.1 INSTALLATION OF POWER SUITE SOFTWARE ...............................................................................................57 24.2 USING POWERSUITE V3.X: A START UP GUIDE. ..........................................................................................58 24.3 USING POWERSUITE V3.X: OPERATION. .....................................................................................................58 24.4 EFFICIENCY MANAGEMENT ........................................................................................................................67





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24.5 SAVE/LOAD ―XML‖ FILE .............................................................................................................................68 25. ATTACHMENTS ................................................................................................................... 70





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1. SCOPE

This Installation and Commissioning Manual provides simple instructions as to the

installation requirements for the Eltek -48 Volt DC Flatpack2 system. All maintenance &

installation work must be carried out by suitably trained personnel. This manual also includes

Operation & Maintenance information and technical data regarding the Flatpack2 and

Smartpack controller.

Part number # battery strings # rectifiers Note

A111223.001 1 x 12NDF100 2 x HE All these systems can be expanded with the

A461033.001 battery expansion rack

A112007.001 1 x AG12V100F 2 x HE

SEF29-X-189 0 0

SEF29-5BS9-181 5 9

SEF29-11BS9-182 11 9 Expanded with SEB6-12NDF100

Table 1.1

System Part numbers

Part number Note/Component

A111223.xxx

„Base model‟ cabinet contains no rectifiers. Can accommodate up to 6 strings of 12NDF100 or AG12V100F batteries (11 strings using the A461033.001 rack)

A112007.001 FlatPack2 16kW 5 battery shelves System, contains 1 x 118 Smartpack, 2 rectifier, LVBD, 1 string of gel battery

A601182.000 Upgrade Kit, 1 String AG12V100F battery & 1 x HE Rectifier

242100.110 Smartpack Controller

242100.118 Smartpack Controller Web/SNMP (Optional)

241115.100 2 kW Flatpack2 Rectifier

241115.105 2 kW Flatpack2 HE Rectifier (Optional)

A461033.001 Battery Expansion Rack, up to 6 strings of 12NDF100 or AG12V100F batteries.

12NDF100 Narada 12V, 100Ah, AGM, front access VRLA battery.

AG12V100F Narada 12V, 100Ah, Gel, front access VRLA battery.

Table 1.2

Component Part numbers





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2. SYSTEM OVERVIEW

The Flatpack2 system is a 18kW -48V DC power system comprising of:

1 Main System Cabinet (Figure 2.1, 2.2, 2.3 and 2.4)

Up to 9 FlatPack2 -48V 2kW rectifiers

Or 8 Flatpack2 -48V 2kW rectifiers HE rectifiers

1 x 118 Smartpack Control Module, Ethernet

Ethernet extension port

5 Battery shelves

Expansion Battery Cabinet (optional, Figure 2.5)

If required, the main system cabinet can be supplemented with a battery expansion cabinet for

increased battery capacity. Details of the expansion battery cabinets are given later in this

manual.

Figure 2.1

Top view with cover removed.

Monitor fail PCB

95mm² earth cable

Battery expansion rack alarm

0V DC bar (SPC)

Alarm PCBs

Anderson connector for battery expansion rack

Serial Number lable

System connection board

Load CBs

Symmetry PCB (hidden)

AC mains input

Output cable management rail





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Figure 2.2

Front and side views of a A111223.xxx

2200mm(H) x 600mm(W) x 400mm(D)





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Figure 2.3

Front and side views of a A111223.xxx

2067mm(H) x 600mm(W) x 400mm(D)





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Figure 2.4

Front and side views of a A111223.001

2067mm(H) x 600mm(W) x 400mm(D)





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Figure 2.5

Front and side views of battery expansion cabinet with A461033.001, with 12NDF100/AG12V100F

2200mm(H) x 600mm(W) x 400mm(D)





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3. REQUIREMENTS

3.1 Installation requirements

Termination or configuration of the AC Mains connection is only to be performed by

a licensed electrical installer.

Standard tools used by an authorized electrician.

A torque wrench for installing the battery cable bolts.

The system should only be installed into locations that have restricted access to personnel.

IMPORTANT: All tools should be insulated

3.2 For communication with the controller:

A laptop computer running either windows 2000 or windows XP (preferred).

PowerSuite software on CD (supplied with system).

Standard A-B type USB cable.

RJ45 cable for Ethernet connection (crossover cable for PC or straight cable for LAN)

IP Setup software on CD (supplied with system).





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3.3 Warnings

IMPORTANT: DO NOT mix the standard VRLA (12NDF100) and Polymer Gel

(AG12V100F) Batteries, despite having the same system settings, as batteries they

have different electrochemical properties (for example different internal resistance)

these characteristics can cause dissimilar performance during charging and

discharging process (example: particular string can be discharge faster than the others

but will be slow to recharge) which can affect the service life of the battery bank.

Communications Grade valve regulated gas recombination lead acid cells and

monoblocs are electrically live at all times and must be treated with care. The products

are generally capable of supplying high short circuit currents even if the case or lid is

damaged. Remember that the battery is electrically live at all times and cannot be

isolated in the conventional sense, although the voltage at any point can be reduced by

removal of appropriate inter battery links. Take care that short circuits are not caused

by accidentally dropping or touching metal objects onto the cell or monoblocs

terminals.

Before connecting batteries and cables remove all metallic objects such as rings,

watches etc from your hands and wrists to avoid causing a short circuit.

Do not smoke or permit open flames near batteries. Avoid any activity near the

batteries that may cause sparks.

If the rectifier module is damaged in any way or develops a fault it should be replaced

immediately. This should only be done by appropriately qualified personnel. Refer to

the operations manual for instructions.

The equipment contains voltages that may be lethal. The AC distribution front cover

plate should not be removed without first isolating the AC supplies. AC supply

connection should only be done by appropriately qualified personnel.

Allow for adequate ventilation around the units. A 5 –10 mm clearance should be kept

between the batteries as they may expand in high temperatures.

Be aware that the rectifier is rated for high temperature operations. Therefore care

must be taken when handling the modules as they can reach temperatures of 60oC





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The system must not be located in an explosive atmosphere, i.e. in the presence of

flammable gases and fumes. Suitable ventilation for the battery must be provided.

Narada 12NDF100 batteries are heavy, 33kg, & may require two people to lift.





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4. PACKING LIST

A fully equipped Flatpack2 system is dispatched from Eltek Pacific in a number of packages.

Each package is clearly marked indicating its content. The packages include the following:

1 x Rectifier Cabinet box OK Rectifier Cabinet Accessories Insulation panel Manual on CD Controllers modules Rectifier modules

Note: The cabinet may contain 1 Smartpack controller and can have up to 9 x 2kW FlatPack2

rectifiers or up to 8 x 2kW FlatPack2 HE rectifiers already fitted.

1 x Battery Cabinet box (if ordered) OK Battery Cabinet Dynabolts DC power connection cable with Anderson connectors (For connecting the battery rack

and the rectifier rack)

Earth cable Symmetry/alarm PCB Extension cable

Battery crates OK Batteries as required (Monoblocs) Solid links (Attached to the inside of the cardboard battery box)

5. SYSTEM CONFIGURATION

The different configurations of the Flatpack2 system and expansion battery cabinets are listed

below:

All systems except A111223.001 are 2200MM (H) x 600MM (W) x 400MM (D), and all

use Narada 12NDF100 batteries.

A112007.001 and A111223.001 system are 2067MM (H) x 600MM (W) x 400MM (D), and

they use either Narada 12NDF100 or AG12V100F batteries.

A112007.001 has maximum of 9 rectifier slots.

A111223.001 has maximum of 8 rectifier slots





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6. UNPACKING

All equipment is suitable for being moved with a normal pallet truck whilst packed. When

unpacked, cabinets may weigh 145kg and are heavier at the top end of the cabinet.

IMPORTANT: These units are top heavy, and can tip over unexpectedly if not handled

with care.

