ENTER

OK

USB

e n e r g y M A N A GER

RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE
2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C

RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE
2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C

L1 L2 L3 N

MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB
27mm 27mm 27mm 27mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm
AC Surge Protector AC Surge Protector
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX DS240S-230 DS240S-230
XXXX XXXX XXXX
125A 125A 125A 125A XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX 63A 63A 63A
230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V Uc 400V Uc 400V 230/400V 230/400V 230/400V
15000 15000 15000 15000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000
In 20kA In 20kA
Imax 40kA Imax 40kA
.
O OFF .
O OFF .
O OFF .
O OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF Up 2kV Up 2kV O . OFF O . OFF O . OFF

T2 C T2 C
CITEL CITEL

RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE
2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C

RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE
2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C

flexi Compact
DC Compact Power Systems

Installation Manual
Scope

This manual covers essential information for the installation and commissioning of the Enatel
flexiCompact range of Compact DC Power Systems.

The power system must be installed by suitably qualified technicians. Please read this
manual thoroughly before commencing installation.

System set-up for the power modules, monitoring and alarms are provided in separate
manuals for the RM2048 series of rectifiers and SM36 supervisory module.

For your protection, the information in the product manual should

be read and thoroughly understood before unpacking, installing and

using any of the equipment.

Manual Version

V1.0 September 2013 Initial release

V1.1 October 2013 Schematic updated
V1.2 August 2014 Update Essential Systems Setup

Installation Manual Page 2 of 37

Table of Contents

System Overview ................................................................................................................... 4

Installation.............................................................................................................................. 9

Installation Best Practices................................................................................................... 9

Unpacking & Installing in Frame ....................................................................................... 11

AC Connection ................................................................................................................. 12

DC Connection ................................................................................................................. 19

Alarm/Ancillary Cabling .................................................................................................... 21

Commissioning .................................................................................................................... 25

Pre-check: ........................................................................................................................ 26

Start-up ............................................................................................................................ 26

System Monitoring ............................................................................................................... 29

Interface Options .............................................................................................................. 29

Maintenance ........................................................................................................................ 31

Appendix 1 - System Wiring Diagram ................................................................................... 32

Appendix 1 - Enatel Essential System Set-up Parameters ................................................... 32

Installation Manual Page 3 of 37

System Overview

The flexi compact range is designed to allow a customised DC power solution with all of the
benefits of a standard “off the shelf” system.

The system is intended to be a complete power system in a box with no connections needed
to be made internally. The system is designed to be extremely simple to install and set up.

All the AC and DC (Load and Battery) connections are made from the front of the unit. Alarm
connections are also accessible from the front by opening the hinged front cover.

By adding smart distribution modules, the system can be customised to suit most
requirements whilst maintaining a robust and smart user experience.

Note: This system is supplied with the AC and DC earths connected. The standard system
output has the DC Common in the positive side of the circuit (+ve earth system).
The earth link can be removed from the system to isolate earths.

12x 35mm2 , 7x 16mm2 Load & Battery Common (+ve) Terminals

L1 L2 L3 N

MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB
27mm 27mm 27mm 27mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm
AC Surge Protector AC Surge Protector
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX DS240S-230 DS240S-230
XXXX XXXX XXXX
125A 125A 125A 125A XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX 63A 63A 63A
230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V Uc 400V Uc 400V 230/400V 230/400V 230/400V
15000 15000 15000 15000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000
In 20kA In 20kA
Imax 40kA Imax 40kA
.
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF .
O OFF Up 2kV Up 2kV .
O OFF .
O OFF O . OFF

T2 C T2 C
CITEL CITEL

4x Battery Breakers 6x Priority Load Breakers 6x Non-priority Load Breakers AC Input Breakers
Surge Diverters

RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE
2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C

RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE RM 2 0 4 8 HE
2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C 2 .0 kW 4 8 V D C

Figure 1.0: Enatel flexi2 DC Compact System (fully optioned)

Installation Manual Page 4 of 37

Power System

Standard features

The base unit is supplied with the following standard options:

 SM36 supervisory module (fully integrated in the system)

 Battery Low Voltage Disconnect (300A rating).

 Three individual AC input circuit breakers

 Minimum of 6x load MCB’s, capacities to be specified at time of order (from 6A to

63A). Additional breakers can also be specified at time of order.

