Eltek Flatpack 2 User Manual

I nstallation & Commissioning,
Operation & Maintenance Manual

TG6206M MAN I&C + O&M Manual 149 150 156, A111171.000, A112040.000 and
A112041.000 FlatPack2 systems
Page 1 of 64

Eltek Australia Pty Ltd
Unit 1, 22 Narabang Way, Belrose, NSW, 2085, Australia
Telephone: +61 2 9479 4200 Facsimile: +61 2 9479 4292

Installation & Commissioning +
Operation & Maintenance
manual for FlatPack2
SEF29-X-149, 150, 156 and
A111171.000, A112040.000 and
A112041.000
systems
REVISION CONTROL
Rev Date Revision Description Orig Check App
H 25/10/06 Added extra wall mounting option. GT BD
I 29/11/07 Added system for this manual AL
J 14/04/11 Changed logo and fax number RB
K 14/06/11 Added Ethernet connection RB
L 23/11/11 4 Battery Shelves, SP18-RRU, SP18 DA
M 07/03/12 Updated to manufacturing version DA
This manual is in process of revision if you require updated manual please contact with
Eltek Australia engineering department

DOCUMENT DISTRIBUTION CONTROL
Copy No: 1 Controlled: X Uncontrolled:

Page 2 of 64

Eltek Australia Pty Ltd
ACN072 645 446 ABN 90 072 645 446
Unit 1, 22 Narabang Way
Belrose NSW 2085
Phone: (02) 9479 4200
Fax: (02) 9479 4292

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


Page 3 of 64

TABLE OF CONTENTS

1. SCOPE ............................................................................................................................................................... 5
2. SYSTEM OVERVIEW .................................................................................................................................... 5
3. REQUIREMENTS ......................................................................................................................................... 14
4. PACKING LIST ............................................................................................................................................. 16
5. SYSTEM CONFIGURATION ...................................................................................................................... 17
6. UNPACKING.................................................................................................................................................. 18
7. CABINET ASSEMBLY ................................................................................................................................. 19
7.1 SPECIALISED WALL MOUNTING KIT ................................................................................................................. 20
8. FLOOR INSULATION .................................................................................................................................. 22
9. EARTH CABLING ........................................................................................................................................ 23
10. CONNECTING THE BATTERIES ....................................................................................................... 24
11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS. ................................. 26
12. EXPANSION RACK ALARM CONFIGURATION ............................................................................ 28
13. INSTALATION & REFRESHING VOLTAGES OF BATTERIES .................................................. 29
14. EXPANSION RACK INSTALLATION CHECK LIST ....................................................................... 30
15. INSTALLATION AND OPERATION OF RECTIFIER MODULES ................................................ 31
15.1 VISUAL INDICATIONS..................................................................................................................................... 32
15.2 PLUGGING IN RECTIFIERS .............................................................................................................................. 33
15.3 IDENTIFICATION OF DIFFERENT RATED RECTIFIERS ....................................................................................... 33
15.4 REPLACING AND INSTALLING RECTIFIER MODULES ........................................................................................ 34
16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER (ETHERNET
CONNECTION) ..................................................................................................................................................... 35
17. OPERATION OF THE SMARTPACK CONTROLLER .................................................................... 38
17.1 FRONT PANEL OPERATION ............................................................................................................................. 38
17.2 OPERATING MENUS, (MENU MODE) .............................................................................................................. 40
17.3 FRONT KEYPAD MENU TREE FOR SMARTPACK CONTROLLER: ........................................................................ 41
USER ..................................................................................................................................................................... 41
Service ......................................................................................................................................................... 41
18. REMOTE ALARM CONNECTIONS.................................................................................................... 42
18.2 DIGITAL INPUTS. ............................................................................................................................................ 45
19. +24 V DC/DC CONVERTER .................................................................................................................. 47
20. AC MAIN SUPPLY INSTALLATION .................................................................................................. 49
21. DC DISTRIBUTION INSTALLATION ................................................................................................ 51
LOAD CABLE INSTALLATION CONSIDERATIONS .................................................................................................... 52
22. TEMPERATURE COMPENSATION ................................................................................................... 52

Page 4 of 64

23. COMMISSIONING ................................................................................................................................. 54
PRE-START / INITIAL CHECKS ............................................................................................................................... 54
SYSTEM START-UP ................................................................................................................................................ 54
CHECKING THE ALARMS ....................................................................................................................................... 55
DEFAULT -48V SYSTEM SETTINGS ........................................................................................................................ 58
24. GENERAL MAINTENANCE CHECKS ............................................................................................... 58
25. MODULE MAINTENANCE .................................................................................................................. 59
26. GENERAL PROCEDURES.................................................................................................................... 59
27. SYSTEM COMPONENTS MINIMUM OPERATING LIFE ............................................................. 59
28. USING SMART SUITE SOFTWARE ................................................................................................... 60
28.1 INSTALLATION OF SMART SUITE SOFTWARE ................................................................................................. 63
SETTING UP COMMUNICATION BETWEEN PC AND SMARTPACK ............................................................................. 63
28.2 USING SMARTSUITE: A START UP GUIDE. ...................................................................................................... 63
29. ATTACHMENTS .................................................................................................................................... 64


Page 5 of 64

1. SCOPE
This Installation and Commissioning Manual provides simple instructions as to the installation
requirements for the Eltek -48 Volt DC Flatpack2 systems. 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, Smartpack controller and DC/DC converters (factory fitted option.)
2. SYSTEM OVERVIEW
The Flatpack2 Mobile systems are 18kW -48V DC power system comprising of:
1 Main System Cabinet (fig 2.2, 2.3, 2.4, 2.7 & 2.8)
Up to 9 FlatPack2 -48V 2kW or 1.8kW rectifiers
1 Smartpack Control Module
4, 5 or 6 Battery strings
Expansion Battery Cabinet (optional, fig 2.5, 2.6 & 2.9)
Up to 4 off +24V 1.1kW DC/DC converters (factory fitted option in 600D rack only)

The Main System Cabinet is available in 2 configurations, a 600 deep cabinet option and a
400 deep cabinet option. The 600 deep cabinets can accommodate up to 6 strings of 100Ah
12FFT100 batteries or 4 strings of 190Ah SBS190 batteries, and the 400 deep cabinets can
accommodate up to 5 strings of 100Ah 12FIT100 batteries. If required, the main system
cabinets for either option can be supplemented with a battery expansion cabinet for increased
battery capacity. Details of the expansion battery cabinets are given later in this manual.
The system is also available with an optional DC/DC converter rack to supply +24V supply
as needed. This extra rack can deliver up to 4.4kW at 24V and has an extendable alarm output.
It input is supplied via an MCB on the -48V load distribution, with the 24V output given via a
top mounted Anderson connector.

Monitor fail
PCB
AC mains
input
Alarm PCBs
Battery Alarm for the
Expansion rack
+48VDC bar
(SPC)
Output cable
management
rail
Serial Number
Anderson
connector for
battery
expansion rack
Bulk feed point for
external battery
connection
(Available only in
SP18&SP18-RRU)

Page 6 of 64

Fig 2.2, Front and side views of an A111105.000 (SEF29-X-156).
2200(H)x 600(W)x 600(D)


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Fig 2.3, Front and side views of an A1110886.00x (SEF29-X-149).
2200(H)x 600(W)x 400(D)


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Fig 2.4, Front and side views of an A111160.00x (SEF29-X-150).
2200(H)x 600(W)x 600(D)


Page 9 of 64

Fig 2.5, Front and side views of an A451028.000 (SEB5-12FIT100-002) battery cabinet.
2200(H)x 600(W)x 400(D)


Page 10 of 64

Fig 2.6, Front and side views of an A461032.000 (SEB6-12FFT100-002) battery cabinet.
2200(H)x 600(W)x 600(D)


Page 11 of 64

Fig 2.7, Front and side views of a SP18-RRU A112040.000.
2200(H)x 600(W)x 600(D)


Page 12 of 64

Fig 2.8, Front and side views of a SP18 A112041.000.
2200(H)x 600(W)x 600(D)


Page 13 of 64

Fig 2.9, Front and side views of a SP18 Battery Expansion Rack A401049.000
2200(H)x 600(W)x 600(D)

Page 14 of 64

3. REQUIREMENTS

Installation:

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 cables nuts.

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

Note: All tools should be insulated

For communication with the controller:

A laptop computer running either windows 2000 or windows XP.
SmartSuite software on CD (supplied with system)
Standard A-B type USB cable.

Page 15 of 64

WARNINGS

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 60
o
C

Page 16 of 64

4. PACKING LIST
A fully equipped Flatpack2 system is dispatched from Eltek in a number of packages. Each
package is clearly marked indicating its content. The packages include the following.
1 x Rectifier Cabinet box
Including: Rectifier Cabinet, Manual on CD, lifting eye bolts, floor insulation kit and dyna
bolts/dynasets.
May contain up to 9 x 2kW FlatPack2 rectifiers already fitted. (see packing list).

1 x Battery Cabinet box (if ordered)
Including: Battery Cabinet, Floor Insulation Kit, dynabolts and battery rack to rectifier rack DC
power connection cable with Anderson connectors, earth cable & alarm extension cable. (See
packing list on box.)
Batteries crates
Each Crate contains batteries (Monoblocs) as required, including solid links & washers.


Page 17 of 64

5. SYSTEM CONFIGURATION
The different configurations of the Flatpack2 system and expansion battery cabinets are listed
below:

Part # Dimensions Battery Type Max #
strings
Notes
A1110886.00x
(SEF29-X-149)
2200(H)x600(W)x400(D)
12FIT100 5 Can
accommodate up
to 10 strings
using the SEB5-
12FIT100-002
Cabinet.
A451028.000
(SEB5-12FIT100.002)
2200(H)x600(W)x400(D) 12FIT100 5
Battery
Expansion
To suit
SEF29-X-149
A111160.00x
(SEF29-X-150)
2200(H)x600(W)x600(D) 12FFT100 6 Can
accommodate up
to 12 strings
using the SEB6-
12FFT100-002
Cabinet.
A111105.000
(SEF29-X-156)
2200(H)x600(W)x600(D) 12FFT100 5 As SEF29-X-
150, but with a
DC/DC converter
rack factory fitted
A461032.000
(SEB6-12FFT100.002)
2200(H)x 600(W)x600(D) 12FFT100 6
Battery
Expansion
To suit
SEF29-X-150 /
SEF29-X-156
A112040.000
2200(H)x600(W)x600(D) SBS190(Default)
PWL100 (Optional)
4(Default)
6(Optional)
Can
accommodate up
to 9 (or 11)
strings using the
A401049.000
SP18 battery
expansion rack
A112041.000
PWL100 (Optional)
4(Default)
6(Optional)
Can
accommodate up
to 9 (or 11)
strings using the
A401049.000
SP18 battery
expansion rack
A401049.000
PWL100 (Optional)
5
Battery
Expansion To
suit
A112040.000
A112041.000

Fig 5.1
System Part numbers


Page 18 of 64

Component name Part number
Smartpack Controller 242100.100
Smartpack Controller 242100.118(later type)
Flatpack2 Rectifier 241115.002
Flatpack HE Rectifier 241115.105
DC/DC Converter 241114.503
SP18-RRU Label Kit A641031.000

Fig 5.2
Component Part numbers

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.