Appropriate lifting equipment should be used, and suitable care must be taken while handling

these units. The most appropriate method of moving the racks is with the use of a hand

trolley. Some packaging material should be placed between the trolley and the rack to avoid

damage to the rack. It is however recommended that the complete boxes be positioned as

close as possible to the actual location where the system is to be installed.

IMPORTANT: If lifting using eye bolts, a spreader bar must be used.

Figure 6.1

Lifting arrangement for the cabinet, using eyebolts and spreader bar

Lifting Cables Spreader bar, used to prevent eyebolts from bending inwards M8 Eyebolt, placed in the wall mounting bracket‟s bolt position Cabinet





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7. CABINET ASSEMBLY

The Cabinets will arrive packed in a box. The following are instructions for assembling this

cabinet.

1. Inspect the installation site and determine where the system will be located. Position the

packages close to the final systems destination.

2. Each package will have affixed to it, a complete packing list, listing the contents of each

package and the quantity. Check to ensure that you have all items marked on the packing

list.

3. Unpack the cabinet from its box.

4. Follow the floor fixing instructions in the next section to fix the cabinet in position.

5. Attach the cabinet to the wall using wall mounting brackets insulation kit.

Figure 7.1

Top wall mounting bracket and insulation kits





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8. FLOOR FIXING

All cabinets include a fixing kit. One fixing kit consists of 4 round washers and 4 dynabolts.

Bolt through the 4 holes in the bottom using dynabolts.

Figure 8.1

Dynabolts Fixing

9. EARTH CABLING

Each cabinet should be bound to earth using links. There is one 95mm² earth cable shipped

with each cabinet. Ensure this converter cubicle bond is bonding the cabinet M8 bolt to the

positive common bar (SPC) inside the cabinet, creating a bonded -48V DC supply. External

earthing should be done to relevant company standards, to the common positive bar.

Also connect the battery extension cabinet, if being used, to the SPC inside the rectifier

cabinet with the 95mm² earth cable supplied with the extension cabinet.

Dyna-bolt

Nut

Washer

Concrete Floor

Cabinet





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10. CONNECTING THE BATTERIES

IMPORTANT: DO NOT mix the standard VRLA (12NDF100) and Polymer Gel

(AG12V100F) Batteries

The FlatPack2 system is supplied with a 100A battery circuit breaker with auxiliary for each

string. The string CB‘s are located on the left-hand side of each battery shelf. The system is

supplied with cables from the battery CB‘s to the battery trays already fitted. Ensure that the

battery CB‘s are turned OFF before connecting the batteries. See the attachments section at

the end of the manual for the battery MSDS. All unused battery CBs should be switch on

to prevent a battery CB alarm. For battery shelves not being used, ensure cable ends

remain insulated with heat shrink provided.

Installation Steps

1. Before commencing the installation, ensure that each battery is in good condition and

has not been damaged during transport. When installing, be careful that the case of the

battery is not permitted to be cracked by resting or dropping on anything pointed.

2. Monoblocs are heavy; and accordingly the recommended lifting equipment should be

used.

3. Remove rack battery retaining strap. Position the batteries on shelves as per Figure

10.1. We suggest that one monobloc be lifted into place at a time. Leave a clearance

space of between 5 – 10 mm between the batteries. Slide the batteries gently back to

the rear of the system to avoid any risk of damaging them on the rear of the shelf.

4. Particular care should be taken when placing on the shelves to ensure the correct

positioning of the positive (red) and negative (blue) terminals.

5. Connect inter battery flexible cables and inter tier links. To ensure a low resistance

joint, clean the flat contact making surfaces of the terminal posts and connectors with

a soft clean cloth. The links do not normally require cleaning and can be fitted without

any operation. However in some cases the links could show encrustation and this

should be removed using Scotchbrite or fine grade abrasive paper. Do not use a wire

brush and be especially careful not to break through the lead plating. Apply a light

coating of grease to the contact – making surfaces and place a solid connector strap or

flexible link in position.

6. Connect the symmetry loom (if used) to the battery terminals. See section 10.1 for

more information on symmetry connections.

7. Tighten the nuts firmly: 7-8 Nm using an insulated torque wrench. Lightly smear

grease on the washer and bolt.

8. Place battery link covers on all battery links.

9. Place the battery numbering labels in place starting at the first battery (on the bottom

shelf) and working to the last.

10. Update the Smartpack controller information for # of symmetry strings.

11. Wait 24 Hours and re-torque the battery terminals.

IMPORTANT: Particular care should be taken to ensure the batteries are not short-

circuited during this procedure. Short circuit current is approximately 2000A





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10.1 Symmetry connections

The main rectifier rack contains a symmetry connection card or a symmetry monitor box that

needs no configuring. This card contains a temperature probe connection, as well as battery

symmetry connections. While using symmetry monitor box, the temperature probe is

connected to CON4. Both the symmetry card and symmetry monitor box can monitor up to

four strings of batteries and uses the ‗Mid-point measurement‘ method. The battery expansion

rack contains its own symmetry card or symmetry monitor box with similar connections as

above, but the temperature probe is not used. The symmetry loom is only connected to the

first four battery strings of each rectifier or battery expansion cabinet.

Figure 10.1

Symmetry connection point, to either side of the middle hard link

M6 Ring terminals for battery connections

Figure 10.2

Symmetry PCB connection points

Rectifier rack Optional expansion rack

Controller

CON 3

CON 4

Battery symmetry

connections Temperature probe

Battery symmetry

connections

Symmetry PCB

Symmetry PCB

symmetry connection

Positive battery cable

Negative battery cable - + - + - + - +

Battery 4 Battery 1





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Figure 10.3

Symmetry Monitor Box connection points

10.2 Controller setup

Five parameters will need to be adjusted when adding to the number of battery strings or

rectifiers. Shown below are tables and snapshots from PowerSuite on how to change the

systems setup when additional rectifiers and batteries are added. For details on how to

connect to the controller using a PC, see section 24, using PowerSuite.

1) Change the number of strings installed, refer to Figure 10.4

2) Change the rectifier over current alarm, refer to Figure 10.5

3) Set the Battery Current limit, refer to Figure 10.6

4) Activate the extra strings to be monitored by symmetry, refer to Figure 10.7

5) Redeploy temperature compensation probe to the top of the uppermost installed

battery string when installing extra battery strings, refer to Figure 10.8

Battery symmetry

connections

Battery symmetry

connections

Rectifier rack Optional expansion rack

M6 Ring terminals for battery

Smartpack

Symmetry Monitor Box

Symmetry Monitor Box

CAN CAN

CON4

CAN

Temperature probe

CAN





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1. Change the number of strings.

No. of rectifiers

(system current

rating)

Rectifier

capacity alarm

setting (60%)

Number of

rectifiers

Number of

battery

modules

(strings)

Battery

current limit

setting

2 (37A) 22A 2 1 10

3 (74A) 44A 3 2 20

4 (111A) 67A 4 3 30

5 (148A) 89A 5 4 40

6 (185A) 111A 6 5 50

7 (222A) 133A 7 6 60

8 (259A) 155A 8 7 70

9 (296A) 178A 9 8 80

9 90

10 100

11 110

Table 10.1

Controller settings for each level of upgrade

This value is needed for correct battery testing as this value is multiplied by the Ah of the

battery to give the total system capacity.

Figure 10.4

String number screen (using Power Suite 3.x)

DO NOT change this value





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2. Change the rectifier over-current alarm.

Table 10.2


Figure 10.5

Rectifier over-current alarm setting screen (using Power Suite 3.x)

No. of rectifiers

(system current

rating)

Rectifier

capacity alarm

setting (60%)

Number of

rectifiers

Number of

battery

modules

(strings)

Battery

current limit

setting

2 (37A) 22A 2 1 10

3 (74A) 44A 3 2 20

4 (111A) 67A 4 3 30

5 (148A) 89A 5 4 40

6 (185A) 111A 6 5 50

7 (222A) 133A 7 6 60

8 (259A) 155A 8 7 70

9 (296A) 178A 9 8 80

9 90

10 100

11 110

Important!

