Eaton Flexi-3G Guide

Flexi -3G

Installation & Commissioning

Manual

Document No 4493-CM-EN-10989402

Issue: 02

Issue Date: 05 May 2009

Eaton Corporation

Telecommunications Solutions Division

www.powerware.com

e-mail: - [email protected]

Flexi -3G Installation & Commissioning Manual

Preface

Page 2 of 94 Document No: - 4493-CM-EN-10989402

Revision History

Issue Issue Date Amendment Description Author

01 22 Apr 2009 Original Version Clive Twinley

02 05 May 2009 Battery and AC Cables Identified in Graphics Clive Twinley

Eaton Corporation disclaims any liability for direct, indirect, incidental, special or consequential damages arising out of the

application or use of any information contained in this document. The foregoing disclaimer applies to damages or personal

injury, property damage, loss of operation, loss of profits, loss of product or loss of time, whether incurred by the purchaser, the

purchaser’s employees or third party.

Information in this document does not constitute a warranty, representation or guarantee concerning the suitability or

performance of Eaton Powerware products. No such warranty, representation or guarantee is expressed or implied.

Furthermore, information contained in this document, does not guarantee or imply any ownership of site specific design. It is

therefore the total responsibility of the installation designer to ensure compliance with any legal or statutory requirements in the

country of use.

Additionally, information contained in this document is subject to change without further notice.

Eaton, Powerware, Intergy, CellSure, SiteSure, PowerManagerII and DCTools are trade names, trademarks, and/or service

marks of Eaton Power Quality Corporation or its subsidiaries and affiliates. Unless otherwise noted, brands, product names,

trademarks or registered trademarks are the property of their respective holders.

Subject to the right to use its equipment, Eaton Corporation does not convey any right, title or interest in its intellectual property,

including, without limitation, its patents, copyrights and know-how.

No part of this document may be reproduced or transmitted in any form, by any means or for any purpose other than the

Customer’s personal use, without the express written permission of Eaton Corporation.

Flexi -3G Installation & Commissioning Manual

Preface

Document No: - 4493-CM-EN-10989402 Page 3 of 94

Table of Contents

Page No

Chapter 1. Introduction..........................................................................5

Chapter 2. Flexi - 3G System General Description..............................9

Chapter 3. Installation Procedure .......................................................19

Chapter 4. Battery Installation ............................................................35

Chapter 5. Rectifier Installation ..........................................................47

Chapter 6. Installation of AC Cables ..................................................53

Chapter 7. Installation of DC Cables ..................................................63

Chapter 8. Commissioning..................................................................69

Chapter 9. Appendices ........................................................................73

Flexi -3G Installation & Commissioning Manual

Preface

Page 4 of 94 Document No: - 4493-CM-EN-10989402

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Flexi -3G Installation & Commissioning Manual

Document No: - 4493-CM-EN-10989402 Page 5 of 94

Chapter 1. Introduction

Table of Contents

Topic Page No

1.1. Purpose .........................................................................................................5

1.2. Health and Safety..........................................................................................5

1.3. Related Information ......................................................................................5

1.4. Reporting Problems with this Manual.........................................................5

1.5. Contact Information......................................................................................6

1.5.1. Manufacturers Address..................................................................................... 6

1.5.2. Other Contact Details ........................................................................................ 6

1.6. Document Numbering ..................................................................................6

1.7. Symbols Used in this Document.................................................................6

1.8. Directives & Standards ................................................................................7

1.1. Purpose

This document is the Installation & Commissioning Manual for the Eaton Flexi -3G Access Power

Solution.

1.2. Health and Safety

For details regarding health and safety, refer to document 4493-GD-EN-11037101, entitled Installation

& General Health & Safety Guidelines.

Any health and safety issues directly associated with the task will be found adjacent to the task.

1.3. Related Information

Document No Title

4493-GD-EN-11037101 Health & Safety Guidelines

4493-GN-EN-10974200 Generic Risk Assessment

4493-GN-EN-11016400 Site Specific Risk Assessment

4493-MM-EN11016200 Flexi - 3G Maintenance Manual

4493-AP-EN-11051800 Assembly Instructions for the Battery Cabinet in a Flexi - 3G System

IPN 997-00012-50 SC200 System Controller Operation Handbook www.dc.powerware.com

1.4. Reporting Problems with this Manual

Please use this fax or email address to report any problems you find in this manual:

Eaton DC Product Marketing Communications

FAX: 01243 868613

EMAIL:

[email protected]

Flexi -3G Installation & Commissioning Manual

Chapter 1. Introduction

Page 6 of 94 Document No: - 4493-CM-EN-10989402

1.5. Contact Information

1.5.1. Manufacturers Address

Eaton Power Solutions Ltd

Heath Place

Ash Grove

Bognor Regis

West Sussex

England

PO22 9SJ

1.5.2. Other Contact Details

General: 01243 810500

Main Fax: 01243 868613

Technical Helpline (Mon-Fri 08:00 to 17:00 GMT/BST): 01243-810618

Service Repair RMA Website: http://epsl.powerware.com

1.6. Document Numbering

For details of document numbering, refer to EQP300-1

1.7. Symbols Used in this Document



Warnings

•Advice on hazardous conditions. Possibility of personnel injury and/or equipment

damage



Cautions etc.