CAUTION: 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.

Fig 6.1
Lifting arrangement for the cabinet, using eyebolts and spreader bar.
Lifting Cables

Spreader bar, used to
prevent eyebolts from
bending inwards

Eyebolt, placed in the wall
mounting brackets bolt
positions

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

Page 19 of 64

7. CABINET ASSEMBLY
The Cabinets will arrive packed in a box. The following are step by step 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 as below.

Fig 7.1
Wall mounting brackets.
Note: the distance between the top of the cabinet and the wall will be 100mm larger for the
600mm cabinet type than for the 400mm cabinet, due to the greater battery depth.
600mm Cabinet example 400mm Cabinet example

Page 20 of 64

7.1 Specialised Wall mounting kit
This section details the mounting of an optional wall mounting kit, for mounting in
transportable huts.

Fig 7.2

Fig 7.4
Contained with the kit (Part number):
2 wall mount brackets (MB300)
12 top hat washers (XZ045)
2 short wall insulators (KZ207)
2 Long wall insulators (KZ208)
Fig 7.3
Assembled brackets with insulators
& hat washers in place.
Drill a counter sunk hole here to
correspond with the holes in the
vertical wall mount. Two extra holes
will need to be drilled in each of the
top five shelves. (See TG6308 in
attachments for a drawing)

The existing cross brace attachment
hole can be used as the 2
nd
mounting
position. 61mm
Remove the X brace
from all shelves.

Page 21 of 64

Fig 7.5
Each vertical bracket uses 4 hat
washers & one long wall
insulator to insulate from the
wall.
Place the short edge of the
bracket against the wall in the
location shown to align with the
holes drilled in the rear of the
battery shelves.
Use the short wall insulator with 2 hat washers to
insulate the top L bracket from the wall.

The insulator is installed between the wall &
bracket; shown here beside the L bracket.

Remove the X bracing
from all shelves.

Page 22 of 64

8. FLOOR INSULATION

All cabinets include an insulation kit, which isolates the racks from earth. One insulation kit
consists of appropriate insulation plates, 4 insulation washers, 4 round washers and 4 M8
dynabolts/dynasets. The insulating plate can be used as a template to mark the positions of the
holes on the concrete floor. After the holes have been drilled, position the insulating plate
between the cabinet and the cabinet floor. Bolt through the 4 holes in the bottom battery tray
using the dynabolts/dynasets provided. Note: the insulating plate may be provided in separate
pieces that need to be positioned on the floor.

Dyna-bolt/
Dyna-set

Fig 8.1 Dynabolt Fixing

Fig 8.2 Floor template and insulating plates 400mm option
Insulating Washer
Concrete
Floor
Nut
Washer
Insulating Plate
Cabinet
288mm
400mm
600mm
556mm

Page 23 of 64

Fig 8.3 Floor template and insulating plates, 600mm option

9. EARTH CABLING
Each cabinet should be bound to earth using links. There is one 95mm earth cable shipped
with each cabinet (Except SP18-RRU system). Ensure this converter cubicle bond is bonding
the cabinet M8 bolt to the positive common bar (SPC) inside the cabinet. Also ensure flat and
spring washers are used and the links are secure. External earthing should be done to relevant
company standards.
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.
There is also a M6 bolt that is connected to the protective earth on the AC input terminals that
needs no further connections
.
540mm
563mm
600mm
600mm

Page 24 of 64

10. CONNECTING THE BATTERIES
The FlatPack2 system is supplied with a 100A battery circuit breaker with auxiliary for each
string. The battery CBs are located on the left-hand side of each battery shelf.
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.
NOTE:
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.
2. Monoblocs are heavy; and accordingly the recommended lifting equipment should be used.
3. Remove retaining strap.
4. Position the batteries on shelves as per fig 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.
5. Particular care should be taken when placing on the shelves to ensure the correct
positioning of the +ve and ve terminals.
6. 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 mating
surfaces and place a solid connector strap or flexible link in position. Tighten the nuts
firmly: 7-8 Nm for a Stud type terminal; (12FIT100 [M6], SBS190 [M6]), 8-10 Nm for
a socket type terminal (12FFT100 [M8]) using an insulated torque wrench. (A non-torque
insulated wrench is supplied with the batteries. This should be used only when the installer
is familiar with battery installations and knows from experience what level of torque needs
to be applied) Lightly smear grease on the washer and nut.
WARNING: Particular care should be taken to ensure the batteries are not short-
circuited during this procedure.
7. Place terminal boots and battery link caps on all battery terminals.
8. Place the battery numbering labels in place starting at the first battery (on the bottom shelf)
and working to the last. Replace the battery
9. Wait 24 Hours and re-torque the battery terminals.
You will find the following colour coding on the battery cables. Blue () negative and Red (+)
Positive

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.

Page 25 of 64

Note: the solid battery links have slots that allow the batteries to be easier positioned and
connected, but may allow the batteries to come too close together if not installed correctly.
Please enure that there is proper spacing maintained between the batteries to allow for
ventilation of heat.
Fig 10.1
Front view of batteries, showing spacing & battery
circuit breaker position

(Cables / links are
not shown)
Battery Circuit
breaker.
Retaining
bracket

Page 26 of 64

11. EXPANSION RACK CONNECTION AND ADDING BATTERY STRINGS.
The Flatpack2 system can be supplied with an expansion battery cabinet. The following table
outlines which expansion cabinet is supplied with which system.

Part # Dimensions Type of
battery
Number
of battery
shelves
To suit System
A451028.000
(SEB5-12FIT100.002)
2200(H)x 600(W) x 400(D) 12FIT100 5
A1110886.00x
(SEF29-X-149)
A461032.000
(SEB6-12FFT100.002)
2200(H)x 600(W) x 600(D) 12FFT100 6
A111160.00x
(SEF29-X-150)
A401049.000
2200(H)x 600(W) x 600(D)
SBS190
12FFT100
5
A112040.000
A112041.000
To install extra strings of batteries:
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 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 fig.11.2 below.
For SP18 and SP18-RRU systems, there is a bulk feed point supplied in the system
for direct connection of battery rack without using Anderson connector. (Fig 11.1)

Figure 11.1
Bulk Feed Point for External Battery Connection

Page 27 of 64

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.
Each expansion battery cabinet is fitted with a flying lead with an Anderson connector on one
end to connect to the +ve/-ve bus bars in the system cabinet as shown below: (SP18 Expansion
rack has additional bulk feed connection)

Rectifier Cabinet Battery Cabinet

Figure 11.2
When connecting extra batteries to the system, the controller needs to be updated manually.
Use the keypad menu in Section 17 to change the battery charge current limit setting if no PC is
available. The battery charge current limit should be set to = [25% of the C10 rating of the
battery] x [the number of strings installed], which in the case of 12FFT100 & 12FIT100
batteries is 25A x [the number of strings.]
Flying Lead with
Anderson Connector
Battery CB
alarm.

Earth cable

Page 28 of 64

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 a normally closed loop which if broken, will create an alarm

Alarm Interconnection cables
Each system cabinet is supplied with an alarm interconnection cable that connects the system
cabinet to the expansion battery cabinet. The alarm interconnection cable is a 2000mm long, 2
way cable.

Installation Steps for Expansion Cabinet alarm wiring
There is a four way terminal block fitted in the rectifier cabinet on the LHS under the
distribution. When an external battery cabinet has been installed remove the link wire on the
top of the terminals:-

1. Connect one end of the 2 core alarm interconnection cable to the two terminals located in
the top LHS of the cabinet.
2. Run the cable through the top cover of the cabinet to the terminal block located in the top of
the battery cabinet.
3. Secure the alarm cable wiring with cable ties.

Figure 12.1 Battery Alarm Schematic showing expansion battery cabinet

Page 29 of 64

13. INSTALATION & REFRESHING VOLTAGES OF BATTERIES

If the batteries are in service on a temperature compensated power supply in temperatures
above an ambient of 20C, the service life of the battery will be affected. See table 13.1 below.

Ambient temperature (deg C) Expected life (% of nominal)
20 100
25 70
30 50
35 35
40 25
45 18
50 15

Table 13.1

To check if a refresh is needed, follow the below procedure.

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.


Page 30 of 64

14. EXPANSION RACK INSTALLATION CHECK LIST
Check these points OK
1. Check that the cabinet is fixed to the wall securely.

2. Check that the battery connections are all of correct polarity.

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

4. Check that the Anderson flying lead is connected.

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

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

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


Page 31 of 64

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. See also section 25, for important information
regarding rectifier operation and positioning.

It is to be 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 rectifier 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 figs 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.

Fig. 15.1
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.

Fig. 15.2
2. Use the handles to pull the rectifier loose.

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.

Hole to release the handles
spring mechanism
Handle in locked position
Handle in unlocked position

Page 32 of 64

Fig. 15.3 Flatpack2 front view

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)

Interna

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
The remote Current Limit is activated
The rectifier is communication with the controller over a
current sharing / current limiting issue
AC input voltage is out o
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

Page 33 of 64

15.2 Plugging in Rectifiers
When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller
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,
3 and so on.

During continuous operation, the metal case of the rectifier unit can become hot.
There is no danger of contact burns occurring, but all care should still be taken
when handling recently unplugged rectifiers.

15.3 Identification of different rated rectifiers

Three different types of Flatpack2 rectifiers are compatible these systems; a 1.8kW rectifier &
a 2.0kW rectifier and a 2.0kW HE rectifier. These interoperate fully, including alarms &
current sharing (current sharing is by a percentage of total output). The only functional
difference between the 1.8kW and 2.0kW rectifiers is their maximum power output. For easy
identification, the 1.8kW rectifier has a silver front, the 2kW rectifier has a light blue front and
2kW HE rectifier has a black front.

Fig. 15.4
Flatpack2 1.8kW & 2kW and 2kW HE rectifiers.