Make sure BOTH major and minor alarms are set to the new value





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3. Set the Battery Current Limit

Table 10.3


Figure 10.6

Battery charge current limit setting (using Power Suite 3.x)

No. of rectifiers

(system current

rating)

Rectifier

capacity alarm

setting (60%)

Number of

rectifiers

Number of

battery

modules

(strings)

Battery

current limit

setting

2 (37A) 22A 2 1 10

3 (74A) 44A 3 2 20

4 (111A) 67A 4 3 30

5 (148A) 89A 5 4 40

6 (185A) 111A 6 5 50

7 (222A) 133A 7 6 60

8 (259A) 155A 8 7 70

9 (296A) 178A 9 8 80

9 90

10 100

11 110





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4: Activate symmetry battery strings.

Click on the battery strings that have symmetry loom connected & press the tick box to

activate the monitoring on that string. Note: the top battery string will not have a symmetry

loom connection, so with 5 strings connected, only the bottom 4 will be monitored & only

these should be activated. Also be aware that the symmetry alarm is a ‗latching‘ alarm that

will be present even when the initial cause has been removed. This will need to be manually

reset by the controller front panel, or by right clicking in the explorer tree to the left of the

screen & selecting ‗reset alarms‘. A Blue colour indicates that an alarm is actively monitoring

that string, grey indicates there is no monitoring, click to change.

Figure 10.7

Symmetry activation setting screen (using PowerSuite 3.x)

Figure 10.8

Install probe within the rack above batteries

Symmetry alarms can be collected via symmetry card (shown as symmetries under Battery Bank Tree) or symmetry monitor box (shown as BattMonStr.1 under Battery Tree). The procedures to configure them are the same

5 Redeploy temperature compensation

probe:

Important Note:

Redeploy temperature compensation

probe to the top of the uppermost

installed battery string when installing

extra battery strings. (Use cable ties to

fix it into place.)

Install

probe in

this area





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11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS.

Each expansion battery cabinet is fitted with a flying lead with an Anderson connector on one

end to connect, a 95mm² earth cable (to be attached to the SPC) & a battery alarm / symmetry

cable, all to be taken to the system cabinet:

1. Position expansion cabinet and fix it to the floor in the same manner as the rectifier

cabinet.

2. Ensure that all the individual string MCB‘s are turned OFF

3. Install the batteries and symmetry connections in the controller as detailed in section 10.

4. Double check all the string MCB‘s are OFF and connect the flying lead with the

Anderson connector to the existing rectifier cabinet as in Figure.11.1 below.

5. Once the battery strings are in place turn on the strings of batteries one by one. Pause

between turning each string on to let the system equalize with the string.

6. Check the string voltage and the battery current on the Smartpack display. There should

be a small positive current flowing to the batteries.

Rectifier Cabinet Battery Cabinet

Figure 11.1

Expansion rack connections

12. EXPANSION RACK ALARM CONFIGURATION

The battery alarms provide signals to the Smartpack control module via auxiliary switch‘s on

each battery circuit breaker. The purpose of this signal is to initiate an alarm condition if the

battery CB has tripped. This is a normally-closed loop which if broken, will create an alarm.

Each system cabinet is supplied with an alarm interconnection cable that connects the system

cabinet to the expansion battery cabinet. The alarm interconnection cable contains both

battery symmetry information, as well as the battery fuse fail alarm. This cable should be

brought back to the back of the Smartpack controller.

Flying Lead with Anderson Connector Battery CB

alarm & symmetry cable. Earth cable





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13. BATTERY VOLTAGES

13.1 Refreshing of batteries

Follow the below procedures to check whether a refresh operation is needed

1. Check the open circuit voltage of each battery.

The minimum monobloc open circuit voltage that the battery can be considered as not

requiring refresh is 12.72V. Any monoblocs that are below this voltage will have to be

refreshed as below. Above this value, they may be considered acceptable for use & do not

need to be refreshed.

2. Put the batteries on a float voltage charge of 54.48V for a period of 48 hours at 20degC.

3. After float charging leave the batteries to settle for a further 48 hours.

4. Check the open circuit voltages of the monoblocs.

The minimum monobloc open circuit voltage after refresh is 12.72V. Any monoblocs

that are below this voltage cannot be considered as serviceable.

13.2 Low Voltage Battery Disconnect (LVBD)

The Low Voltage Battery Disconnect (LVBD) contactor will disconnect the batteries if the

battery voltage falls below the disconnect voltage (set to 43.2V) to prevent the batteries from

deep discharge. The controller reconnects the batteries back on-line if the battery bus voltage

gets higher than the set reconnect voltage, typically when AC mains is restored.

The LVBD will only disconnect if BOTH the DC voltage is low, and an AC fail is active. In

this way, the LVBD will never activate during a requested battery test. The LVBD will also

disconnect any battery expansion rack connected to the system.

The LVBD mechanism uses a latching contactor that sends a momentary pulse of current to

the coil to activate / deactivate the contactor. In this way, a service switch is not needed to

keep the contactor closed during servicing of the system.

13.3 Temperature compensation

The system is supplied with a temperature-sensing probe for temperature compensation

charging. The temperature compensation cable is temporarily cable tied to the system. The

cable should be carefully untied and the transistor probe should be placed in the space

above the uppermost string of installed batteries for measurement of air temperature as

close as possible to the batteries. Do not rest the probe directly against any of the batteries

as this will give a false reading in the event of that individual battery having a fault.

Important Note: Redeploy temperature compensation probe to the top of the uppermost

installed battery string when installing extra battery strings. (Use cable ties to fix it into

place.)





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Figure 13.1

Temperature probe deployment should be near, but not touching, above the uppermost string of batteries.

Battery type Max compensation V/cell

Min compensation V/cell

Reference voltage

@ 25C/cell

Slope mV/deg/cell

12NDF100 2.310 2.205 2.25 -3.0

AG12V100F 2.310 2.205 2.25 -3.0

Table 13.1

Battery temperature compensation values.

Important Note: All power settings are the same for both AG12V100F and 12NDF100

Batteries.

Figure 13.2

Front view of batteries, showing spacing & battery circuit breaker position.

(Cables / links are not shown)

Install

probe in

this area

Battery CBs

Retaining bracket





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14. EXPANSION RACK INSTALLATION CHECK LIST

Check these points OK

Check that the cabinet is fixed to the wall securely.

Check that the battery connections are all of correct polarity.

Check that the terminal boots and battery link caps are fitted on all the batteries.

Check that the Anderson flying lead is connected.

Check that the battery rack expansion rack earth cable is securely connected to the common positive bar (SPC) inside the rectifier cabinet.

Symmetry loom is connected.

Check that battery string voltage is between -48 and -55 V.

Check that the MCB alarm cabling to the main rack is installed and terminated.

Table 14.1

Expansion Rack Installation Check List





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Handle in unlocked position

15. INSTALLATION AND OPERATION OF RECTIFIER MODULES

If for any reason any of the rectifiers have to be removed, or additional rectifiers are being

fitted, please refer to the following procedure. Each rectifier is automatically logged with the

controller & starts operation immediately upon insertion. However, additional rectifiers

require changes to relevant alarm settings, see section 10. For important information

regarding rectifier operation and positioning also see section 25. Noted that the Flatpack2

rectifier module is a ―Hot‖ plug rectifier allowing expandability and serviceability without

power shutdown. The current share functionality of the modules ensures all modules deliver

the same amount of current. The FlatPack2 rectifier cabinet accommodates up to 9 FP2

rectifier modules or up to 8 FP2 HE rectifiers. The HE rectifier use the same install and

uninstall procedures as the FP2 2kW modules

Installing rectifiers

1. Unpack the rectifier modules from their packaging.

2. Refer to section 15.3: for information regarding the correct rectifier positioning.

3. With the system on, slide each module into place, but do not push the rectifier all the way

home at this point. Make sure the pull out handles have been released as shown in Figures

15.1 and 15.2 below, then push the unit into place and lock the rectifier into position by

pushing the handles firmly into their housing.