Current Capacities

 flexi1 system capacity is up to 166A with a maximum of 4x RM2048 power modules

 flexi2 system capacity is up to 333A with a maximum of 8x RM2048 power modules

 flexi3 system capacity is up to 500A with a maximum of 12x RM2048 power modules

Optional features

Additional options that can be specified at the time of order:

 Three phase AC surge suppression

 1-4x 125A battery breakers

 Load breakers up to a maximum of 15 (dependant on selection of other options)

 300A Load low voltage disconnect for non-priority loads

 AC metering

 Battery monitoring

 Site monitoring

 Additional I/O support

Note: Additional options can be added at a later date but installation outside of the factory
is beyond the contents of this manual.

Please consult your sales representative for more details.

Installation Manual Page 5 of 37

Model flexi 1 flexi 2 flexi 3

Depth (Total) 380mm 380mm 380mm

Width (Total) 483mm (19” mount) 483mm (19” mount) 483mm (19” mount)

Height 178mm (4U) 222mm (5U) 267mm (6U)

Weight without rectifiers 18.3kg* 20.5kg* 22.7kg*

Weight with max. rectifiers 23.5kg* 30.9kg* 38.3kg*

* Maximum weights are indicated based all possible configuration options included

Table 1.1: flexiCompact dimensions and weights

Energy Manager

The flexiCompact range has been designed to incorporate the Enatel SM36 energyManager
supervisory module.

The SM36 includes a large backlit LCD screen with tactile buttons to allow system
parameters and alarms to be easily seen and menu options to allow local adjustment to be
made.

There are 3 LED indicators on the system front panel that indicates the operational state of
the complete system giving a summary of the parameters monitored and are controlled by
the SM36.

 The green LED indicates that DC power is connected to the unit and that the monitor
is functioning.

 The yellow LED indicates a Non-Urgent alarm state within the system.

 The red LED indicates an Urgent alarm state within the system.

Mapping of the LEDs can be modified as required.

USB connection allows connection of a PC to the supervisory module. The control

parameters of the monitor are set using a configuration file that can be loaded through this
interface. Systems are supplied preconfigured with a default configuration file. A backup of
this file can be found included on the CD supplied with the flexiCompact system.

Installation Manual Page 6 of 37

 LCD Summary
Screen Alarms

Menu
Buttons

ENTER

OK

USB

e n e r g y M A NA GER

USB
Connector

Figure 1.2: Enatel SM36 energyManager Supervisory module

Rectifier Modules

The flexiCompact range has been designed to accommodate Enatel 2kW rectifier modules.

Rectifier modules are fan cooled, hot pluggable and include a local LED alarm summary for
each module.

There are 3 LED indicators on the front panel indicate the operational state of the rectifier.

 The green LED indicates that mains power is connected to the unit and that the
primary stages of the rectifier are operating.

 The yellow LED indicates a Non-Urgent alarm state within the rectifier.

 The red LED indicates an Urgent alarm state within the rectifier.

Installation Manual Page 7 of 37

Modules are secured into the flexiCompact system by one of the following 2 methods:

RM2048XE

The RM2048XE is pushed fully into position within the flexiCompact power shelf and a tool
(pen or thin screwdriver can be used) is used to move the green locking tab into the locked
position. Removal is the reverse of this procedure.

eNaTeL
Locking
Tab
RM2048XE
Rectifier
Alarms

Figure 1.3: Enatel 2kW RM2048XE Module

RM2048HE

The RM2048HE is pushed fully into position within the flexiCompact power shelf and will
automatically lock with an audible click. Removal requires the locking button to be held down
whilst the module is removed.

RM 2 0 4 8 HE
2 .0 kW 4 8 V D C Locking
Button

Rectifier
Alarms

Figure 1.4: Enatel 2kW RM2048HE High Efficiency Module

Installation Manual Page 8 of 37

Installation

Installation Best Practices

Rectifiers

 Do not operate the rectifier if the covers are damaged or removed in any way

 Electrical hazards exist inside the rectifier; at no point should the cover be removed.
Servicing must be completed by fully trained technicians.

 The rectifier contains voltages that may be lethal even after the input supply has
been removed

 The rectifier contains components at high temperatures that may burn if touched

 Installation of the rectifiers should only be completed once the site has been
completed and cleaned to avoid concrete and plaster dust being ingested into
rectifiers.

DC Power System

 Use extreme care when fixing all AC and DC connections.

 Remove all jewellery and rings from oneself prior to commencing the installation.

 Always use insulated tools and take extreme care not to short terminals when
working on them.

