Installation, Commissioning and Operations Manual for Flatpack2 Optus System

Installation & Commissioning,
Operation & Maintenance Manual
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 RB/RZ
and minor edit
G 07/02/11 Included: AG12V100F battery, RZ
manual battery test.
Updated: packing list, scope.
DOCUMENT DISTRIBUTION CONTROL

Copy No: 1 Controlled: X Uncontrolled:
TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 1 of 70

MANUAL FLATPACK2 HE OPTUS SYSTEM A111223 00x
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.): sales@eltek.com.au

E-Mail (Service Dept.): service@eltek.com.au
E-Mail (all departments): admin@eltek.com.au

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
24.5 SAVE/LOAD XML FILE .............................................................................................................................68

25. ATTACHMENTS ................................................................................................................... 70

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
A112007.001 1 x AG12V100F 2 x HE with the
SEF29-X-189 0 0 A461033.001 battery expansion
rack
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

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.
Output cable
management Anderson
rail connector
for battery
expansion
rack
0V DC bar 95mm
(SPC) earth
cable
Monitor AC
fail PCB mains
input
Serial
Number
lable
Load
CBs System
connection
board
Battery
expansion Symmetry
rack alarm PCB
(hidden)
Alarm PCBs
Figure 2.1
Top view with cover removed.

Figure 2.2
Front and side views of a A111223.xxx
2200mm(H) x 600mm(W) x 400mm(D)

Figure 2.3
Front and side views of a A111223.xxx
2067mm(H) x 600mm(W) x 400mm(D)

Figure 2.4
Front and side views of a A111223.001
2067mm(H) x 600mm(W) x 400mm(D)

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)

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).

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

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.

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

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.
Lifting Cables
Spreader bar, used to prevent

eyebolts from bending inwards
M8 Eyebolt, placed
in the wall mounting brackets bolt
position
Cabinet
Figure 6.1
Lifting arrangement for the cabinet, using eyebolts and spreader bar

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

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.
Nut
Washer
Cabinet
Dyna-bolt
Concrete Floor
Figure 8.1
Dynabolts Fixing
9. EARTH CABLING
Each cabinet should be bound to earth using links. There is one 95mm 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 95mm earth cable supplied with the extension cabinet.

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 CBs are located on the left-hand side of each battery shelf. The system is
supplied with cables from the battery CBs to the battery trays already fitted. Ensure that the
battery CBs 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
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.
symmetry connection
Negative
battery cable - + - + - + - + Positive
battery
cable
Battery 4 Battery 1
Figure 10.1
Symmetry connection point, to either side of the middle hard link
Rectifier rack Optional expansion rack
Controller
CON 3
CON 4
Symmetry Symmetry
PCB PCB
Battery Battery
symmetry symmetry
connections Temperature connections
probe
M6 Ring terminals for

battery connections
Figure 10.2
Symmetry PCB connection points

Rectifier rack Optional expansion rack

Smartpack
CAN CAN CAN

CAN
Symmetry Symmetry
CON4
Monitor Box Monitor Box
Temperature
probe
Battery Battery
symmetry symmetry
connections connections
M6 Ring terminals
for battery
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

1. Change the number of strings.

No. of rectifiers Rectifier Number of Number of Battery
(system current capacity alarm rectifiers battery current limit
rating) setting (60%) modules setting
(strings)
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.
DO NOT change
this value
Figure 10.4
String number screen (using Power Suite 3.x)
2. Change the rectifier over-current alarm.