Figure 15.1 Figure 15.2

To remove a rectifier, follow the steps below:

1. Unlock and release the handles by inserting a small screw driver into the holes in the upper

corners of the rectifier front panel and carefully push it downwards. The handle will release

and pop out.

2. Use the handles to pull the rectifier loose.

IMPORTANT: During continuous operation, the metal case of the rectifier unit can

become hot. There is no danger of contact burns occurring, but care should still be

taken when handling recently unplugged rectifiers.

IMPORTANT: Rectifier efficiency management may be active on this system. This will

cause some under-used rectifiers to periodically power on & off and show no LED

display on the front of the rectifier. This function is detailed in section 15.4 .

Holes to release the handles spring mechanism





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Figure 15.3

Front view of Flatpack2 2kW and HE rectifier modules

The Flatpack2 is intended for use as a stand-alone unit or in systems with multiple modules

and an external alarm / control module. The Flatpack2 will operate in a default mode if the

control module fails

The Flatpack2 Rectifier Module has the following LED indications:

―Power‖ (green) indicates whether the power supply is OFF, ON, or communicating.

―Alarm‖ (red) indicates an alarm situation.

―Notice‖ (yellow) indicates an atypical situation.

15.1 Visual Indications

LED Status Description

Power (green)

ON Rectifier is powered

Flashing Smartpack controller accessing information on the rectifier

OFF Mains are unavailable

Alarm (red)

ON

Rectifier is in Shut-down Mode due to low mains (0 – 85VAC) or high internal temperature (+75 °C or higher) or high output voltag

CAN bus failure

OFF No alarm situation is present

Notice (yellow)

ON

Rectifier is in Derating Mode (reduced output power) due to high internal temperature (+45 to 75 °C) or low input voltage (lower than 185VAC) or fan failure

Current Limit is activated

The rectifier is communication with the controller over a current sharing / current limiting issue

Rectifier in stand-alone mode (or loss of communication with the Smartpack controller

Flashing Rectifier is in Over-voltage Protection Mode

OFF No atypical situation is present

All off AC mains Fail.

Rectifier efficiency management is active. See 15.4

Table 15.1

Visual alarm indications





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15.2 Plugging in Rectifiers

When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller

automatically assigns the next available ID number to the rectifier, starting with ―01‖. This

ID number (or CAN bus address) and the rectifier‘s serial number are stored in both

SmartPack and Rectifier modules. When a previously installed (hot plugged) Flatpack2

rectifier is inserted in a power shelf, the Smartpack controller ―recognizes‖ the module, and

assigns the same ID to the rectifier. In other words, the controller and the rectifier

―remember‖ the assigned ID and serial numbers, even after removing and reinserting the

rectifier in the shelf. To achieve a more controlled ID assignment, you should always insert

& hot-plug new Flatpack2 rectifiers in the power shelves, one module at a time, starting with

shelf position 1, 2, and 3 and so on.

15.3 Replacing and installing rectifier modules

If a upgrading a system with additional rectifiers

Place the new rectifiers into the next highest rectifier position, in order. See table below.

Their existence will be automatically logged by the controller, no further configuration is

required.

If a replacing a faulty rectifier and a replacement rectifier is immediately available

1. Fit the new rectifier into the position left by the faulty rectifier.

2. Eliminate any rectifier alarm by performing a „rectifier recount‟ that resets the

number of rectifiers using the front keypad, under service menu (see section 17.3)

If a replacing a faulty rectifier and a replacement rectifier is not immediately available

1. Remove the highest ID rectifier (important) and fit into the vacant faulty rectifier

position, in order to maintain continuity.

2. Eliminate any rectifier alarm by performing a „rectifier recount‟ that resets the

number of rectifiers using the front keypad, under service menu (see section 17.3) The

highest ID rectifier is now reassigned to the ID of the faulty rectifier in the system.

3. When a new rectifier is obtained, fit it into the highest vacant ID position. Its

existence will be automatically logged by the controller.

Smartpack (controller)

ID1 ID4 ID7

(Blank) ID2 ID5 ID8

(Blank) ID3 ID6 ID9

Table 15.2

Rectifier ID positions for C801047





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ID1 ID2 ID3 ID4

ID5 ID6 ID7 ID8

Table 15.3

HE Rectifier ID positions for A111223.00x

15.4 Rectifier efficiency Management / Load shedding

Efficiency Management is an elegant way of maximizing both the lifetime of the rectifiers

installed in the system & also utilizing the AC input power most effectively. To do this, the

controller can send a signal to de-activate under-used rectifiers. This will accomplish two

things; the shutdown rectifiers will no longer be in active use & will therefore have an

extended lifetime / MTBF. The remaining rectifiers will potentially be operating closer to

their peak efficiency value which is in the range of 40% to 90%.

All rectifiers will eventually be cycled into & out of active use by this method over the course

of many hours. The controller will always ensure that there are enough rectifiers active to

supply the load, including an additional active redundant rectifier. If at any time the load were

to increase, additional rectifiers will be taken on-line in a matter of seconds. Also, if any

rectifier error were to occur, then all installed rectifiers will be taken on-line, effectively

disabling efficiency management until the error is cleared.

Turning off rectifiers

The system starts up with all rectifiers on. After a delay, the first rectifier will be turned off, if

the average load is below the power limit set by the selected policy. Then a new cycle of

average calculation is started, another rectifier is turned on, and after a delay to confirm that

the new rectifier is operational, the next rectifier is turned off.

Turning on Rectifiers

The average load is monitored continuously. If the system load increases above the ‗high

load‘ limit, the number of operating rectifiers is increased by the number needed to get the

average load within limits.

Safety

There are certain system events that may halt the efficiency manager. These events will

immediately turn on all rectifiers and set the efficiency manager to idle mode.

1. One or more rectifiers stops communicating or has an error.

2. The number of rectifiers installed is changed.

3. System Voltages is changed

4. Battery Boost or Test is started

IMPORTANT: When a rectifier is operating in efficiency management mode,

no lights will be shown on the front of the rectifier.





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16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER

The Smartpack controller is physically held in place using a similar method as the Flatpack2

rectifiers: It incorporates handles that serve both to lock the module into position and to pull it

out of its housing.

IMPORTANT: Do not hand-carry the controller by its restraining handles.

If in the event that the Smartpack needs to be removed for any reason the following procedure

should be used:

1. Release the handles (using similar method as the Flatpack2 rectifiers as described

above)

2. Grasp the Smartpack by the handles at either side of the unit and pull the unit out. The

connection cables are attached to the rear of the controller via several ‗D‘ type

connectors. Pull out the controller enough to access the rear of the unit, and unplug the

cables as detailed over page. See Figure 16.3

IMPORTANT: Open the handles before inserting the controller into the power shelf.

To refit the Smartpack:

3. Carefully reconnect the cables to the appropriate positions in the rear of the controller.

4. Slide the controller unit into place making sure that all cables are not overly bent.

5. Fasten the unit by firmly pushing the handles into their housing.

Removing the Smartpack controller:

1) Open the handles (insert a screwdriver into the holes to release the spring mechanism) Remove the module

2) Use both handles to pull the module gently loose; support it from underneath; hidden cables are connected to the rear panel.