 A minimum of 1U (44.5mm) space is required above the installed unit to allow cable
access to the top of the unit. A blank panel should be installed above the unit to
prevent recirculation of heated air from the rear of the unit.

 The space directly behind the DC power system should be clear to allow heated
exhaust air to be dissipated. A rear ventilated cabinet is recommended.

 Unoccupied rectifier spaces should be filled with blank panels to prevent recirculation
of heated air from the rear of the unit.

 Ensure all incoming cables have adequate strain relief.

Installation Manual Page 9 of 37

Battery

 Use extreme care when fitting batteries & their connections.

 Remove all jewellery and rings from oneself prior to commencing the installation.

 Wear eye protection when working near batteries

 Always use insulated tools and take extreme care not to short terminals when
working on them.

 Be aware of battery fumes and electrolyte

 Keep naked flames away from batteries on charge

 Do not dispose of batteries in the garbage

 Always recycle lead acid batteries

Installation Manual Page 10 of 37

Unpacking & Installing in Frame

Upon unpacking, check that the unit is not damaged, and that you have the required number
of rectifier modules.

The flexiCompact unit fits into a standard 19” mounting frame (450mm between the inside of
19” rails). Remove the shipping brackets prior to fitment. M6 mounting screws should be
used to mount the unit in the frame securely.

Please note the complete system weight when fitted with rectifier modules is substantial.
Ensure the 19” mounting rails are able to withstand mounting of the system. System weights
are specified in the flexiCompact dimensions and weights table (refer to page 6).

Clearances

The flexiCompact DC System has a maximum depth of 360mm behind the 19” mounting
brackets and protrudes forward 20mm from this point.

With the Supervisory Module folded forward for terminal or breaker access, the door
measures a maximum of 120mm from the 19” rail mount. Ensure adequate clearance is
provided to allow for full extension of the monitor door.

The rear of the rectifier shelf should be kept clear of obstructions to allow heated exhaust air
to exit either through a ventilated rear panel or the top of the cabinet. Any unused rectifier
positions should be fitted with a blank panel to prevent unwanted recirculation of heated
exhaust air.

Installation in a 19” cabinet will require a minimum of 1U space directly above the unit to
allow for cable exit from the front/top termination access. A blank panel should be fitted
above the unit to prevent any recirculating air.

Installation Manual Page 11 of 37

AC Connection

The flexiCompact system is supplied fitted with a set of 3-phase AC input circuit breakers as
standard. An optional AC surge protection device internally fitted to the flexiCompact solution
can be included during the order process for factory fitment or purchased at a later date in kit
form to allow fitment during commissioning.

The information in this manual covers installation of both the standard AC circuit breaker and
factory fitted SPD configurations. Fitment of the kit form SPD device at commissioning stage
is covered in a separate document that is supplied with the SPD kit. Please refer to your
local Enatel distributor for further information.

Upstream Over-current Protection

There are two considerations to take into account when selecting an appropriate upstream
fuse or circuit breaker.

1. The upstream protection should be sized to protect the downstream cable from
overload situations.

2. Discrimination should be maintained with the downstream device protection device.

Cable Rating

The upstream protection device must be able to supply the maximum current drawn by the
DC power system under all conditions without tripping.

Note: The current carrying capacity of cables is dependent on the type and length of cable
used and the manner in which it is installed.

Please check with local regulations and suppliers for appropriate sizing.

Installation Manual Page 12 of 37

Discrimination

Discrimination ensures that the upstream circuit breaker or fuse does not activate before the
downstream device internal fuse has an opportunity to activate in the case of the unit failing
short circuit. Therefore it is important to ensure the upstream protection discriminates with
the internal fuse of the rectifier. Please refer to the rectifier manual for detailed fuse
information.

Surge Protection Device (SPD)

Type 1

A Type 1 surge arrester is the first stage of the electrical network's protection. It is important
that Type 1 protection is fitted in any installation's main electrical switchboard and is capable
of diverting the energy of a direct lightning strike.

Type 2

A Type 2 surge arrester should be used in coordination with the main (Type 1) incoming
surge arrester. This is the second stage of protection. Type 2 Surge arrester is designed to
run-off energy caused by an overvoltage comparable to that of an indirect lightning strike or
an operating overvoltage.

The Enatel flexiCompact has an option to include a Type 2 Surge Protection Device in the
AC input section of the power system.