Black
2.0kW
Silver
1.8kW
Blue
2kW
2000w
label
HE and 2000W label

Page 34 of 64

15.4 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. Unclip handles of faulty rectifier as shown above and pull out rectifier.
2. Fit the new rectifier into the position left by the faulty rectifier.
3. Eliminate any rectifier alarm by performing a rectifier recount [rectifier reset, under
rectifier info] that resets the number of rectifiers using the front keypad, under user
menu (see section 17.3)

If a replacing a faulty rectifier and a replacement rectifier is not
immediately available:
1. Unclip handles of faulty rectifier as shown above and pull out rectifier.
2. Remove the highest ID rectifier (important) and fit into the vacant faulty rectifier
position, in order to maintain continuity.
3. Eliminate any rectifier alarm by performing a rectifier recount [rectifier reset, under
rectifier info] that resets the number of rectifiers using the front keypad, under user
menu (see section 17.3)

NOTE: The highest ID rectifier is now reassigned to the ID of the faulty
rectifier in the system

4. When a new rectifier is obtained, fit it into the highest vacant ID position. Its existence
will be automatically logged by the controller (as in the above scenario, upgrading a
system with additional rectifiers.)

Smartpack
(controller)
ID1 ID4 ID7
(Blank) ID2 ID5 ID8
(Blank) ID3 ID6 ID9


Page 35 of 64

16. INSTALLING AND REMOVING THE SMARTPACK CONTROLLER
(ETHERNET CONNECTION)
The Smartpack controller is physically held in place using 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.

CAUTION: Do not hand-carry the controller by its handles. Cables are plugged to the
controllers rear panel.

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. NOTE: make a record of which positions the connectors
were removed from for future reference.

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

To refit the Smartpack:

1. Carefully reconnect the cables to the appropriate positions in the rear of the controller.
2. Slide the controller unit into place making sure that all cables are not overly bent.
3. Fasten the unit by firmly pushing the handles into their housing.

Removing the Smartpack controller

Open the handles (insert a screwdriver into the
holes to release the spring mechanism)
Remove the module
Use both handles to pull the module gently
loose; support it from underneath; hidden
cables are connected to the rear panel.

Fig. 16.1


Page 36 of 64

WARNING: the rear cables from the system carry live -48V voltages. If completely
disconnecting the controller from the system, ensure that the cable to CON5 is removed
last, as this cable provides the controller with its 48V power. When removing, be careful
that the male plug doesnt make contact with any metallic material that can cause a short
circuit on the pins. There is no danger to personnel.

Early controllers rear view:

Later controllers with Ethernet connection (242100.118) rear view:

For connection to the internet for remote monitoring, connect CAT5 cable to the back of the
Smartpack and route the cable out through the letterbox aperture at the top rear of the power
rack.
Refer to Webpower section of accompanying CD for information on setting up the network
connection.
NOTE: Do not plug networked cables in to the CAN1 connector, this will damage the CAN bus
internally on the controller.
Ethernet port

Page 37 of 64

Removing the cables for replacement purposes:

Fig. 16.2

Note, CON 3 is unused, and CON 4 is only used for connection
of the temperature compensation probe.
Remove the controller until the
rear connectors are exposed.
Unplug the cables, leaving CON5
(red surrounds) until last.
Reverse the procedure when
reconnecting the new controller

Page 38 of 64

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.
Description of Keys, Display and Indicators
The Smartpack controllers front panel consists of two functional areas: the
presentation area (LCD display and LED lamps) and the control area (keys).

`

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.

Page 39 of 64

Front Keys
You can control the whole Flatpack2 DC power system via a network of software
menus accessed with the controllers front keys.
o Press the key to change from Status Mode to Menu Mode.

o Press the or keys to scroll up or down and navigate to find menu
options (function or parameter).

o 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:
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

Notice: If no keys are pressed within 30
seconds the display will automatically switch
from Menu Mode to Status Mode.

Page 40 of 64

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
o Browsing down to a menu option
Press the key, to scroll down within the same menu level, and find menu
options (functions or parameters)
o Selecting a menu option
Press the key to select the displayed menu option or parameter
o 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.

Notice: If no keys are pressed within 30
seconds the display will automatically
switch from Menu Mode to Status Mode.


Page 41 of 64

17.3 Front keypad menu tree for Smartpack controller:

Fig 17.1
NomVolt
BoostVolt
LowBatt1
LowBatt2
HighBatt1
High Batt2
LVD1
LVD2
Sw Info SwInfo
Rectifier Info
NoOfRects. Nn
RECTIFIER RESET
RectCurrent
RectSerialNumber
Rect.PrimaryVolt
Rectifier Status
Rectifier Temp
Mains Info NoOfPhases nn
Mains Status
Mains Voltage
Temp Level Info Temp Level Info
Display messages Display messages
Serial Number Controller S/N
User
VoltAdjustment
Password = Service password
Alarm Reset Alarm Reset
Voltage Info NomVolt
BoostVolt
LowBatt1
LowBatt2
HighBatt1
High Batt2
LVD1
LVD2
Service
Volt Calibration VoltCal
Change Password Password
SetBoostTime BoostTime
Start/StopBoost StartBoost/StopBoost
Auto Boost Cfg Enable/Disable
Threshold
Batt. Test Setup Nxt Test Date Time
End Volt
Max Test Duration
Test Interval
Guard Time
Start/Stop Test StartTest/StopTest
Charge Curr Lim Enable/Disable
Max ChargeCurr
Battery Setup NumOfString
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

Page 42 of 64

18. REMOTE ALARM CONNECTIONS
The Smartpack controller incorporates 6 alarm relay outputs and provides both normally open
and normally closed states on the output relay. See table 18.1 for pin connections.

PLEASE NOTE: Normal operation is when the system is energized and there are no alarms present on the system.

Fig 18.1 Alarm terminal blocks
Relay Output
Card 2
Relay Output
Card 1
Monitor fail
DCDC converter alarm
terminal block.

Black: common.
White: normally closed
(failsafe)
Brown: normally open. Battery fuse alarm
extension.
Relay Output Card 3
(SP18, SP18-RRU)

Page 43 of 64

ALARM CONTACT
RELAY
#
PIN #
TB

Mains Fail

NC
1
5
TB2
COM 6
NO 7

High Load / Low Load

NC
2
8
COM 9
NO 10

High Float / Low Float

NC
3
9
TB1
COM 10
NO 11
Battery Fuse/CB fail
NC
4
12
COM 13
NO 14

Rectifier Fail

NC
5
15
COM 16
NO 17

Off Normal

NC
6
18
COM 19
NO 20
NC
External PCB Monitor Fail NO
COM
Figure 18.2 Output relay pin out assignment for SP18 and SP18-RRU Systems

ALARM CONTACT RELAY #
RELAY
OUTPUT
CARD #
PIN #
Mains Fail NO
1 1
5
Mains Fail COM 6
Mains Fail NC 7
High Load / Low Load NO
2 1
8
High Load / Low Load COM 9
High Load / Low Load NC 10

High Float / Low Float NO
3 2
9
High Float / Low Float COM 10
High Float / Low Float NC 11
Load / Battery CB fail NO
4 2
12
Load / Battery CB fail COM 13
Load / Battery CB fail NC 14
Rectifier Fail NO
5 2
15
Rectifier Fail COM 16
Rectifier Fail NC 17
Off Normal / BCM NO
6 2
18
Off Normal / BCM COM 19
Off Normal / BCM NC 20
Monitor Fail NO
External PCB located LHS,
above Smartpack controller
Monitor Fail COM
Monitor Fail NC

Table 18.3 Output relay PIN connection for other systems

Page 44 of 64

Figure 18.4
Top view of monitor fail PCB showing connection points for monitor fail alarm

Alarm name Trigger
Failed AC supply Total loss of any one phase or all phases AC
supply to the system.
Battery CB tripped Failure of any battery CB
Load CB tripped Failure of any load fuse
High Load voltage System voltage is above 57.0Vdc
High Float voltage System voltage is above 55.70Vdc
Low Load voltage System voltage is below 48Vdc
Low Float voltage System voltage is below 52.8Vdc
Failed Rectifier Loss of output and input information from a
rectifier, Loss of communication between
Smartpack controller and rectifier
System monitor failure Smartpack output failure

Table 18.5 Alarm trigger conditions
Common
Normally closed
Normally open

Page 45 of 64

18.2 Digital inputs.
For SP18 / SP18-RRU Systems:
The alarm PCB also has up to six digital inputs that can be used on, two of which are pre set for
Generator Feed and Off Normal (but disabled).
Input 1: Generator input.
Input 2: Off normal input.

Figure 18.6 Alarm PCB showing digital input pin outs

Input voltage range 0-75V
Terminal impedance 200k
Operating current between terminals 30mA
Figure 18.7 Digital input specification

Input 1: Generator input (Disabled).
When operating on AC mains, the digital input is left open, (its normal state.) If this input is
closed (shorted), the controller will assume that it is now operating from a generator. The
controller will then limit the battery charge current down to a small value in order to limit the
strain introduced on the generator. In this way, the generator can be used to supply only the
load, and not be burdened by also trying to recharge discharged batteries at the same time.

Input 2: Off normal input (Disabled).
When in a normal state the digital input is left open. If this input is closed (shorted), the
controller will extend an off normal alarm on the alarm relay output (relay 6.), This could be
used in combination with a switch to indicate someone is on site.

Input 3: Spare Connection.

Input 4: Load MCB fail alarm.
When a load MCB is in the off position and alarm will be generated and sent to the
Smartpack which will change the state for relay #4. (see Fig 13-3)
Alarm State TB Pin
Input 1 +
2
1
Input 1 - 2
Input 2 +
2
3
Input 2 - 4
Alarm State TB Pin
Input 3 +
1
1
Input 3 - 2
Input 4 +
1
3
Input 4 - 4
Input 5 +
1
5
Input 5 - 6
Input 6 +
1
7
Input 6 - 8

Page 46 of 64

Input 5: Used for external load fuse alarm (Disabled).

Input 6: Spare Connection.
For more information, refer to Quick Start Guide: Flatpack2, PS System
(356804.103).

For other Systems:
The Smartpack controller accepts up to 6 inputs to the system, 2 are used.
Input 1: Generator input. Normally closed.
Input 2: Off normal input. Normally closed.

Alarm State TB Pin
Input 1 +
1
1
Input 1 - 2
Input 2 +
1
3
Input 2 - 4

Alarm State TB 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

Input 1: Generator input.

When operating on AC mains, the digital input is left open, (its normal state.) If this input is
closed (shorted), the controller will assume that it is now operating from a generator. The
controller will then limit the battery charge current down to a small value in order to limit the
strain introduced on the generator. In this way, the generator can be used to supply only the
load, and not be burdened by also trying to recharge discharged batteries at the same time.

Input 2: Off normal input.
When in a normal state the digital input is left open. If this input is closed (shorted), the
controller will extend an off normal alarm on the alarm relay output (relay 6.)