Figure 16.1

Rectifier locking mechanism





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Figure 16.2

The rear of the smartpack controller

Plug Function

CAN 1 Data bus 120 terminating resistor

CAN 2 Communication with the FP2 rectifiers

CON 1 Alarm relay 1-2 & inputs 1-2


CON 3 Battery expansion symmetry

CON 4 Local rectifier cabinet symmetry & temperature

CON 5 Controller power, voltage measurement, CB fail & other system connections

Table 16.1

Controller connection key

Figure 16.3

The rear of the Smartpack controller Web/SNMP

Plug Function

CAN 1 Data bus 120 terminating resistor

CAN 2 Communication with the FP2 rectifiers



CON 3 Not Available

Ethernet RJ45 Port for web server and SNMP

CON 4 Local rectifier cabinet symmetry & temperature

CON 5 Controller power, voltage measurement, CB fail & other system connections

Table 16.2

Controller Web/SNMP connection key

Ethernet Port





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17. OPERATION OF THE SMARTPACK CONTROLLER

The Smartpack unit controls, monitors and regulates each FlatPack rectifier module and

provides battery & system surveillance in order to protect and optimize the battery lifetime. If

the alarm module is removed, voltage control / regulation will be lost and system voltage will

equal to default rectifier voltage.

17.1 Front Panel Operation

This chapter describes the Smartpack controller‘s keys and indicators, and how to operate the

Flatpack2 DC power system from the controller‘s front panel. The Smartpack controller‘s

front panel consists of two functional areas: the presentation area (LCD display and LED

lamps) and the control area (keys).

Figure 17.1

Smartpack front panel

LED indicators

The Smartpack controller has the following LED indications:

―Power‖ (green LED) indicates that the power supply is ON or OFF

―Alarm‖ (red LED) indicates an alarm situation (major alarm)

―Notice‖ (yellow LED, or minor warning) indicates an atypical situation.

LCD display

The graphic display is an important part of the power supply system‘s user

interface. The display can be shown in Status Mode (displays the system‘s status)

or in Menu Mode (displays the menu structure). Depending on the display‘s

mode, the upper line shows the output voltage or menu options, while the lower

line displays battery and load current, alarms, or information about which key to

press.





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Front Keys

You can control the many of the Flatpack2 DC power systems via a network of

software menus accessed with the controller‘s front keys.

Press the key to change from Status Mode to Menu Mode.

Press the or keys to scroll up or down and navigate to find menu

options (function or parameter).

Press then the key to select the function.

Modes of Operation

The controller‘s display is either in Status Mode or in Menu Mode.

Status Mode

When the front keys are not in operation, the display is in Status Mode. The

following information is then scrolled through the display:

The upper line continuously displays the battery voltage.

The lower line continuously scrolls the following information: Press to ‗fast

forward‘ through the messages.

Battery Current

Load Current

Active alarms

Other messages

Menu Mode

When the front keys are in operation, the controller‘s display switches to Menu

Mode and the following information is scrolled through the display:

The upper line shows the name of the active menu or sub-menu

The lower line indicates which key to press

IMPORTANT: If no keys are pressed within 30 seconds the display will automatically

switch from Menu Mode to Status Mode.





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17.2 Operating Menus, (Menu Mode)

The Flatpack2 DC power system‘s functionality is accessed via a network of

software menus and submenus, enabling you to configure and control the whole

power system.

The functionality is divided in two different hierarchical menu structures: the

User Options menus and the Service Options menus (password protected, only

authorized personnel have access to them).

Special, not so frequently used options — such as calibration and adjustments —

are accessible in the Service Options sub-menus.

User Options

When you ―enter‖ Menu Mode, you access the User Options.

How to browse the display menus:

To enter Menu Mode

Press on the key to change from Status Mode to Menu Mode

Browsing “down” to a menu option

Press the key, to scroll down within the same menu level, and find menu

options (functions or parameters)

Selecting a menu option

Press the key to select the displayed menu option or parameter

Browsing “up” to a menu option or level

Press the key to scroll up to the previous menu option, and out to the

previous menu level.

Service Options

When you enter Menu Mode, you access the User Options. You may then scroll

down to the password protected Service Options.

The Service Option‘s password is factory-programmed to <0003>. If the wrong

password is entered three times, the controller will be locked out for a period of

time.

IMPORTANT: If no keys are pressed within 30 seconds the display will automatically

switch from Menu Mode to Status Mode.





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17.3 Front keypad menu tree for Smartpack controller:

Figure 17.2

Rectifier reset is now under the service menu.

Mains Info NoOfPhases nn

Mains Status

Mains Voltage

Temp Level Info Temp Level Info

Display messages Display messages

Serial Number Controller S/N

Alarm Reset Alarm Reset

Voltage Info NomVolt

BoostVolt

LowBatt1

LowBatt2

HighBatt1

High Batt2

LVD1

LVD2

SwInfo Sw Info

NoOfRects. Nn

RectCurrent

RectSerialNumber

Rect.PrimaryVolt

Rectifier Status

Rectifier Temp

Rectifier Info

Rectifier SW Ver

Rect OutputVolt

Change Language

Volt Calibration VoltCal

Change Password Password

Set MANBoostTime BoostTime

Start/StopBoost StartBoost/StopBo

ost

Auto Boost Cfg Enable/Disable

Threshold

Batt. Test Setup Nxt Test Date

Time

End Volt

Max Test Duration

Test Interval

Guard Time

Charge Curr Lim Enable/Disable

Max ChargeCurr

Battery Setup NumOfStrings

OutputControl Temp.Comp

VoltageControl Change Date/Time

Relay Test Alarm Output 1

Batt Contactor

Load Contactor

Alarm Output nn

Alarm Output 2

BattLifeTime Rst BattLifeTime Rst

NomVolt

BoostVolt

LowBatt1

LowBatt2

HighBatt1

High Batt2

LVD1

LVD2

VoltAdjustment

Start/Stop Test StartTest/StopTest

No of Rects

RECTIFIER

RESET

Password = 0003

User Service





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18. ALARM MONITORING

18.1 Alarm PCBs

The Smartpack controller incorporates 6 alarm relay outputs and provides both normally open

and normally closed states on the output relay. See table 18.2 for pin connections.

Figure 18.1

Relay Output Card 1; inputs 1 & 2, and outputs 1 & 2

Figure 18.2

Relay Output Card 2; inputs 3 to 6 and outputs 3 to 6

Figure 18.3

Monitor Fail PCB





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18.2 Alarm Outputs

Alarm Relays Alarm Relays

Low load 1 & 4 Low float 2

High load 1 High float 2

Critical Rectifier fail 1 & 6 Single rectifier fail 2 & 6

Mains fail 1 Batt test active 2 & 5

Load / Batt CB fail 1 & 3 Batt test failed 2

LVD disconnect 1 & 4 Rectifier capacity alarm 2

Temp probe fail 2

Batt Symmetry alarm 2

Table 18.1

Alarm relay output positions

Relays 1,2 are on Relay output card 1, relays 3,4,5,6 are on relay output card 2. Monitor fail

is on a separate card. See the attachments section for full alarm matrix.

18.3 Alarm connections

CONTACT RELAY # RELAY OUTPUT CARD # PIN #

NO

1 1

5

COM 6

NC 7

NO

2 1

8

COM 9

NC 10

NO

3 2

9

COM 10

NC 11

NO

4 2

12

COM 13

NC 14

NO

5 2

15

COM 16

NC 17

NO

6 2

18

COM 19

NC 20

Table 18.2

Output relay pin connections





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Figure 18.4

Top view of monitor fail PCB showing connection points for monitor fail alarm.

18.4 Alarm levels setup

Alarm name Trigger

Failed AC supply Total loss, or low voltage value of any one phase, or all AC phases supply to the system.

Load / Battery CB fail Failure of any load or battery CB.

High Load voltage System voltage is above 57.6 VDC

High Float voltage System voltage is above 55.7 VDC

Low Load voltage System voltage is below 47.0V VDC

Low Float voltage System voltage is below 52.8 VDC

Rectifier fail Loss of output and input information from a rectifier. Loss of communication between Smartpack controller and rectifier. Removal of a rectifier from the system.

Critical rectifier fail More than one simultaneous rectifier fail.

LVBD Low battery voltage of 43.2V and mains fail.