(strings)
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 10.2
Important!
Make sure BOTH
major and minor
alarms are set to the
new value
Figure 10.5
Rectifier over-current alarm setting screen (using Power Suite 3.x)

3. Set the Battery Current Limit

(strings)
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 10.3
Figure 10.6
Battery charge current limit setting (using Power Suite 3.x)

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.
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
Figure 10.7
Symmetry activation setting screen (using PowerSuite 3.x)
5 Redeploy temperature compensation

probe:
Important Note:
Install
Redeploy temperature compensation
probe in
probe to the top of the uppermost
this area
installed battery string when installing
extra battery strings. (Use cable ties to
fix it into place.)
Figure 10.8
Install probe within the rack above batteries

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 95mm 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 MCBs are turned OFF
3. Install the batteries and symmetry connections in the controller as detailed in section 10.
4. Double check all the string MCBs 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 Flying Lead with Anderson
Connector Battery CB
alarm &
symmetry
cable.
Earth cable
Figure 11.1
Expansion rack connections
12. EXPANSION RACK ALARM CONFIGURATION
The battery alarms provide signals to the Smartpack control module via auxiliary switchs 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.

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.)

Install
probe in
this area
Figure 13.1
Temperature probe deployment should be near, but not touching, above the uppermost string of batteries.
Battery type Max Min compensation Reference voltage Slope mV/deg/cell

compensation V/cell
V/cell @ 25C/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.
Battery
CBs
Retaining
bracket
Figure 13.2
Front view of batteries, showing spacing & battery circuit breaker position.
(Cables / links are not shown)

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

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.
Holes to release the handles

spring mechanism
Handle in unlocked position
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 .

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 ON Rectifier is powered

(green) Flashing Smartpack controller accessing information on the rectifier
OFF Mains are unavailable
Alarm Rectifier is in Shut-down Mode due to low mains (0 85VAC) or high internal
(red) temperature (+75 C or higher) or high output voltag
ON CAN bus failure

OFF No alarm situation is present
Notice Rectifier is in Derating Mode (reduced output power) due to high internal
(yellow) 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

ON 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

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 rectifiers 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
ID1 ID4 ID7
(controller)
(Blank) ID2 ID5 ID8
(Blank) ID3 ID6 ID9
Table 15.2
Rectifier ID positions for C801047

Smartpack
(controller)
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.

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 2) Use both handles to pull the module
holes to release the spring mechanism) Remove gently loose; support it from underneath;
the module hidden cables are connected to the rear
panel.
Figure 16.1
Rectifier locking mechanism

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
Ethernet Port
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
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 controllers keys and indicators, and how to operate the
Flatpack2 DC power system from the controllers front panel. The Smartpack controllers
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 systems user
interface. The display can be shown in Status Mode (displays the systems status)
or in Menu Mode (displays the menu structure). Depending on the displays
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.

Front Keys
You can control the many of the Flatpack2 DC power systems via a network of
software menus accessed with the controllers 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 controllers 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 controllers 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.

17.2 Operating Menus, (Menu Mode)

The Flatpack2 DC power systems 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 Options 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.

17.3 Front keypad menu tree for Smartpack controller:
User Service
Password = 0003
Change Language
Alarm Reset Alarm Reset
VoltAdjustment NomVolt
Voltage Info NomVolt
BoostVolt
BoostVolt
LowBatt1
LowBatt1
Volt Calibration VoltCal LowBatt2

LowBatt2
Change Password Password HighBatt1

HighBatt1
Set MANBoostTime BoostTime High Batt2

High Batt2
Start/StopBoost StartBoost/StopBo LVD1

LVD1 ost
Auto Boost Cfg Enable/Disable LVD2

LVD2
Threshold
Display messages Display messages
Batt. Test Setup Nxt Test Date

Time
Sw Info SwInfo
Start/Stop Test StartTest/StopTest End Volt
Serial Number Controller S/N No of Rects Max Test Duration

RECTIFIER
RESET
Test Interval
Rectifier Info NoOfRects. Nn Charge Curr Lim Enable/Disable
Guard Time
RectCurrent Max ChargeCurr
RectSerialNumber Battery Setup NumOfStrings
Rect.PrimaryVolt
OutputControl Temp.Comp
Rectifier Status
VoltageControl
Change Date/Time
Rectifier Temp
Rect OutputVolt Relay Test Alarm Output 1
Rectifier SW Ver Alarm Output 2
Batt Contactor
Mains Info NoOfPhases nn

Load Contactor
Mains Status
Alarm Output nn
Mains Voltage
BattLifeTime Rst BattLifeTime Rst
Temp Level Info Temp Level Info
Figure 17.2
Rectifier reset is now under the service menu.