Pin 1
Pin 10
Pin 1
Pin
20
TB1
TB2

Page 47 of 64

19. +24 V DC/DC CONVERTER

The Flatpack DC/DC 48/24, a modular hot plug-in DC/DC converter.

Fig 19.1 A DC/DC converter module

The converter is specially designed to provide a high quality and highly reliable DC output
voltage. The module has a soft start power-up and an internal blocking diode allows hot plug-in
and isolates any faults in the converter output from the DC bus. Several internal protection
circuits ensure safe operation, even outside specified limits for normal operation.. A module
failure alarm is given if the module shuts down due to high output voltage, or in case of an
internal failure. Converters connected in parallel will exhibit active load sharing via CAN bus.
Front LEDs show power ON/OFF and alarm status in addition to a LED bar graph for output
current indication. The Flatpack DC/DC 48/24 will operate in ambient temperatures up to
+75C (+167F). At temperatures above +65C the output power may be derated.

This unit has the part number: 241114.503, and is only included in SEF29-X-156 systems .

The output of the 24V DC/DC converter is found on top if the cabinet, via a 175A red
Anderson connection.

The 24V output of the SEF29-X-156 systems are floating. That is, to achieve a non floating
+24V output with respect to the -48V output, the negative of the DC/DC converter will need to
be brought back to the common positive bar inside the distribution at the top of the cabinet.

The alarms extended from the DC/DC converter are to be found on a labeled terminal block
inside the -48V distribution area.

See the attachments for more data regarding the DC/DC Converter.

Page 48 of 64

Fig 19.2

Do not use the top battery shelf if the DCDC converter rack is being used. If additional battery
strings are needed, please use a battery extension rack. Note: This is relevant only for systems
with a DCDC converter rack fitted.

DCDC converter
rack with 4
modules in place

Do not use this
top battery shelf if
the DCDC
converter rack is
being used.


Page 49 of 64

20. 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 10mm
2
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 a 3-phase +N and Earth AC supply. Other configurations are
possible, see above. The phase distribution for the rectifiers 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 20.1 Cabinet Front view.

Distribution
controller L1 L1 L1
(Blank) L2 L2 L2
(Blank) L3 L3 L3
DC/DC Converter DC/DC Converter
DC/DC Converter DC/DC Converter

Figure 20.2 AC Phase arrangement
9 Way Rectifier Rack showing AC Phase positions
and (optional) DC/DC converters

Page 50 of 64

Figure 20.3 Three-Phase
Figure 20.5 1xSingle-Phase

Termination or configuration of the AC Mains connection is only to be
performed by a licensed electrical installer.

Three-Phase Input
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 the neutral bridges are in place.
3) Connect Earth conductor to terminal PE, Phase
conductors to terminals L1, L2 and L3, and
Neutral conductor to terminal N.
4) Tie the incoming AC cables securely with cable
ties for support. Ensure that cables do not pass
through any sharp edges.
3 x Single-Phase Input(s)
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.
1 x Single-Phase Input
Include bridges across the active terminals to activate all 9
rectifier positions, as well as bridges across the neutral
terminals.
Alternatively, if no active bridges are on hand and the
system has need for only three rectifiers, it is possible to
only use the three rectifier positions that are powered by the
single connected phase.
In all these cases the system must be labeled
accordingly.

L1 L2 L3 N N N PE
N Bridges in place
Figure 20.4 3xSingle-Phases
L1 L2 L3 N1 N2 N3 PE
Remove
bridges
L1 L2 L3 N N N PE
Active
bridges

Page 51 of 64

21. 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 6x 80-125A
(27mm pitch) + up to 18x 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.

Note: -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.

When installing DC load cables, be aware of the position of the AC input
terminal block, behind the positive common bar.

The circuit breakers are arranged from left to right as:

Position # from
left
Accommodate CB
size
CB Factory fitted
1 80 to 125A 100A
2 80 to 125A 100A
3 80 to 125A 125A
4 80 to 125A
(125A for DCDC
converter if fitted)
5 80 to 125A
6 80 to 125A
7 1 to 63A 32A
8 1 to 63A 32A
9 1 to 63A 32A
10 1 to 63A 32A
11 1 to 63A 32A
12 1 to 63A 32A
13 1 to 63A 32A
14 1 to 63A 32A
15 1 to 63A
16 1 to 63A
17 1 to 63A
18 1 to 63A
19 1 to 63A 10A
20 1 to 63A 4A
21 1 to 63A 4A
22 1 to 63A 4A
23 1 to 63A
24 1 to 63A

Fig 21.1 DC distribution

Page 52 of 64

Load Cable Installation Considerations

Consideration should be given to the entry arrangement of load cables to ensure easy
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 a cross beam, making sure not to over stress the
common positive bar and circuit breakers.

22. TEMPERATURE COMPENSATION

The system is supplied with a temperature-sensing probe for temperature compensation
charging. The temperature compensation cable is temporarily cabled tied to the system. The
cable should be carefully untied and the transistor probe should be placed in the middle of the
battery string(s) 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.

Fig 22.1 Temperature probe deployment should be near, but not touching, the middle string of
batteries.


Page 53 of 64

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).


Page 54 of 64

23. COMMISSIONING
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.

System Start-Up
Check the following: OK
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 systems Default Settings (end of this section) and note in the section
immediately to the right.
V
DC

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
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*

Page 55 of 64

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 the voltage recommended by the battery manufacturer
(54.0Vdc at 25C)
Verify that the Low Battery Alarm is not activated. Record the
voltage*
Measured
with DVM*

* DVM must be a Calibrated True RMS meter

Checking the Alarms
The Alarms are factory preset and should not require any re-setting on site. To verify the
operation of the Alarms use the following procedure.

Check the following:
OK
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. Refer to table 18.1. Please ensure batteries are connected
prior to starting this test. Turn on the mains again and verify that the
Active alarm is automatically reset.


Page 56 of 64

2. 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. Refer to table 18.1 for relay outputs:
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 is 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.
Note: Once each of the alarms (below) have 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. Off Normal
This alarm indicates that a battery test initiated by a PC is in progress,
and can be tested using a PC and the Powersuite software.
Alternatively, short pins 3 & 4 on TB1 to create an off normal ( see
section 18.2 Digital inputs)

4. 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.


Page 57 of 64

5. 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.

6. 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.

7. 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.

8. DCDC Converter Fail.
Ensure the Converter is off then insert a plastic object into the fan of the
rectifier. Turn ON converter; this should give a converter fail alarm. Using a
Continuity Tester, check the operation of the N/O N/C relays at the
converter alarm PCB. The fan should never be stopped by inserting an
object into it while running, as this could damage the fan.
The DCDC converter alarm terminal block is located to the left of the
cabinet below the monitor fail alarm, and is mounted with the battery
expansion alarm extension. See section 18.


Page 58 of 64

Default -48V System Settings
Alarm & Boost Settings
Factory set
Default
Checked
System Voltage
54.00

High Load Voltage (High Batt 2)
57.60

High Float Voltage (High Batt 1) 55.70

Low Load Voltage (Low Batt 2) 48.00

Low Float Voltage (Low Batt 1) 52.80

Boost Voltage 52.00 -56.00 Disabled

24. GENERAL MAINTENANCE CHECKS
The following general maintenance checks should be performed on all equipment. Detailed
maintenance procedures for specific equipment is 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.

Page 59 of 64

25. 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 DC/DC converter has no customer
serviceable components.
Should a converter 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)

26. GENERAL 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
Battery Discharge
Test via control
module
6 monthly To determine battery performance
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

27. 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
DC/DC Converter >15 Failure Red LED lit Replace
Module


Page 60 of 64

28. POWERSUITE AND WEB POWER
Installation and Using of PowerSuite Software.
The PowerSuite system communication software must be installed on your personal
computer. PowerSuite 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.
Setting up Communication between PC and Smartpack.
There are two methods to build the connection between a computer and a SMARTPACK.
Firstly, a connection can be set from a computer, via an A-B USB cable, to the USB port in
the front panel of a SMARTPACK.
The following steps show how to login to PowerSuite.
1. Via USB connection open PowerSuite 3.3, go to Connect Serial (Virtual USB) 1
Find COM Port # enter Password 3 and click Connect.

Figure 28.1 Connect to the Smartpack
2. If you have an Ethernet connection plugged into the back of the Smartpack, then you
can communicate with the Smartpack. You will need to setup the IP address of the
Smartpack following the Webpower system manual (which is on the accompanying
CD). To open an Ethernet connection, open PowerSuite 3.3, go to Network New
Connection, fill in the IP address, enter password 3 and click Connect.

On the CD you will find Webpower install folder and the EVIPsetup file in the Eltek
Network Utility folder that can be used to set up the IP address of the Smartpack.
Following the manual (also in this folder) will show how to setup the IP and log into the
PowerSuite via local network.

Figure 28.2 Contents of accompanying CD

Page 61 of 64

Configuration of the Smartpack
The Smartpack is pre-configured before shipment, and all the pre-configuration is saved in an
xml file on the CD. To upload the configuration to the Smartpack, simply import the xml
file to Smartpack via PowerSuite. If it is necessary to re-configure it, please follow the step
below.

1. Import the required .xml file into Smartpack. Go to Power Suite Tools
Import/Export Configuration Source Read from file .Click Open

Figure 28.3 Import xml file (a)

2. Check the box Read from file and click NEXT, browse to your xml file on the CD
and follow the prompts.

Figure 28.4 Import xml file (b)


Page 62 of 64

Using PowerSuite to Monitor the Smartpack
The site information should be updated at the beginning of the commissioning (Fig 15.6).
Message 1 and 2 will be filled out already with some information.

Figure 28.5 Site Information Window

The status of each part of the power system can also be read
form PowerSuite. To check the status of any particular part
of the system, simply double click the name of the coloured
indicator in the Power Explorer. Alarm indicators:
The Green shows working normally.
The Red means a failure is present or power is
disconnected.

Figure 28.6 Power Explorer bar


Page 63 of 64

The other parameters of the power system can be read and set in the function block above the
Power Explorer.

Figure 28.7 Other Configuration Tools

The Active alarm group window under Alarms Overview will give you a quick snapshot of
the alarms that are on the system.