Battery test failed Battery test fail or battery symmetry fail (or not connected).

Battery test active Battery test in progress.

Rectifier capacity Total rectifier output exceed set alarm value.

Temp probe fail Temp probe reading out of range or not connected.

System monitor failure

Smartpack failure

Table 18.3

Alarm triggers

Common

Normally closed

Normally open





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18.5 Digital input positions.

The Smartpack controller accepts up to 6 inputs.

Alarm State Relay Card

Pin

Input 1 + 1

1

Input 1 - 2

Input 2 + 1

3

Input 2 - 4

Alarm State Relay Card

Pin

Input 3 + 2

1

Input 3 - 2

Input 4 + 2

3

Input 4 - 4

Input 5 + 2

5

Input 5 - 6

Input 6 + 2

7

Input 6 - 8

Figure 18.5

Digital input locations

IMPORTANT: Normal operation is when the system is energized

and there are no alarms present on the system.

Pin 1 Pin 10

Pin 1 Pin 20

Relay Card 1

Relay Card 2





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19. AC MAIN SUPPLY INSTALLATION

AC mains connection terminals are provided for the AC mains connection. The terminals are

pre-connected to the rectifier modules. Cables of up to 10mm2 size can be connected to these

terminals. Termination or configuration of the AC Mains connection is only to be performed

by a licensed electrical installer.

When connecting power to this system, a nearby AC mains disconnect device should be

integrated into the circuit to facilitate servicing. This could be an isolating switch, circuit

breaker or equivalent device.

Phase distribution on rectifiers

The system is pre-wired to suit three single-phase AC supplies. The phase distribution of the

rack is shown below. While installing the rectifiers please ensure that they are distributed

evenly between phases to ensure a balanced load on each phase where possible.

Figure 19.1

Cabinet Front view.

Distribution

Controller L1 L1 L1

(Blank) L2 L2 L2

(Blank) L3 L3 L3

Table 19.1

AC Phase arrangement.

Phase 1 Phase 2 Phase 3





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Figure 19.2

Cabinet Front view (A111223.00x)

Figure 19.3

Cabinet Front view (A111223.00x).


L1 L2 L3 L1

L2 L3 L1 L2

Table 19.2

AC Phases arrangement (A111223.00x).





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The flatpack2 system is designed for 3 x Single-Phase Inputs:

Remove the top panel to access the AC mains terminals.

1) Bring the mains cable into the cabinet through

the top of the cabinet. The cable entry is through

the punch out holes on top of the cabinet. Cable

grommets (gland) need to be installed around the

hole for cable protection.

2) Ensure that any neutral bridges are removed.

3) Connect Earth conductor to terminal PE, Phase

conductors to terminals L1, L2 and L3, and

Neutral conductors to terminals N1, N2, N3.

4) Tie the incoming AC cables securely with cable

ties for support. Ensure that cables do not pass

through any sharp edges.

IMPORTANT: If re-configuring as a three phase input, ensure that the supplied

neutral links are installed

Figure 19.5

1 x Three-Phase input

IMPORTANT: AC mains isolation is at the shelter distribution board

The recommended upstream protection for 1 phase connection is shown below:

Number of rectifiers per phase Recommended mains circuit breaker

1 16 C

2 25 C

3 40 C

Figure 19.6

AC input CB size recommendation

May be cable jumpers

Figure 19.4

3xSingle - Phases





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20. DC DISTRIBUTION INSTALLATION

The FlatPack2 System is equipped with a 24-way distribution module fitted at the top of the

cabinet. The circuit breakers that can be fitted on the standard comb bus are 24x 1-63A

standard width (18mm pitch) type. The common terminal bar is located behind the load

circuit breakers and is accessible by removing the top cover.

-48V will be present on the output terminals of the MCB‘s even when in the off position and

no load is connected, due to MCB monitoring. There is no risk to personnel from this voltage.

The current available from the source for the fuse fail diode matrix (through the reverse

biased diode) at short circuit using a 20MOhm multimeter = 0.0052A when direct connection

is made to the cathode of the sensing diodes. This can be considered a safe level.

Position # from left Accommodate CB size CB Factory fitted

1 1 to 63A 63

2 1 to 63A

3 1 to 63A 63

4 1 to 63A

5 1 to 63A 63

6 1 to 63A

7 1 to 63A 63

8 1 to 63A

9 1 to 63A 40

10 1 to 63A

11 1 to 63A 40

12 1 to 63A

13 1 to 63A 40

14 1 to 63A

15 1 to 63A 40

16 1 to 63A

17 1 to 63A 10

18 1 to 63A

19 1 to 63A 10

20 1 to 63A

21 1 to 63A 4

22 1 to 63A

23 1 to 63A 4

24 1 to 63A 4

Table 20.1

DC load circuit breaker distribution (A111223.00x)

Load Cable Installation Considerations should be given to the entry arrangement of load

cables to ensure correct installation of additional load cables when the system is operating.

Ensure protective edging is fitted to any sharp edges over which cables pass. Ensure cables

are suitably supported by the internal cable management rail, making sure not to over stress

the common positive bar and circuit breakers.

IMPORTANT: Be aware that AC voltages are present within the system when

installing DC load cables.





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21. INSTALLATION CHECKLIST

Check these points OK

Check that the incoming AC connections are correct.

Check that the terminal boots and battery link caps are fitted on all the batteries.

Check that the load connections are of correct polarity

Check that battery string voltage is between -48 and -55 Vdc

Check that the external alarm cabling is installed and terminated

Check that the temperature probe is extended to the batteries.

Check that the temperature compensation is on (activated by default).

Table 21.1

Install Checklist

22. COMMISSIONING CHECKLIST

22.1 Pre-Start / Initial Checks

Check the following: OK

System installation is completed Check that the system installation has been correctly performed (ref. Installation sections of this manual).

Battery and load are disconnected Verify that the battery circuit breakers and load circuit breakers are in the OFF position.

Rectifier modules are connected Verify that all rectifier modules are plugged in properly & the front pull out levers are pushed in. NOTE: Rectifiers are allocated with a ID that is relevant to its position in shelves.

Rectifier system connected to mains supply and Protective Earth Check that the system‟s mains cable is connected to the mains supply.

Table 22.1

Pre-Start / Initial Checks

22.1 System Start-Up


Turn the system ON from the AC input supply

Read output voltage* (approx. 54- 55V)

Wait for about 1 min. and check there is DC output voltage* on the alarm module‟s display

Measure output voltage

Use a Digital Voltmeter* to verify that the output voltage is in accordance with the system‟s Default Settings (end of this section) and note in the section immediately to the right.

VDC

Rectifier modules are ON and without fault alarms

Verify that the Flatpack2 modules are in normal operating mode (not reporting alarms)





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Check and calibrate voltage reading in the alarm display

If the measured voltage deviates more than 0.2V from the display reading, re-calibrate the alarm module.

Measure DVM*

Display in Alarm Mod.

Switch the system OFF at the Input supply

Connect the load MCB Battery circuit breakers are NOT connected

Switch the system ON at the input supply.

Measure the Battery Voltage* Using a DVM measure the battery voltage

Measured with DVM*

Adjust output voltage to equal the measured battery voltage from the alarm module‟s keypad

adjust the rectifier output voltage to equal ( 1 V) the measured battery voltage. Temperature-compensated charging must be deactivated when adjusting the output voltage.

Close the battery circuit breakers It is important that the system is switched ON before connecting the batteries. Otherwise, the battery terminals could be damaged by high currents trying to charge the rectifiers‟ internal capacitors.

Adjust output voltage (float voltage) from the alarm module‟s keypad to the voltage recommended by the battery manufacturer (54.0Vdc at 25°C) Verify that the Low Battery Alarm is not activated. Record the voltage*

Measured with DVM*

*DVM must be a Calibrated True RMS meter

Table 22.2

System Start Up

22.3 Checking the Alarms

The Alarms are factory pre-set and should not require any re-setting on site. To verify the

operation of the Alarms use the following procedure.