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

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 5
COM 1 1 6
NC 7
NO 8
COM 2 1 9
NC 10
NO 9
COM 3 2 10
NC 11
NO 12
COM 4 2 13
NC 14
NO 15
COM 5 2 16
NC 17
NO 18
COM 6 2 19
NC 20
Table 18.2
Output relay pin connections

Normally closed
Normally open
Common
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 Smartpack failure
failure
Table 18.3
Alarm triggers
18.5 Digital input positions.
The Smartpack controller accepts up to 6 inputs.
Relay
Alarm State Pin
Card
Input 1 + 1
1
Input 1 - 2
Input 2 + 3 Pin 1 Pin 10
1
Input 2 - 4
Relay Card 1
Relay
Alarm State Pin
Card
Input 3 + 1
2
Input 3 - 2
Input 4 + 3
2
Input 4 - 4
Input 5 + 5
2 Pin 1 Pin 20
Input 5 - 6
Input 6 + 7 Relay Card 2
2
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.

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.
Phase 1
Phase 2
Phase 3
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.

Figure 19.2
Cabinet Front view (A111223.00x)
Figure 19.3
Cabinet Front view (A111223.00x).
Smartpack
(controller)
L1 L2 L3 L1
L2 L3 L1 L2
Table 19.2
AC Phases arrangement (A111223.00x).

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.
Figure 19.4
3xSingle - Phases
IMPORTANT: If re-configuring as a three phase input, ensure that the supplied

neutral links are installed
May be cable
jumpers
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

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 MCBs 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.
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 systems 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 modules display
Measure output voltage
Use a Digital Voltmeter* to verify that the output voltage is in accordance with the VDC
systems Default Settings (end of this section) and note in the section immediately to
the right.
Rectifier modules are ON and without fault alarms

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

Check and calibrate voltage reading in the alarm display Meas Display in
ure Alarm
If the measured voltage deviates more than 0.2V from the display
Mod.
reading, re-calibrate the alarm module. DVM*
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* Measured

Using a DVM measure the battery voltage with DVM*
Adjust output voltage to equal the measured battery voltage from the alarm modules 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 modules keypad to Measured
the voltage recommended by the battery manufacturer (54.0Vdc at 25C) with DVM*
Verify that the Low Battery Alarm is not activated. Record the voltage*
*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 MCBs 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

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
To test Low Battery Alarm 1 (Low Float), change its value to at least 0.5V above the system
To test Low Battery Alarm 2 (Low Load), change its value to at least 0.5V above the system
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 CBs 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.
4. Follow steps in Figure 22.1. Select the simplified battery test, click Start Test
button
This should appear

in a moment after
simplified test
started
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.

Relay #5 change
states
Ensure the
Battery test Act
alarm activates
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

Ensure the relay

output #2 is still
open
Ensure the Battery

test Fail alarm
activates after
external voltage set
below 45.3V
Figure 22.3
Right click power

explorer and click
Reset manual
alarms
Click OK to reset
battery test fail
alarm
Figure 22.4
Table 22.3
Checking the alarm

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

22.6 Default -48V System Settings
Alarm & Boost Settings Factory set Checked

Default
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

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 Ensuring the system is free from dust and dirt.
top using an insulated hose
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 Verify that all alarm voltage settings are set as the
User menu via the front keypad system default settings.
Check alarm relay operation to remote Call remote monitoring station and confirm
monitoring by toggling individual relays using operation as required.
the Service menu via the front keypad.
Table 23.1
General Checks
23.2 Module maintenance