Type 3

The Enatel RM2048 range includes an input stage that contains components that are
compliant with EN61000-4-5. This is equivalent with a Type 3 surge protection device
without any external/upstream surge suppression.

Feeder Cable

Installation Manual Page 13 of 37

To ensure correct operation of the SPDs, at least 10m of AC feeder cable is required to be
fitted between the Type 1 and Type 2 protection. If the distance is less than 10m, then loop
the cable until at least 10m of cable is used. This ensures correct de-coupling of the SPD
devices. Avoid running input and output cables from AC Surge Protection Devices together.

Distance between SPD1 &

SPD2 should be minimum
of 10 metres
N

L
SPD 1
Type 1 SPD

Earth Bar
E L

Earth Bar
SPD 2
N
Type 2 SPD

AC to DC
Earth Link
RECTIFIER

Type 3 + -

equivalent SPD To Loads

No other connections DC Common (+ve)
to earth between earth Busbar
bar and ground

Figure 2.1: Typical Layout of a Surge Protected Shelter

Note: To maintain a coordinated approach to surge suppression, Type 2 SPD should be

installed upstream if it is not fitted in the DC system as well as the Type 1 protection

device installed at the main electrical switchboard.

Damage sustained from power surges or electrical storms is not covered by the

standard factory warranty, it is the responsibility of the installer to ensure the

appropriate protection is in fitted upstream of the rectifier modules.

Installation Manual Page 14 of 37

AC Termination

Access to the AC input section of the power system is made by undoing the thumb screws
securing the front panel of the flexiCompact system and folding it down to a level sufficient to
give clear and unrestricted access to the breakers.

The incoming AC termination is made by cable to the input circuit breakers for live phases
and to the terminal blocks marked for earth and neutral. All AC terminals can accept up to
16mm2 cables.

The AC earth terminal is connected directly to the system chassis.

AC Earth

DC Earth Termination

Chassis Earth

Figure 2.2: AC & DC Earth termination

Note: DC Common (+ve) is connected to the AC earth point as shown in Fig 2.2, but can

be removed if output is required to be isolated.

Installation Manual Page 15 of 37

 N L1 L2 L3 E

O . OFF O . OFF O . OFF O . OFF

AC Input Breakers

Figure 2.3a: AC Termination of AC Input Breakers

N L1 L2 L3 E

L1 L2 L3 N

O . OFF O . OFF O . OFF O . OFF

Surge Diverters AC Input Breakers

Figure 2.3b: AC Termination of AC Input Breakers with SPD

AC Terminal Cover

Once AC termination is completed, the supplied AC terminal cover should be installed to

protect from possibilities of contact with the incoming AC voltages.

 Connect the incoming AC cables and ensure terminals are tightened to the correct
torque.

Installation Manual Page 16 of 37

  Insert the AC terminal cover into the
slots provided in the top cover

Figure 2.4a: AC Terminal Cover Fitment

 Lower the terminal cover into position.

Ensure the washer provided is
positioned between the securing nut
and the polycarbonate cover.

Figure 2.4b: AC Terminal Cover Fitment

 Tighten the securing nut to lock the cover into position.

Installation Manual Page 17 of 37

 Cable Tie to
Secure

Tighten Nut

Figure 2.4c: AC Terminal Cover Fitment

 The incoming AC cable can be secured to the top cover by cable tie to provide strain
relief.

Installation Manual Page 18 of 37

DC Connection

The internal battery bus connects the battery circuit breakers via a Low Voltage Disconnect
(LVD) contactor and current shunt to the internal live bus. The load bus connects the load
circuit breakers directly to the internal live bus.

Operation of the Battery LVD will disconnect all loads from the battery when the bus voltage
reduces below an adjustable set-point following a prolonged AC outage. The SM36
supervisory module is normally powered from the internal live bus but also connects to a
secondary supply direct from the battery to allow monitoring of the system in the case of an
LVD event.

An option to include a secondary Partial Load Low Voltage Disconnect can be made during
the order process for factory fitment or kit form to allow fitment during commissioning. This
allows the monitor to initially disconnect non-essential loads after some discharge (voltage
set point is adjustable) to extend backup time of the essential circuits in an installation.