1) Mains Fail Turn off the mains power at the input MCB‟s and let the batteries supply the load. Verify if the Alarm LED is illuminated on the Alarm Module. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. Please ensure batteries are connected prior to starting this test. Turn on the mains again and verify that the Active alarm is automatically reset.

2) Voltage Alarms The voltage alarms can be tested using any method in which the system voltage can be varied, or the alarm setting can be adjusted. Two methods are listed here.

External Power Supply Method

Isolate the batteries from the system and connect a 0-60Vdc external power supply to the output bars. Ensure the correct polarity when connecting!

Once the mains to the system are turned off, the controller will display the output voltage of the external power supply. The power supply can then be adjusted to activate the various high and low voltage alarms.

This method will have a constant mains alarm as well as the alarms being tested.

Adjusting Alarm Activation Level Method





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Connect a PC/laptop to the Smartpack controller and run the latest version of Powersuite.

Once each of the alarms (below) has been tested, ensure you change their alarm levels back to their original values. Each alarm is to be tested, one at a time.

To test High Battery Alarm 1 (High Float), change its value to at least 0.5V below the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.

To test High Battery Alarm 2 (High Load), change its value to at least 0.5V below the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.

To test Low Battery Alarm 1 (Low Float), change its value to at least 0.5V above the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.

To test Low Battery Alarm 2 (Low Load), change its value to at least 0.5V above the system voltage. This will activate an alarm on the display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.

3) Rectifier Fail Ensure the rectifier is off then insert a plastic object into the fan of the rectifier. Turn ON rectifier; this should give a rectifier fail alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB. The fan should never be stopped by inserting an object into it while running, as this could damage the fan.

4) Load Fuse Turn off one of the load circuit breakers. (Note: The CB must be connected to a load). This will activate an Alarm on the Display and at the alarm PCB. Using a Continuity Tester check the operation of the N/O N/C relays at the alarm PCB.

5) Battery Fuse

NOTE: All battery CB’s have to be ON for there to be NO Battery fuse alarm. Ensure all vacant battery shelves have heatshrink on their loose cables When the Battery is connected, simply switch off one Battery circuit breaker. This will activate an Alarm on the Display and at the alarm PCB. Using a Continuity Tester, check the operation of the N/O N/C relays at the alarm PCB.

6) Monitor Fail Unlock and release the handles of the SmartPack alarm module by inserting a small screw driver into the holes in the upper corners of the front panel and carefully push it downwards. The handle will release and pop out. Remove CON5 from the rear on the Smartpack controller. This will activate the Monitor Fail Alarm. Using a Continuity Tester, check the operation of the N/O N/C relays at the Monitor Fail PCB.

7) LVBD Active. (Low Voltage Battery Disconnect) With an external power supply connected, Disconnect the batteries & turn off the AC supply. Set the supply to a value below that of the LVBD disconnect. The contactor should open & the system be turned off. The LVBD alarm should activate. NOTE: As a safety mechanism, the voltage of the rectifiers cannot be deliberately set below that of the LVBD value.

8) In order to test the ―Battery Test Fail Alarm‖, the procedure below must be

followed:

1. With the system running normally, i.e. no alarms, turn off all the batteries.

2. Attach an external DC source to a pair of the spare battery leads (Ensure the

polarity if correct). If there are no spare battery leads connect via a spare

circuit breaker.

3. Turn ON the external DC source and increase to 54 VDC.





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4. Follow steps in Figure 22.1. Select the simplified battery test, click ―Start Test‖

button

Figure 22.1

5. Wait until battery test warning ―MANUAL TEST‖ appears at the bottom of the

screen.

6. Follow the steps in Figure 22.2

a. Click ―Alarms Overview‖

b. Click ―Summary

c. Check that ―Battery test active‖ alarm is present

d. Check if Relay #5 has changed state.

This should appear in a moment after

simplified test started





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Figure 22.2

1. Turn external DC source voltage down to below 45.3 V (1.90V/cell)

2. Refer to Figure 22.3

a. Check in ―Alarms Overview/Summary‖ if battery quality major alarm

has activated

b. Check if Relay #2 output is still in alarm state.

3. Use manual reset to clear alarm. Refer to Figure 22.4

Relay #5 change states

Ensure the “Battery test Act” alarm activates





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Figure 22.3

Figure 22.4

Table 22.3

Checking the alarm

Ensure the “Battery test Fail” alarm activates after

external voltage set below 45.3V

Ensure the relay output #2 is still

open

Right click power explorer and click

“Reset manual alarms”

Click OK to reset battery test fail

alarm





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22.4 Other Commissioning checks

Check system capacity setup.

Ensure that the system values ( current & symmetry) are setup as per Section 10.2.

Battery test setup.

Change the battery test start date to be 6 months from the install date to prevent all systems nationwide from commencing a battery test on the same day.

See Figure 24.5, [battery] / [test] / [interval test] tab.

Power System details page

Enter install time / site specific values here as appropriate. See Figure 24.14

Enter the correct local time, under Tools, adjust Date , Time

Table 22.4

Other Commissioning Checks





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22.6 Default -48V System Settings

Alarm & Boost Settings Factory set Default

Checked

System Voltage 54.50

High Load Voltage (High Batt 2) 57.60

High Float Voltage (High Batt 1) 55.70

Low Load Voltage (Low Batt 2) 47.00

Low Float Voltage (Low Batt 1) 52.80

LVBD (low Voltage Battery Disconnect) 43.20

Boost Voltage 56.00 Disabled

Symmetry delta voltage 1.8V

Table 22.5

Default-48V System settings





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23. ON-GOING MAINTENANCE PROCEDURES

23.1 General checks

The following general maintenance checks should be performed on all equipment. Detailed

maintenance procedures for specific equipment are included later in this document.

Step Comments

Documentation available Ensure that all relevant site-specific drawings are available i.e. Layouts, cabling schedule, signal connections.

Remove front Panels Allowing access to system components.

Carefully vacuum inside underneath and on top using an insulated hose

Ensuring the system is free from dust and dirt.

Ensure that all connections are correct Look for any possible defective or loose connections, and excessive temperatures.

Ensure that all equipment is free from damage Verify that damage has not occurred since installation and commissioning

Check the alarm voltage settings using the “User” menu via the front keypad

Verify that all alarm voltage settings are set as the system default settings.

Check alarm relay operation to remote monitoring by toggling individual relays using the “Service” menu via the front keypad.

Call remote monitoring station and confirm operation as required.

Table 23.1

General Checks

23.2 Module maintenance

The Flatpack2 rectifier has no customer serviceable components

Should a rectifier exhibit a fault, simply pop the handles out, and pull out using these same handles on the front of the module

(Contact Eltek Pacific for repairs/ replacement)

The Smartpack controller has no customer serviceable components.

Should a controller exhibit a fault, simply pop the handles out, and pull out using these same handles on the front of the module

(Contact Eltek Pacific for repairs/ replacement)

23.3 General ongoing maintenance Procedures

As a general requirement we would recommend the following checks be made to the system

at six monthly intervals.

Check Frequency Purpose

Visual inspection Monthly To identify any obvious problems. Such as corrosion to terminal posts, leaking batteries, not excessively dirty or dusty, not mechanically





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damaged in any way

Check and adjust DC output voltage

6 Monthly To ensure rectifier is charging at correct voltage level.

Torque battery terminals

6 Monthly To ensure correct level of torque as per battery manufacturers install instructions.

General clean 6 Monthly Wipe down systems remove any dust build up

Table 23.2

General ongoing maintenance procedures

23.4 System components Minimum Operating life

Description Minimum Operating Life (years)

Potential Failure

Indication Action

FlatPack2 Rectifier >15 Fault LED lit Red LED lit Replace Module

Smartpack Control Module

>15 Monitor Failure Monitor fail relay Replace Module

Table 23.3

System components Minimum Operating life





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24. USING POWER SUITE SOFTWARE

24.1 Installation of Power Suite software

A PC is required to install and run Power Suite. You will need:

Intel compatible PC running Windows 2000 or Windows XP (preferred)

At least 80 MB of free disk space.