The Flatpack2 rectifier has no customer Should a rectifier exhibit a fault, simply pop the
serviceable components 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 Should a controller exhibit a fault, simply pop the
serviceable components. 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

damaged in any way

Check and adjust DC 6 Monthly To ensure rectifier is charging at correct voltage
output voltage level.
Torque battery 6 Monthly To ensure correct level of torque as per battery
terminals 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 Potential Indication Action
Life (years) Failure
FlatPack2 Rectifier >15 Fault LED lit Red LED lit Replace Module
Smartpack Control >15 Monitor Failure Monitor fail relay Replace Module
Module
Table 23.3
System components Minimum Operating life

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

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.
Click the Green

Cross button to
add a new site
connection
Click here to find

the port for USB
COM-Port
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)
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.
6 8
1
2 3
4
Figure 24.3
The Main Screen

Battery Alarm Levels
Apply the changes

Figure 24.4
Battery Configuration
Enter the battery type

in this description box
(Free text entry box)
Apply the
changes
Check the box to enable the
temperature compensation
Figure 24.5
Battery Configuration

Apply the changes
Date and Time to

start Battery test
Figure 24.6
Battery configuration
Choose settings of
the Shunt, and click Apply the changes
Apply
Figure 24.7
Shunt Configuration

Use this window to

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

calibrate the battery
current, and click
Apply.
Figure 24.8
Battery Voltage and Current Calibration
Figure 24.9
Event log

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.

Download time. Event time. Event. Type of event
Figure 24.10
Event log downloading
Change setting of
system voltages at
here
Apply the changes
Figure 24.11
System Voltages

Contact Open
Contact Close
Click on it
for testing
Testing timeout
Figure 24.12
Output Relays
Choose controller
module, such as
Smartpack or I/O box
Apply the changes
Figure 24.13
Alarms Overview

Check the box for more

detail information
Apply the changes

Local alarms list:
Red= alarm on
Green= alarm off
Figure 24.14
Alarms Overview
Reset the number of

rectifiers and
controller modules
Figure 24.15
Module number resetting

Export the battery

test result
Figure 24.16
Active alarms & battery test results
Company name
System S/N:
Reference No. for
Location / Site service and warranty
name or No.
Click here to
update to today
Figure 24.17 Apply the changes

System Information

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.
Apply the changes
Figure 24.18
Efficiency Manager (Load Shedding)

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
Close the window

after loading
Figure 24.19
Load xml to a Smartpack controller
Close the window

after loading
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
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


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Installation & Commissioning,

Operation & Maintenance Manual

Eltek Valere Australia Pty Ltd

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TG6506H MAN INSTALLATION COMMISSIONING AND OPERATIONS Page 1 of 70

Eltek Valere Australia Pty Ltd

E-Mail (Sales Dept.): sales@eltek.com.au

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24.5 SAVE/LOAD XML FILE .............................................................................................................................68

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This Installation and Commissioning Manual provides simple instructions as to the

Part number # battery strings # rectifiers Note

Part number Note/Component

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

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3.1 Installation requirements

IMPORTANT: All tools should be insulated

3.2 For communication with the controller:

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1 x Rectifier Cabinet box OK

1 x Battery Cabinet box (if ordered) OK

A111223.001 has maximum of 8 rectifier slots

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

Spreader bar, used to prevent

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10. CONNECTING THE BATTERIES

10.1 Symmetry connections

Rectifier rack Optional expansion rack

M6 Ring terminals for

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Rectifier rack Optional expansion rack

CAN CAN CAN

10.2 Controller setup

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1. Change the number of strings.

2. Change the rectifier over-current alarm.

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3. Set the Battery Current Limit

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4: Activate symmetry battery strings.

Symmetry alarms can be collected via

5 Redeploy temperature compensation

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11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS.

Rectifier Cabinet Battery

12. EXPANSION RACK ALARM CONFIGURATION

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13. BATTERY VOLTAGES

13.1 Refreshing of batteries

1. Check the open circuit voltage of each battery.

13.2 Low Voltage Battery Disconnect (LVBD)

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Battery type Max Min compensation Reference voltage Slope mV/deg/cell