Figure 28.8 Activate Alarm Group Window

For more detailed information on using PowerSuite see the attachment:
PowerSuite User Guide (356807.063)


Page 64 of 64

29. ATTACHMENTS

29.1 Flatpack2 2kW rectifier Datasheet
29.2 Flatpack2 1.8kW rectifier Datasheet
29.3 Smartpack Datasheet
29.4 Flatpack DC/DC -48/+24 Datasheet
29.5 12FFT100 Battery Datasheet
29.6 12FIT100 Battery Datasheet
29.7 Battery MSDS
29.8 TG6209 Battery bracket label swatch
29.9 TG5537 Front panel label swatch
29.10 TG5536 Black on Yellow self adhesive vinyl labels
29.11 TG6208 Software setting file FP2
29.12 TG6223 Alarm matrix FP2
29.13 TG6228 Alarm matrix DC/DC converter
29.14 TG6217 Alarm pinout FP2
29.15 TG6210 General arrangement SEF29-X-149
29.17 TG6215 General arrangement SEB5-12FIT100-002
29.18 TG6216 General arrangement SEB6-12FFT100-002
29.20 TG6308 Cabinet to wall support channel
29.21 TG6224 Wiring diagram (Legacy)
29.22 TG6682A Schematic for SP18 System
29.23 TG6683A Schematic for SP18-RRU System
29.24 TG6678A General arrangement SP18 system
29.25 TG6667D General arrangement SP18-RRU system
29.26 TG9280A General arrangement SP18 Battery Extension Rack
29.27 PowerSuite User Guide (356807.063)

www.eltekvalere.com
See reverse side f or specif icat ions

Fl at pack2 48/ 2000 HE
Rectifier Module
Product Features and Advantages

Flexibility and reliability
Ext ensive use of digit al cont rollers has enabled advanced
f unct ionalit y t o meet most cust omers requirement s. It also
provides int elligent self -prot ect ive f eat ures like reduced
out put power at high t emperat ures or low mains.

Plug and play
Plug a new rect if ier int o t he syst em, and it aut omat ically
logs on, get s an assigned ID, downloads t he syst em set
paramet ers f rom t he cont rol syst em and st art s up wit h a
minimum of inst allat ion t ime, and wit hout int errupt ing t he
syst em or at t ached equipment .

The HE rect if ier is made f ully compliant wit h t he st andard
Flat pack2 rect if ier which means it can be used in any FP2
syst em solut ions, whet her it is in new inst allat ions, sit e
expansions or replacement programs.

Global compliance
Elt ek Valere is among t he market leaders in all regions in t he
world, and designs t he core product s t o be compliant t o all
relevant st andards and cust omer requirement s. All
Flat pack2 rect if iers are CE marked, UL recognized and NEBS
compliant .

Patents pending
Flat pack2 HE is a result of int ensive research over many
years. Several unique t echnical solut ions are int roduced,
prot ect ed by pat ent applicat ions.
The most efficient rectifier in the industry!
The combinat ion of innovat ive design, ef f iciency and reliabilit y makes
t he Flat pack2 HE st and out . Wit h an ef f iciency up t o 96.5%, t he losses
have been reduced by 50% compared t o t he current indust ry st andard.

In a global perspect ive, considering t he high energy consumpt ion in t he
t elecom indust ry, t his t echnology breakt hrough is not only reducing
operat ional cost f or t he operat ors, but it can also have a signif icant
environment al impact .
Applications

Wireless, fiber and fixed line communication
Todays communicat ions demand st at e of t he art , cost
ef f ect ive and compact DC power syst ems. Flat pack2 HE
delivers an indust ry leading power densit y and superb
reliabilit y at lowest lif et ime cost .

The HE rect if ier also has an ext remely high ef f iciency at low
load, which hist orically has been a drawback wit h most
modern sof t swit ching t echnologies.

Broadband and network access
Increasing net work speed demands f lexible and expandable
DC power solut ions. The Flat pack2 HE rect if iers are your key
building blocks f or f ut ure needs.

Small and large
Due t o t he high power densit y, cost compet it ive design and
a highly f lexible syst em communicat ion int erf ace, Flat pack2
HE rect if iers are used in syst em solut ions f rom 2kW t o
192kW.

www.elt ekvalere.com

Eltek Valere
Grt erudv. 8, PB 2340 St rms, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

Applicable St andards
Elect rical saf et y IEC 60950-1
UL 60950-1
CSA 22.2
EMC ETSI EN 300 386 V.1.3.2
EN 61000-6-1 (immunit y, light
indust ry)
EN 61000-6-2 (immunit y, indust ry)
EN 61000-6-3 (emission, light indust ry)
EN 61000-6-4 (emission, indust ry)
Telcordia NEBS GR1089 CORE
Mains Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2-1 Class 1.2
ETSI EN 300 019-2-2 Class 2.3
ETSI EN 300 019-2-3 Class 3.2
ETSI EN 300 132-2
Telcordia NEBS GR63 CORE Zone 4
RoHS compliant

Specif icat ions are subject t o change wit hout not ice

Ef f iciency
85%
90%
95%
100%
200 400 600 800 1000 1200 1400 1600 1800 2000
Output Load (W)
96% 95%

241115.105.DS3 v9

Fl at pack2 48/ 2000 HE
Additional Technical Specifications
Ordering Inf ormat ion
Part no. Descript ion
241115.105 Flat pack2 48/ 2000 HE

AC Input
Volt age 85-300 VAC (Nominal 185 275 VAC)
Frequency 45 t o 66Hz
Maximum Current 11.6 A
rms
maximum at nominal input
and f ull load
Power Fact or > 0.99 at 50% load or more
Input Prot ect ion o Varist ors f or t ransient prot ect ion
o Mains f use in bot h lines
o Disconnect above 300 VAC

DC Out put
Volt age 53.5 VDC (adj. range: 43.5-57.6 VDC)
Out put Power 2000 W at nominal input
Maximum Current 41.7 Amps at 48 VDC and nominal
input
Current Sharing 5% of maximum current f rom 10 t o
100% load
St at ic volt age
regulat ion
0.5% f rom 10% t o 100% load
Dynamic volt age
regulat ion
5.0% f or 10-90% or 90-10% load
variat ion, regulat ion t ime < 50ms
Hold up t ime > 20ms; out put volt age > 43.5 VDC at
1500W load
Ripple and Noise o < 100 mV peak t o peak,
o 30 MHz bandwidt h
o < 2 mV rms psophomet ric
Out put Prot ect ion o Overvolt age shut down
o Hot plug-in - Inrush current limit ing
o Short circuit proof
o High t emperat ure prot ect ion

Ot her Specif icat ions
Ef f iciency >96% at 30-70% load
Isolat ion 3.0 KVAC input and out put
1.5 KVAC input eart h
0.5 KVDC out put eart h
Alarms: o Low mains shut down
o High t emperat ure shut down
o Rect if ier Failure
o Overvolt age shut down on out put
o Fan f ailure
o Low volt age alarm at 43.5V
o CAN bus f ailure
Warnings: o Low t emperat ure shut down
o Rect if ier in power derat e mode
o Remot e bat t ery current limit act ivat ed
o Input volt age out of range, f lashing at
overvolt age
o Loss of CAN communicat ion wit h
cont rol unit , st and alone mode
Visual
indicat ions
o Green LED: ON, no f ault s
o Red LED: rect if ier f ailure
o Yellow LED : rect if ier warning
Operat ing
t emp
-40 t o +75C (-40 t o +167F)
St orage t emp -40 t o +85C (-40 t o +185F)
Cooling Fan (f ront t o back airf low)
Fan Speed Temperat ure and current regulat ed
MTBF > 350, 000 hours Telcordia SR-332 Issue I,
met hod III (a) (T
ambient
: 25C)
Acoust ic
Noise
< 20dBA at nominal input and f ull load
(T
ambient
<= 25C)
(T
ambient
> 40C)
Humidit y Operat ing: 5% t o 95% RH non-condensing
St orage: 0% t o 99% RH non-condensing
Dimensions 109 x 41.5 x 327mm (wxhxd)
(4.25 x 1.69 x 13)
Weight 1.950 kg (4.3lbs)

www.eltekvalere.com

Fl at pack2 48/ 2000
Rectifier Module
Key Features
Highest efficiency in minimum space
Resonant t opology makes t he module ef f iciency indust ry
leading and cont ribut es t o t he rect if iers ult ra compact
dimensions.
Digital controllers
Primary and secondary cont rols are digit alized, enabling
excellent monit oring and regulat ion charact erist ics. Thus,
t he number of component has been reduced by 40% - f or
highly reliable, long lif e, t rouble f ree DC power syst ems.
Heat management
Front -t o-back air f low wit h chassis-int egrat ed heat sinks
gives t he module t he most suit able working environment
and no limit at ions in t he scalabilit y of t he desired syst em
solut ion.
Unique connection
A t rue plug-and-play connect ion syst em: t ime-t o-inst all and
cost -reducing solut ion.
Global approvals
Flat pack2 is CE marked, UL recognized and NEBS cert if ied f or
worldwide inst allat ion.

Versatile and powerful solution for any application
The combinat ion of cost -ef f ect ive design, power densit y and
reliabilit y makes t he Flat pack2 a product f amily t hat t ruly st ands
out s and provides unparalleled net work availabilit y. The versat ilit y
of t he Flat pack2 rect if ier means t hat it can be used in a wide
variet y of 48VDC and 24VDC applicat ions across t he globe.
Applications
Todays communicat ions demand st at e of t he art , cost
ef f ect ive and compact DC power syst ems. Flat pack2
delivers an indust ry leading power densit y and superb
reliabilit y at lowest lif et ime cost
Increasing net work speed demands f lexible and expandable
DC power solut ions. The Flat pack2 rect if iers are your key
building blocks f or f ut ure needs.
Small and large
Due t o t he high power densit y, cost compet it ive design and
a highly f lexible syst em communicat ion int erf ace, Flat pack2
rect if iers are used in syst em solut ions f rom 5kW t o 96kW.

Product Description
The Flat pack2 is a bat t ery charger and rect if ier f or st and-
alone use or f or working in parallel as part of a DC power
syst em cont rolled and monit ored by t he Smart pack.
Flat pack2 is opt imized f or a wide range of syst em sizes.
Digit al communicat ion over CAN bus wit h Smart pack
simplif ies syst em design and enhances f lexibilit y.
Realizat ion of Flat pack2 syst ems is possible by f it t ing 4
rect if iers across a 23 or 19 shelf .