Minimum 800x600 screen resolution

Latest copy of Smart Suite

Standard AB type USB cable

Install the software supplied on the CD before connecting the computer to the controller. If

the controller is connected before the supplied software is run, the controller driver software

may need to be uninstalled from the computer. To do so, leave the controller connected to the

computer, then use the windows device manager to uninstall the device. Install the software

on the CD. Disconnect and reconnect the USB cable and then the correct connection should

be automatically installed.

The Smart Suite system communication software must be installed on your personal

computer. Smart Suite is available on CD-ROM . By inserting the CD-ROM in the CD-ROM

drive. The installation program will guide you through a complete installation. NOTE, this

program requires Microsoft .NET 2.1 to be installed if not already done. This is included in

the software package supplied. Also required is the windows installer 3.0 program or later

(3.1 included on CD). It is also recommended to install any updates to .NET that may be

available.

Setting up communication between PC and Smartpack

The two are linked together using a standard ‗AB‘ USB cable. ( After installation of the

software)

Note: Do not connect Smartpack while starting installation of PowerSuite.

First install software:

Then connect:

Figure 24.1

Correct Software installation





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24.2 Using PowerSuite V3.x: A start up guide.

First, install the software supplied on the CD before connecting the computer to the

controller.

Figure 24.2

Powersuite Startup guide

To find a free COM port:

Go to click ―Connect‖ button / Click ―Find COM-Port #‖ button

The COM port may vary on different computers. If no Comms port is displayed, it may be

that the controller was connected before the supplied software was run; the controller driver

software may need to be uninstalled from the computer. To do so, leave the controller

connected to the computer, then use the windows device manager to uninstall the device.

Disconnect and reconnect the USB cable & restart the Powersuite program.

24.3 Using PowerSuite V3.x: Operation.

This screen details most of the information of immediate interest:

1. Power Explorer: This panel shows an overview of all the (selectable) components of

the system in a collapsible tree structure. (can be hidden / shown with [CTRL] E)

2. Power animation: A real-time pictorial representation of the voltages, currents and

temperature of the system. (can be hidden / shown with [CTRL] A)

Click the “Green” Cross button to add a new site connection

Click here to find the port for USB COM-Port





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3. Power summary: A summary of the information presented in the Power animation

panel. (can be hidden / shown with [CTRL] S)

4. Sub windows: These windows will appear in the lower panel when other menu /

information windows appear.

5. Quick access buttons: These provide access to other functions in the Powersuite

software.

6. Non critical alarms are shown in Yellow.

7. Critical alarms are shown in Red.

8. Log in here. Service password is ‗3‘. Using the front keypad, the password is ‗0003‘.

Figure 24.3

The Main Screen

1

5

4

3 2

6

7

8





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Figure 24.4

Battery Configuration

Figure 24.5

Battery Configuration

Battery Alarm Levels

“Apply the changes”

Check the box to enable the temperature compensation


Enter the battery type

in this description box

(Free text entry box)





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Figure 24.6

Battery configuration

Figure 24.7

Shunt Configuration

Date and Time to start Battery test


Choose settings of the Shunt, and click “Apply”






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Figure 24.8

Battery Voltage and Current Calibration

Figure 24.9

Event log

Use this window to calibrate the battery current, and click “Apply”.

Use this window to calibrate the battery voltage, and click “Apply”.





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Event log download: Use the [Latest XX events] & [Get all] to download the controller alarm

events. It can store up to 1000 events before overwriting the oldest event.

[Export to file] will create an .XML file that can be imported into Excel. When importing use

the option ―as an XML list‖

The events and time of occurrence can now be examined.

Figure 24.10

Event log downloading

Figure 24.11

System Voltages

Download time. Event time. Event. Type of event

Change setting of system voltages at here






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Figure 24.12

Output Relays

Figure 24.13

Alarms Overview

Click on it for testing

Testing timeout

Contact Open

Contact Close

Choose controller module, such as Smartpack or I/O box






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Figure 24.14

Alarms Overview

Figure 24.15

Module number resetting

Local alarms list: “Red”= alarm on “Green”= alarm off

Check the box for more detail information


Reset the number of rectifiers and controller modules





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Figure 24.16

Active alarms & battery test results

Figure 24.17

System Information

Reset the number of Rectifiers and controller modules

Export the battery test result

Company name

Click here to update to today

Location / Site name or No.

System S/N: Reference No. for service and warranty






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24.4 Efficiency Management

In simple terms, when the FP2 system has excess capacity for the current "load" (the sum of

all load devises on the DC output), the system will shutdown rectifiers to help ensure the

remaining rectifiers will operate in the most efficient zone of the output efficiency

characteristic (typically between 50 to 80% max output on FP2).

Therefore, if the load current is less than (approx) 50% the total capacity, then rectifiers can

be switched off, which it turn reduces the AC current required and saves the customer money.

Obviously, the bigger the system, the bigger the potential savings, especially in a system that

has a large battery re-charge capacity provisioned. (you only need those extra rectifiers on

when the batteries need to be re-charged). More rectifiers will be immediately switched on if

the load increases.

Another cost saving is the Shuffle rectifier setting, which helps reduce rectifier fatigue by

sequentially rotate which rectifiers are switched on. The interval of rotation is set in

PowerSuite by field (hours): Shuffle Time

Furthermore, during the rotation cycle, 1 rectifier turns on and after a interval period, the

longest running rectifier will then be turned off. The interval is user set in PowerSuite by field

(mins) : "Rectifier Off" delay.

The rectifiers can be configured in to Redundancy or Non-Redundancy mode: Redundancy

mode will have one more rectifier turned on than what is considered ideal. This is especially

important if the current load is less than 2Kw, as this will ensure that 2 rectifiers will always

be on.

To check if Eff Mgmt is working, a user can select Test Mode. This effectively changes the

Shuffle time from hours to minutes and the Rectifier Off units from minutes to Second. By

speeding up the process, a user can watch the process of Eff. Mgmt to confirm it works.

Figure 24.18

Efficiency Manager (Load Shedding)






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24.5 Save/Load “xml” File

This will allow a user to ―Import / Export Configuration F6‖ under ―Tools‖ menu to import

the configuration to the controller:

1. Press [Read from file] Press the [Open] button to find the .XML file on your hard

disk. Press [Next] to follow the procedures and finish the Step1

2. Check the ―Write to the control units‖, and press [Next] to finish Step2.

3. Press [Next] to import the configuration file to the controller.

4. Press [Close] after finish loading

Figure 24.19

Load “xml” to a Smartpack controller

Close the window after loading





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Figure 24.20

Save “xml” to a computer

To export the configuration to the controller:

1. Press [read from system], and press [Next] to continue

2. Press the [Save as] button to save the .XML file to the desired location on your hard

disk. Press [Next] to continue

3. Press [Next] to finish Step3.

4. Press [Close] after finish saving

Close the window after loading





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25. ATTACHMENTS

25.1 TG6365 Alarm matrix

25.2 Flatpack2 2kW HE rectifier Datasheet

25.3 Flatpack2 2kW rectifier Datasheet

25.4 Smartpack Controller Datasheet

25.5 AG12V100F Battery Data Sheet

25.6 12NDF100 Battery Datasheet

25.7 Battery MSDS

25.8 TG6359 Settings list

25.9 FP2 System schedule

25.10 FP2 HE System schedule

25.11 BTS external alarm list

25.12 Alarm labels

25.13 A111223.00x-A3 Schematic Drawing (Page 1/2)

25.14 A111223.00x-A3 Schematic Drawing (Page 2/2)

25.15 A111223.00x General Arrangement Drawing

Eltek FP2 IandC Manual

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