•Advice on seriously hazardous conditions. Possibility of severe/fatal personnel injury

and/or serious equipment damage

I

Electrical Hazard

•Advice on electrically hazardous conditions. Possibility of severe/fatal personnel

injury and/or serious equipment damage



Flow Arrow

•Advises that the procedure continues below.



Note or advice on further information



Recycling information

Flexi -3G Installation & Commissioning Manual

Chapter 1. Introduction

Document No: - 4493-CM-EN-10989402 Page 7 of 94

1.8. Directives & Standards

Eaton power systems have invoked the following directives and standards.

•LVD and EMC directives 2006/95/EC, 2004/108/EC and 1999/5/EC

respectively, by invoking EN60950-1, EN300-386 and EN301-489-1.

•ROHS Directive 2002/95/EC on the restriction of the use of certain

hazardous substances in electrical and electronic equipment.

This Telecommunications Power Supply System complies with or exceeds the following Standards:

•Electromagnetic Directive.

•EN60950-1: Information Technology Equipment – Safety. Part 1: General

Requirements.

•EN300 386: Electromagnetic Compatibility and Radio Spectrum Matters (ERM);

Telecommunications Network Equipment; Electromagnetic Compatibility (EMC)

requirements.

•EN301-489-1: Electromagnetic Compatibility and Radio Spectrum Matters (ERM),

Electromagnetic Compatibility (EMC) standard for radio equipment and services, Part

1: Common Technical Requirements.

This Telecommunications Power Supply System output is classed as earthed SELV at a hazardous

energy level.

Flexi -3G Installation & Commissioning Manual

Chapter 1. Introduction

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Flexi -3G Installation & Commissioning Manual

Document No: - 4493-CM-EN-10989402 Page 9 of 94

Chapter 2. Flexi - 3G System General Description

Table of Contents

Topic Page No

2.1. Flexi – 3G Power Box Description ............................................................10

2.2. Flexi – 3G Battery Cabinet Description ....................................................11

2.2.1. Battery Cabinet Dimensions........................................................................... 11

2.2.2. Battery Accommodation ................................................................................. 12

2.3. Rectifiers .....................................................................................................13

2.3.1. Outline Rectifier Technical Specifications.................................................... 13

2.4. SC200 System Controller...........................................................................14

2.4.1. Input/Output Board.......................................................................................... 14

2.4.2. Connections ..................................................................................................... 16

2.5. Compatible Software ..................................................................................16

2.6. Electrical......................................................................................................17

2.6.1. Power ................................................................................................................ 17

2.6.2. AC Input Configurations ................................................................................. 17

2.6.3. Rated AC Voltage............................................................................................. 17

2.6.4. Continuous AC Voltage................................................................................... 17

2.6.5. AC Frequency .................................................................................................. 17

2.6.6. DC Output Voltage........................................................................................... 17

2.6.7. Earthing ............................................................................................................ 17

2.6.8. Transient Protection........................................................................................ 17

Flexi -3G Installation & Commissioning Manual

Chapter 2. Flexi - 3G System General Description

Page 10 of 94 Document No: - 4493-CM-EN-10989402

2.1. Flexi – 3G Power Box Description

The Eaton Flexi - 3G Power Box is available in three versions: -

Fig. 2-1 PBA-01 Power Box Fig. 2-2 PBA-02 Power Box Fig. 2-3 PBA-03 Power Box

The PBA-01 Power Box

consists of

The PBA-02 Power Box

consists of

The PBA-03 Power Box

consists of

•16.2kW Capacity Base

Power Box

•16.2kW Capacity Base

Power Box

•16.2kW Capacity Base

Power Box

•650H x 600W x 450D •650H x 600W x 450D •650H x 600W x 450D

•9 x APR48-3G Capability •9 x APR48-3G Capability •9 x APR48-3G Capability

•SC200 Controller + IOBGP-

•SC200 Controller •SC200 Controller

•AC Input Terminals only:-

•Optional AC Input Isolator

•AC Input Isolator •Separate A + B Terminals for

AC (4/5 rectifiers on A and 4

on B)

•1PH AC Input (230Vac, 50-

60Hz, 1P + N + PE)

••1PH AC Input (230Vac, 50-

60Hz, 1P + N + PE)

•3PH AC Input (400Vac, 50-

60Hz, 3P + N + PE)

•3PH AC Input (115/230Vac,

50-60Hz, 3P + PE) – 3 Wire

Delta

•3PH AC Input (400Vac, 50-

60Hz, 3P + N + PE)

•Optional Surge Module •Surge Module •

••2-Pole MCBs for each

Rectifier

•

•Plastic Gland Plate for Top

Cable Entry

•Plastic Gland Plate for Top

Cable Entry

•Plastic Gland Plate for Top

Cable Entry

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