Headquart ers:
Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, USA
Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Eltek Valere
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

Applicable St andards
Elect rical saf et y IEC 60950-1
UL 60950-1
CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 (t elecommunicat ion net work)
EN 61000-6-1 (immunit y, light indust ry)
EN 61000-6-2 (immunit y, indust ry)
EN 61000-6-3 (emission, light indust ry)
EN 61000-6-4 (emission, indust ry)
Mains Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2 (-1, -2, -3)
ETSI EN 300 132-2
RoHS compliant

Specif icat ions are subject t o change wit hout not ice 241115.100.DS3 v6

Fl at pack2 48/ 2000
241115.100 Flat pack2 48/ 2000

Input
AC Volt age 85-300 VAC (Nominal 185 275 VAC)
Frequency 45 t o 66Hz
Maximum Current 12.5 A
rms
maximum at nominal input
and f ull load
Power Fact or > 0.99 at 50% load or more
DC Volt age 120-275VDC (Rat ed 140 250VDC)
Input Prot ect ion o Varist ors f or t ransient prot ect ion
o Mains f use in bot h lines
o Disconnect above 300 VAC

DC Out put
Volt age 53.5 VDC (adj. range: 43.5-57.6 VDC)
Out put Power 2000 W at nominal input
input
Current Sharing 5% of maximum current f rom 10%
t o 100% load
St at ic volt age
regulat ion
0.5% f rom 10% t o 100% load
Dynamic volt age
regulat ion
5.0% f or 10-90% or 90-10% load
variat ion, regulat ion t ime < 50ms
Hold up t ime > 20ms; out put volt age > 43.5 VDC
at 1500W load
Ripple and Noise o < 100 mV peak t o peak,
o 30 MHz bandwidt h
o < 0.96 mV rms psophomet ric
Out put Prot ect ion o Overvolt age shut down
o Blocking diode
o Short circuit proof
o High t emperat ure prot ect ion

Ot her Specif icat ions
Ef f iciency Typical 92%, min. 91% at 40-90% load
Isolat ion 3.0 KVAC input and out put
1.5 KVAC input eart h
0.5 KVDC out put eart h
Alarms: o Low mains shut down
o High t emperat ure shut down
o Overvolt age shut down on out put
o Fan f ailure, one or t wo f ans.
o Low volt age alarm at 43.5V
o CAN bus f ailure
Warnings: o Low t emperat ure shut down
o Rect if ier in power derat e mode
o Remot e bat t ery current limit act ivat ed
o Input volt age out of range, f lashing at
overvolt age
o Loss of CAN communicat ion wit h
cont rol unit , st and alone mode
Visual
indicat ions
o Green LED: ON, no f ault s
o Red LED: rect if ier f ailure
o Yellow LED : rect if ier warning
Operat ing
t emp
-40 t o +75C (-40 t o +158F)
St orage t emp -40 t o +85C (-40 t o +185F)
Cooling 2 f ans (f ront t o back airf low)
Fan Speed Temperat ure and current regulat ed
met hod III (a) (Tambient : 25C)
Acoust ic
Noise
(T
ambient
< 30C)
Humidit y Operat ing: 5% t o 95% RH non-condensing
St orage: 0% t o 99% RH non-condensing
(4.25 x 1.69 x 13)
Weight 1.9 kg (4.19lbs)

www.eltekenergy.com I www.flatpack2.com

Flatpack2 48/1800

Switch Mode Power Supply 48VDC

Key Features
Highest efficiency in minimum space
Resonant topology makes the module efficiency industry
leading and contributes to the rectifiers ultra compact
dimensions.
Digital controllers
Primary and secondary controls are digitalized, enabling
excellent monitoring and regulation characteristics.
Thus, the number of component has been reduced by
40% - for highly reliable, long life, trouble free DC
power systems.
Heat management
Front-to-back air flow with chassis-integrated heat sinks
gives the module the most suitable working
environment and no limitations in the scalability of the
desired system solution.
Unique connection
A true plug-and-play connection system: time-to-install
and cost-reducing solution.
Global approvals
Flatpack2 is CE marked, UL recognized and NEBS
certified for world wide installation.
Product Description
The Flatpack2 is a battery charger and rectifier for
stand-alone use or for working in parallel as part of a
DC power system controlled and monitored by the
Smartpack.
Flatpack2 is optimized for a wide range of system sizes.
Digital communication over CAN bus with Smartpack
simplifies system design and enhances flexibility.
Realization of Flatpack2 systems is possible by fitting 5
rectifiers across a 23 shelf and 4 rectifiers across a 19
shelf.
Applications
Todays communications demand state of the art, cost
efficient and compact DC power systems. Flatpack2
delivers the industry leading power density of 21W/in
3

and superb reliability at lowest lifetime cost.
Increasing network speed demands flexible and
expandable DC power solutions. Flatpack2 is your key
building block for future needs.

Flatpack2
Switch Mode Power Supply 48VDC

109.00
4
1
.5
0
327.22

(coming up)
109 mm 327 mm
4
1
,
5

m
m

Location Company Telephone Fax
Europe Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10
Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118
Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602
China Eltek Energy Ltd. +852 28982689 +852 28983189
Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175

www.eltekenergy.com I www.flatpack2.com

Flatpack2

AC Input
Voltage 85-290 VAC (Nominal 185 275 VAC)
Frequency 45 to 66Hz
Maximum
Current
10.7 Arms maximum at nominal input
and full load
Power Factor > 0.99 at 20% load or more
Input Protection Varistors for transient protection
Mains fuse in both lines
Disconnect above 290 VAC

DC Output
Voltage 53.5 VDC (adj. range: 43.5-56.0 VDC)
Output Power 1800 W at nominal input
input
Current Sharing 3% from true average current
between modules
Static voltage
regulation
0.5% from 10% to 100% load
Dynamic voltage
regulation
5.0% for 10-90% or 90-10% load
variation, regulation time < 50ms
Hold up time > 20ms; output voltage > 43.5 VDC at
1500W load
Ripple and Noise < 100 mV peak to peak,
30 MHz bandwith
< 0.96 mV rms psophometric
Output Protection Overvoltage shutdown
Blocking diode
Short circuit proof
High temperature protection

Other Specifications
Efficiency Typical 92%, min. 91% at 40-90% load
Isolation 3.0 KVAC input and output
1.5 KVAC input earth
0.5 KVDC output earth
Alarms:

Warnings:
Low mains shutdown
High temperature shutdown
Rectifier Failure
Overvoltage shutdown on output
Fan failure, one or two fans.
Low voltage alarm at 43.5V
CAN bus failure

Rectifier in power derate mode
Remote battery current limit activated
Input voltage out of range, flashing at
overvoltage
Loss of CAN communication with control
unit, stand alone mode
Visual
indications
Green LED: ON, no faults
Red LED: rectifier failure
Yellow LED : rectifier warning
Operating
temp
-40 to +70C (-40 to +158F)
Storage temp -40 to +85C (-40 to +185F)
Cooling 2 fans (front to back airflow)
Fan Speed Temperature and load regulated
method III (a)
Acoustic Noise < 50dBA at nominal input and 70% load
(Tambient < 30C)
Humidity Operating: 5% to 95% RH non-condensing
Storage: 0% to 99% RH non-condensing
(4.25 x 1.69 x 13)
Weight 1.8 kg (3.97 lbs)

Applicable standards
Electrical safety IEC 60950-1
UL 60950-1
CSA 22.2
EMC ETSI EN 300 386 V.1.3.2 (telecommunication network)
EN 61000-6-4 (emission, industry)
EN 61000-6-3 (emission, light industry)
EN 61000-6-2 (immunity, industry)
EN 61000-6-1 (immunity, light industry)
Harmonics EN 61000-3-2
Environment ETSI EN 300 019-2
ETSI EN 300 132-2
RoHS compliant (pending)
Specifications are subject to change without notice.

ORDERING INFORMATION

Part no. Description
241115.001 Flatpack2 48V

Document Rev. No.: 241115.001.DS3 v.05

www.eltekvalere.com

Smart pack Cont rol l er
Monitoring and Control Unit
Key Features
Front panel LCD and but t ons f or on-sit e service wit hout
PC. (Not on Basic Slave model)
USB- or RS-232 int erf ace f or PC connect ion locally or
remot e monit oring and cont rol via modem, Et hernet ,
web or SNMP.
6/ 2 user programmable relay out put s f or t radit ional
remot e monit oring
6/ 2 user programmable input s f or monit oring of ot her
equipment on sit e
Bat t ery monit oring and t est ing wit hout sit e at t endance
Temperat ure compensat ed charging f or increased
bat t ery lif et ime
Bat t ery lif et ime indicat ion
Password prot ect ed operat or access levels
Alarm/ event log wit h t ime and dat e
Windows-based PC communicat ion sof t ware

Powerful and cost effective control module
The Smartpack cont roller is a monit oring and cont rol unit used as
t he vit al nerve cent er of t he DC power plant . You operat e t he
syst em f rom t he elegant f ront panel, using t hree f ront keys and t he
LCD-display. They represent t he main int erf ace bet ween you and
t he syst em.
Applications
CAN bus communication
Smart pack ut ilizes a digit al int erf ace archit ect ure (CAN bus
communicat ion). It allows t he unit t o support dedicat ed
communicat ion channel wit h each rect if ier, providing f or
increased number of f unct ions and great er f lexibilit y.
Modular design
The Smart pack is ext remely f lexible in it s expandabilit y.
Addit ional unit s connect ed t o t he CAN bus can be added t o
provide ext ended f unct ionalit y and increased number of
measuring point s. Accordingly, syst em component s can be
set up and upgraded t o meet t he demand of any t ailor-made
power solut ion.

Product Description
The Smart pack cont roller is a powerf ul and cost -ef f ect ive
module, developed f or monit oring and cont rolling a wide
range of Elt ek Valeres DC power supply syst ems, such as
Powerpack, Flat pack2 and Minipack DC power syst ems.
You can also operat e t he syst em locally via a PC using t he
PowerSuit e PC applicat ion, or remot ely via modem, Et hernet
and t he Web. The module t hen ut ilizes t he USB- or RS-232
port s t o int erf ace wit h a local PC, SNMP or Web adapt ers.

Headquart ers:
Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, USA
Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Eltek Valere
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

Specif icat ions
Input Volt age 24/ 48/ 60 VDC
nominal syst em volt ages
Dimensions
(WxHxD)
109 x 44 (1U) x 140mm
4.3 x 1.7 x 5.5

Specif icat ions are subject t o change wit hout not ice
242100.100.DS3 v7

Smart pack Cont rol l er
242100.110 Smart pack Ext ended (6 + 6 I/ O, 2 St ring Bat t ery connect ion)
242100.111 Smart pack RS-232 f ront (RS-232, 6 + 6 I/ O, 2 St ring Bat t ery connect ion)
242100.112 Smart pack RS-232 rear (RS-232, 6 + 6 I/ O, 1 St ring Bat t ery connect ion)
242100.113 Smart pack WEB/ SNMP (Et hernet , 2 + 2 I/ O, 2 St ring Bat t ery connect ion)
242100.118 Smart pack WEB/ SNMP (Et hernet , 6 + 6 I/ O, 1 St ring Bat t ery connect ion)
242100.000 Smart pack Basic Slave (wit hout display, but t ons & int ernal power f or dist ribut ed syst ems)

Remot e Monit oring and Cont rol
From a PC running PowerSuite
a Windows-based communicat ion program inst alled
on a remot e comput er, t he syst em can be monit ored
and cont rolled via modem or Et hernet net work
From a PC running a WEB Browser
t he syst em can be monit ored and cont rolled via
Et hernet net work
From an NMS via Ethernet (SNMP)
Wit h an SNMP agent connect ed t o t he Smart pack,
t he syst em can be monit ored and cont rolled f rom a
Net work Management Syst em (NMS) t hrough
Et hernet on Simple Net work Management Prot ocol
(SNMP)
Using alarm relays (voltage free contacts)
6/ 2 int ernal f ailsaf e alarm relays provide volt age f ree
cont act s t hat can be connect ed t o equipment used
f or t radit ional alarm monit oring

Feat ures
System
o Out put Volt age Measurement
o Tot al Load Current Measurement
o Load/ Bat t ery Disconnect
o Alarm Level Set t ings (major / minor)
o Alarm Log (up t o 1000 event s, 10k on HW v2)
o Real Time Clock wit h Bat t ery Backup
o Sit e Text / ID
o Test of Relay Out put s
o Volt age Level set up
o Dat a logging (up t o 7000 dat a point s)

Battery
o Bat t ery Current Measurement
o Bat t ery Temperat ure Measurement (opt ional)
o Bat t ery Test ing (acc. t o discharge t able or set t ime limit )
o Bat t ery Test Inf ormat ion (10 lat est t est s)
o Set up of Bat t ery Dat a
o Bat t ery shunt set up
o Bat t ery qualit y indicat ion
o Bat t ery Boost Charging
o Bat t ery Cable Volt age Drop Compensat ion
o Temperat ure Compensat ed Charging
o Prot ect ion against Temperat ure Probe Failure

Rectifier
o Available inf ormat ion about each rect if ier, e.g. serial
o number, version, int ernal t emperat ure
o Individual Rect if ier Current Measurement
o Individual Rect if ier Input Volt age
o Ef f iciency Management

Local Monit oring and Cont rol
From a PC running PowerSuite
a Windows-based communicat ion sof t ware, can
also communicat e wit h t he Smart pack t hrough an
USB serial or RS-232 cable
LCD and three keypads for local operations
If any alarm (major or minor) is act ivat ed, a (red or
yellow) LED is lit in t he f ront panel, t he alarm t ext
appears in t he LCD and t he corresponding alarm
relay is act ivat ed

In normal operat ion, t he f ront LCD will display t he
out put volt age, bat t ery current , load current and
charge mode. (Not on Basic Slave version)

Available Alarms
All alarms can be set up with monitoring of minor, major,
average and peak levels.

System
o Mains Failure (individual phases)
o Digit al Input s (programmable names)
o Load Disconnect (volt age or t imer)
o Load Fuse
o Load Current

Battery
o High Bat t ery volt age
o Low Bat t ery volt age
o High Bat t ery t emperat ure
o Low Bat t ery t emperat ure
o Bat t ery Capacit y
o Bat t ery Disconnect
o Bat t ery Fuse
o Symmet ry Failure
o Bat t ery qualit y indicat ion
Bat t ery discharge current
Rectifier
o Crit ical Rect if ier Failure (> 1, programmable)
o Rect if ier Capacit y w. programmable level
o Rect if ier Current Limit
o Rect if ier Overvolt age Prot ect ion
o Rect if ier Current

Flatpack DC/DC | 48/24
DC/DC Converter
The converter is specially designed to provide a high
quality and highly reliable DC output voltage.
Switch mode technology with soft switching and high
switching frequency is used to minimise volume and
weight, and to obtain fast output voltage regulation.
The module has a soft start power-up. When working in
parallel, the converters provide active current sharing.
An internal blocking diode allows hot plug-in and
isolates any faults in the converter output from the DC-
bus.
Several internal protection circuits ensure safe
operation, even outside specified limits for normal
operation.
The Flatpack DC/DC 48/24 is a modular hot plug-in
DC/DC converter prepared for stand-alone use, or for
working in parallel as part of a DC/DC rack system.
A module failure alarm is given if the module shuts down
due to high/low input voltage, high output voltage
(selective), or in case of an internal failure.
Converters connected in parallel will exhibit active load
sharing, even without a Monitoring and Control Unit via
CAN bus.
Front LEDs show power ON/OFF and alarm status in
addition to a LED bar graph for output current indication.
The Flatpack DC/DC 48/24 will operate in ambient
temperatures up to +75C (+167F). At temperatures
above +65C (+149F), the output power may be
derated.
Location Company Telephone Fax
Europe Eltek Energy AS +47 32 20 32 00 +47 32 20 32 10
Americas Eltek Energy, LLC +1 815 459 9100 +1 815 459 9118
Asia/Pacific Eltek Energy Pte Ltd. +65 6 7732326 +65 6 7753602
China Eltek Energy Ltd. +852 28982689 +852 28983189
Middle East Eltek Middle East +971 4 887 1176 +971 4 887 1175
FLATPACK
DC/DC 48/24
SPECIFICATIONS
INPUT
Input Voltage
range
40.0-60 VDC
Maximum Current 32 Amps at 40.0 VDC input
Protection Soft start
Internal fuse
Automatic shutdown for input
voltages < 40 VDC and >
62 VDC
OUTPUT
Output Voltage 24-28 VDC
Output Power 1100 W at 27.5 VDC
Output Current 40 Amps at 24 VDC
Current Share 2 Amps
Static Voltage
Regulation
0.5% from 0 to full load
Dynamic Voltage
Regulation
4.0% for 10-90%
or 90-10% load variation
Ripple and Noise <100 mV peak to peak,
30 MHz bandwidth
Protection Blocking diode
Non-destructive short circuit
operation and selective high
output voltage shutdown
(30 V)
OTHER SPECIFICATIONS
Isolation
Voltages
Input/ Earth: 600 VDC
Input/ Output: 600 VDC
Output/ Earth: 600 VDC
Converter
alarms
No output voltage
Overvoltage shutdown
Fan failure 1 or 2
High temperature shutdown
Short circuit/ fold back activated
Converter
warnings
DC input voltage out of range
Single fan failure
High temperature/ derating activated
Current limit
Visual
indications
Green LED: ON, no faults
Red LED: No output, converter failure
Yellow LED bargraph: measuring
output current (0-100%)
Efficiency 90% typical
Operating
Temp
-40 to +65C (-40 to +149F)
+65 to +75 C (+149 to +167F):
Temperature dependent power
limiting may occur
Storage Temp -40 to +85 C (-40 to +185F)
Cooling Temperature controlled fans
Acoustic Noise 6.3 Bels
Dimensions 218 x 43 x 240mm (wxhxd)
(8.58 x 1.69 x 9.45)
Weight < 3kg (< 6.6lbs)
APPLICABLE STANDARDS
Electrical safety EN 60950, UL 60950
EMC ETSI EN 300 386 V.1.3.1
(telecommunication network)
EN 61000-6-3
(emission, light industry)
EN 61000-6-2
(immunity, industry)
EN 61000-6-4 (emission, industry)
EN 61000-6-1 (immunity, light
industry)
Telcordia GR1089 CORE
Environment ETSI EN 300 019-2
ETSI EN 300 132-1
ETSI EN 300 132-2
Telcordia GR63 CORE Zone 4
ETSI EN 300 753 class 3.1
(acoustic noise)
Specifications are subject to change without notice.
ORDERING INFORMATION
Part no. Description
241114.503 Flatpack DC/DC 48/24 converter
241114.503. DS3 v.02
PRODUCT FEATURES
TECHNICAL FEATURES
PIates and Grids: thick pasted plates
and grids of high quality Lead-Tin-Calcium
alloy
Separators: microporous glass mats
Containers and Lids: made from thick-
walled ABS flame retardant plastic
designed for unsurpassed mechanical
strength and in accordance with flame
retardancy standard EC 707 FV0.
TerminaIs: female threaded M8 terminals
provide for high conductivity, minimum
installation time, and maximum torque
retention
FIame Arrestors: expel excess gas while
preventing any errant spark or flame from
entering the battery
HandIes: rope handles facilitate ease of
handling, installation and removal of the
batteries
Safety VaIves: operate at low internal
pressure
Connections: the terminals allow for
front, top or side connections depending
on the space constraints of the installation
Remote Venting System: an optional
RemoteVenting System(RVS) is available
for applications which require small
amounts of gas (generated during normal
operation) to be vented externally
Fits in 23" rack/cabinet
Easy unpacking
Opti onal remote venti ng system
Optional means of connection from the
front, the top and the side of the
monoblocs offering flexibility to connect
the monoblocs according to available
space
The family includes many battery
ranges especially designed to offer the wider security
and reliability for Telecommunication applications
both wireline and wireless . The PPT line covers
the range between 100 Ah and 160 Ah. The FAMM
Valve Regulated Lead Acid batteries (VRLA) are
of Absorbed Glass Mat technology (AGM). Extensive
testing and customer field experience since
's inception during 1985 ensures
ultimate reliability and offers the many benefits. The
FAMM PPT range offering all the advantages of
absorbed electrolyte valve regulated lead-acid
batteries, with the accessibility of front terminals.
The front terminals facilitate access when connection
up the monoblocs during the installation, and simplify
maintenance.Maintenance costs are therefore
reduced and system reliability improved. The front
access terminals are fully insulated by terminal
covers thus ensuring electrical safety. The terminal
covers have a specially designed access hole to
enable voltage readings to be made safely and
easily. The compact design facilitates a minimum
footprint allowing a better battery arrangement both
in cabinets and on racks.The highest quality level
is ensured by the SO 9001 and SO14001
Certificated Quality System.
Eurobat Guide - long life
Telcordia (Bellcore) TR-NWT-000766
British Standard BS 6290 Part 4
British Standard 6334 method FV0
EC 60896 Part 21-22
UL Recognized
www.fiamm.com
12
12
L W
8015
07.05
H T
(mohm) (V)
DMENS NS O
ELECTRICAL CHARACTERISTICS
BATTERY
TYPE
NOMNAL
VOLTAGE
NOMNAL
CAPACTY
WEGHT
(Kg)
(mm)
L W TH
NTERNAL
RESSTANCE
SHORT
CRCUT
CURRENT
(A)
FI AMM FFT r ange
160 126 320 3.9 3200
105
130
4
50
60
126
126
230
270
4.4
4.1
2800
3000 12
12
FFT
FFT
FFT
12 105
12 130
12 160
1
FFT 12 100 100 4.5 2200 126 230 38
558
558
558
558
(Ah at 20 )
10 hrs to1.80VPC
range fit
TECHNICAL FEATURES
Plates and Grids: thick pasted plates
and grids of high quality Lead-Tin-Calcium
alloy
Separators: microporous glass mats
Containers and Lids: made from thick-
walled ABS flame retardant plastic
designed for unsurpassed mechanical
strength and in accordance with flame
retardancy standard IEC 707 FV0 .
Terminals: M6 terminals provide for high
conductivity, minimum installation time,
and maximum torque retention
Flame Arrestors: expel excess gas while
preventing any errant spark or flame from
entering the battery
Handles:facilitate ease in handling,
installation and removal of the batteries
Safety Valves: operate at low internal
pressure
Connections: the terminals allow for
front, top or side connections depending
on the space constraints of the installation
Remote Venting System: an optional
Remote Venting System (RVS) is available
for applications which require small
amounts of gas (generated during normal
operation) to be vented externally
The family includes many battery
ranges especially designed to offer the wider security
and reliability for Telecommunication applications
both wireline and wireless. The fit line covers the
range between 30 Ah and 100 Ah. The FIAMM
Valve Regulated Lead Acid batteries (VRLA) are
of Absorbed Glass Mat technology (AGM). Extensive
testing and customer field experience since
's inception during 1985 ensures
ultimate reliability and offers the many benefits. The
FIAMM fit range offering all the advantages of
absorbed electrolyte valve regulated lead-acid
batteries, with the accessibility of front terminals.
The front terminals facilitate access when connection
up the monoblocs during the installation, and simplify
maintenance.Maintenance costs are therefore
reduced and system reliability improved. The front
access terminals are fully insulated by terminal
covers thus ensuring electrical safety. The terminal
covers have a specially designed access hole to
enable voltage readings to be made safely and
easily. The compact design facilitates a minimum
footprint allowing a better battery arrangement both
in cabinets and on racks.The highest quality level
is ensured by the ISO 9001 and ISO14001
Certificated Quality System.
PRODUCT FEATURES
Fits in 19" rack/cabinet
Easy unpacking
Optional remote venting system
Eurobat Guide - long life
British Standard BS 6290 Part 4
British Standard 6334 method FV0
IEC 60896 Part 21-22
UL Recognized
www.fiamm.com
18
22
33
14
29
287
12 FIT 40
12 FIT 55
12
12
40
55 9.4
800
199 13
1200 199
395
395
108
108
12 FIT 30
4.4 12 FIT100 12 100 2200 395 108
12 30 700 190 13.5 280 105
12 FIT 75 12 75 5.8 1980 395 108 287
range fit 8014
07.05
(mm)
FI AMM FI T r ange
Industrial Batteries Department
Viale Europa, 63 - 36075 Montecchio Maggiore (VI)
ITALY
MATERIAL SAFETY DATA SHEET
FIAMM BATTERIES: Monolite
PRODUCT CHARACTERISTICS
PRODUCT
Valve Regulated Lead Acid Sealed batteries with absorbed electrolyte wet (non spillable).
PRODUCT TECHNICAL COMPONENTS
Components Description %
Lead and Compounds Pb, PbO2, PbSO4 70-80
Electrolyte Sulphuric acid in max concentration of 35% 12-20
Polymer ABS 6-9
TECHNICAL NAME OF DANGEROUS SUBSTANCE
Sealed batteries containing a solution of sulphuric acid and distilled water, completely
absorbed in separators.
PROPERTIES OF CONTAINER
ABS polymer, flame retardant FV0, anti-cracking.
PROPERTIES OF DANGEROUS SUBSTANCE
Liquid, clear, colourless.
BOILING POINT OF DANGEROUS SUBSTANCE
110
o
C
CLASSIFICATION OF DANGEROUS SUBSTANCE
Class 8
Code page IMDG IMCO No.8121
UN No 2800
PACKAGING REQUIRED FOR TRANSPORTATION
Batteries have to be packed in strong outer packagings after insulating each cell
terminals.
Packaging Group III
IMPORTANT NOTE
There is no electrolyte in liquid status inside the battery due to the fact that this
electrolyte is completely absorbed by a spungy material.
This means that even if you turn upside down (ermetically closed) there will be no
leakage of the electrolyte.
Conditions will not change below boiling point (110
o
C).
SAFETY DATA
NATURE OF HAZARD
Corrosive liquid electrolyte causes damage to eyes, skin & air passages.
Attacks many materials & clothing.
Attacks many metals with liberation of hydrogen which is flammable and forms an
explosive mixture with air.
Stored electrical energy.
PROTECTIVE MEASURES
Goggles giving complete protection to eyes, acid resistant clothing and gloves, and
safety footwear.
Have available an eyewash bottle with clean water.
Store in a cool dry place.
Keep all vent plugs in position.
Charge in a well ventilated area, avoid breathing mist.
Keep away from sources of ignition, do not allow smoking or any naked lights.
Keep away from children.
For safe operating practices see BS 6287:1982
FIRST AID
If substance has got into eyes, immediately wash out with plenty of water.
If ingested drink copious amounts of water and seek immediate medical attention.
Remove any contaminated clothing and wash skin with water.
Seek medical treatment.
SPILLAGE
Close off or contain leak if without risk, using plastic containers if available.
Neutralise with soda ash, sodium carbonate or sodium bicarbonate.
If undiluted substance has entered a watercourse or contaminated soil or vegetation,
advise local authority.
FIRE
If circuit still made, and if safe to do so, the emergency services may sever cables with
firemans axe.
Smother with dry powder or foam.
If necessary keep containers cool by spraying with water.
DISPOSAL
This product is defined in SI 232:1994 as being for fitment to an excluded appliance.
The cells contain heavy metal and must not be put out for collection in refuse containers.
Keep all constituents enclosed and upright.
Dispose of only to authorised scrap recoverer.
Move only in accordance with local authority requirements.
Do not incinerate or throw away.
_____________________________________________________________________________
Fiamm Asia Pacific Pte Ltd
36 Tuas Crescent
Singapore
Tel 0065 8653278
Fax 0065 8626550
Industrial Batteries Department
Viale Europa, 63 - 36075 Montecchio Maggiore (VI)
ITALY
MATERIAL SAFETY DATA SHEET
FIAMM BATTERIES: SLA/FAT/UMTB
PRODUCT CHARACTERISTICS
PRODUCT
Valve Regulated Lead Acid Sealed batteries with absorbed electrolyte wet (non spillable).
PRODUCT TECHNICAL COMPONENTS
Components Description %
Lead and Compounds Pb, PbO2, PbSO4 70-80
Electrolyte Sulphuric acid in max concentration of 35% 12-20
Polymer ABS 6-9
TECHNICAL NAME OF DANGEROUS SUBSTANCE
Sealed batteries containing a solution of sulphuric acid and distilled water, completely
absorbed in separators.
PROPERTIES OF CONTAINER
ABS polymer, flame retardant FV0, anti-cracking.
PROPERTIES OF DANGEROUS SUBSTANCE
Liquid, clear, colourless.
BOILING POINT OF DANGEROUS SUBSTANCE
110
o
C
CLASSIFICATION OF DANGEROUS SUBSTANCE
Class 8
Code page IMDG IMCO No.8121
UN No 2800
PACKAGING REQUIRED FOR TRANSPORTATION
Batteries have to be packed in strong outer packagings after insulating each cell
terminals.
Packaging Group III
IMPORTANT NOTE
There is no electrolyte in liquid status inside the battery due to the fact that this
electrolyte is completely absorbed by a spungy material.
This means that even if you turn upside down (ermetically closed) there will be no
leakage of the electrolyte.
Conditions will not change below boiling point (110
o
C).
SAFETY DATA
NATURE OF HAZARD
Corrosive liquid electrolyte causes damage to eyes, skin & air passages.
Attacks many materials & clothing.
Attacks many metals with liberation of hydrogen which is flammable and forms an
explosive mixture with air.
Stored electrical energy.
PROTECTIVE MEASURES
Goggles giving complete protection to eyes, acid resistant clothing and gloves, and
safety footwear.
Have available an eyewash bottle with clean water.
Store in a cool dry place.
Keep all vent plugs in position.
Charge in a well ventilated area, avoid breathing mist.
Keep away from sources of ignition, do not allow smoking or any naked lights.
Keep away from children.
For safe operating practices see BS 6287:1982
FIRST AID
If substance has got into eyes, immediately wash out with plenty of water.
If ingested drink copious amounts of water and seek immediate medical attention.
Remove any contaminated clothing and wash skin with water.
Seek medical treatment.
SPILLAGE
Close off or contain leak if without risk, using plastic containers if available.
Neutralise with soda ash, sodium carbonate or sodium bicarbonate.
If undiluted substance has entered a watercourse or contaminated soil or vegetation,
advise local authority.
FIRE
If circuit still made, and if safe to do so, the emergency services may sever cables with
firemans axe.
Smother with dry powder or foam.
If necessary keep containers cool by spraying with water.
DISPOSAL
This product is defined in SI 232:1994 as being for fitment to an excluded appliance.
The cells contain heavy metal and must not be put out for collection in refuse containers.
Keep all constituents enclosed and upright.
Dispose of only to authorised scrap recoverer.
Move only in accordance with local authority requirements.
Do not incinerate or throw away.
_____________________________________________________________________________
Fiamm Asia Pacific Pte Ltd
36 Tuas Crescent
Singapore
Tel 0065 8653278
Fax 0065 8626550
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ALARM MATRIX (Eltek Flatpack2 Ericsson)

Alarm Causes AC Mains
fail
High Load /
Low load
High Float /
Low Float
Battery CB /
Load CB
Rectifier fail Off-Normal /
BCM
Monitor fail
(Relay output) (1) (2) (3) (4) (5) (6) (External)
Failed AC supply 9 9
Low mains / High
mains supply
9
High Bus Voltage X X
Low Bus Voltage X X
Large Voltage
deviation
9
Small Voltage
deviation
9
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Failed Rectifier 9
Rectifier Overload X X
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Voltage
9
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Alarm module
failure *
X X X X X X 9

X may cause 9 - will always cause

* On Alarm module failure, all alarms from the controller (relays 1-6) will enter an open state, giving
an alarm on the normally closed (failsafe) output terminals.

TG6223A Alarm Matrix FP2 Ericsson.doc
ALARM MATRIX (Eltek DC/DC Converter Ericsson)
Alarm Causes Alarm Output
DC input voltage >60VDC 9
Alarms:
Red LED
Warnings:
amber LED
DC input voltage <40VDC 9
Single fan failure 9
High temperature / Derating activated 9
Current limit 9
No output voltage 9
Over voltage shutdown ( 30V ) 9
Both fans failed 9
High temperature shutdown 9
Short circuit / fold back activated 9
All of the above situations will cause an alarm signal to be output, however, the warnings will produce
an amber light to appear on the module, and an alarm will cause a red light to appear.
TG6228A Alarm Matrix Ericsson DCDC converter.doc
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