Load & Battery Common (+ve) Terminals

N L1 L2 L3 E

L1 L2 L3 N

MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB MCB
27mm 27mm 27mm 27mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm 18mm
AC Surge Protector AC Surge Protector
XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX XXXX DS240S-230 DS240S-230
XXXX XXXX XXXX
125A 125A 125A 125A XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX XXX 63A 63A 63A
230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V 230/400V Uc 400V Uc 400V 230/400V 230/400V 230/400V
15000 15000 15000 15000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000
In 20kA In 20kA
Imax 40kA Imax 40kA
O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF O . OFF Up 2kV Up 2kV O . OFF O . OFF O . OFF

T2 C T2 C
CITEL CITEL

Battery Breakers Priority Load Breakers Non-priority Load Breakers SPD AC Input

Figure 2.5: DC Breaker and Common Terminal Layout*

* Breaker configuration can change depending on system specifications, please consult

specifications of the individual system to ensure correct terminations.

Installation Manual Page 19 of 37

Battery Connection

Access to the battery distribution section of the power system is made by undoing the thumb
screws securing the front panel of the flexiCompact system and folding it down to a level
sufficient to give clear and unrestricted access to the breakers.

Battery Common (+ve)

All Battery Common connections are made to the connectors placed behind the Circuit
breakers. 2 sizes of common terminals are available to accept cables up to 16mm2 and
35mm2.

Battery Live (-ve)

Battery Live cables are connected directly to the terminals at the top of the circuit breakers.
Battery breaker terminals are sized to accept cables up to 35mm2.

Ensure all incoming cables are strain relieved adequately.

Load Connection

Access to the load output section of the power system is made by undoing the thumb screws
securing the front panel of the flexiCompact system and folding it down to a level sufficient to
give clear and unrestricted access to the breakers.

Load Common (+ve)

All Load Common connections are made to the connectors placed behind the Circuit
breakers. 2 sizes of common terminals are available to accept cables up to 16mm2 and
35mm2.

Note: Cables smaller than 6mm2 should be terminated to the 16mm2 connectors to ensure

adequate clamping force.

Load Live (-ve)

Installation Manual Page 20 of 37

Load Live cables are connected directly to the terminals at the top of the circuit breakers.
Load breaker terminals are sized to accept cables up to 16mm2.

Load distributions that include a secondary load LVD (LLVD) are split into 2 sections to allow
prioritisation of the connected loads. Non-priority loads are removed from circuit prior to the
primary battery LVD operation to extend the time of operation of the priority loads. Load
distributions in systems without the secondary LLVD are all removed from circuit together at
the battery LVD disconnect point.

Please refer to the specification of the system to determine which breakers are priority and
non-priority loads (if optioned).

Ensure all incoming cables are strain relieved adequately.

LVD Operation

The primary Low Voltage Disconnect contactor is located in the battery side of the DC
distribution. A secondary Load Low Voltage Disconnect can be optionally included in a
section of the load side of the DC distribution.
The LVD contactor is a bi-stable, magnetically latching contactor. This means that failure of
power or removal of the SM36 from a live system will not cause the contactor to change
state. Periodic pulsing of the LVD control signal allows the monitor to ensure the contactor
remains in the correct state. The contactor is monitored by the SM36 to allow an alarm to be
generated when the contactor is open.
The SM36 supervisory monitor unit is powered from both the rectifier side of the LVD
contactor and direct from the battery source. Following an extended AC outage and the low
output voltage threshold being reached, the primary LVD disconnects the battery from the
system live bus and the SM36 will lose voltage sense (as voltage sense is measuring
system live bus voltage) yet still maintains operation for system monitoring. The LVD
contactor will not re-engage until rectifier input supply is restored (i.e., until the DC bus
voltage is re-established).
LVD adjustments/settings are all made in the supervisory module. Please refer to the SM36
manual for detailed setup information.

Alarm/Ancillary Cabling

Access to the power system monitor is made by undoing the thumb screws securing the
front panel of the flexiCompact system and folding it down to a level sufficient to give clear
and unrestricted access to the terminals.

Alarm and communication cables terminate directly into the SM36 Supervisory Module.
Alarm cables can be made to enter/exit through either side of the front cover or fed through
and out the top or rear of the system. When routing the cables, ensure they are kept away
from the AC and DC power cables when possible and adequate strain relief is made.

Installation Manual Page 21 of 37

This section relates primarily to the terminations of alarms and ancillary cabling of the SM36
supervisory module contained within the flexiCompact systems. For full monitor functionality
and operation information, please refer to the separate SM36 manual for detailed setup
information.

External I/O Connections

J501
RY6 RY5 RY4 RY3 RY2 RY1 TS2 TS1 General Purpose Inputs
C S C S C S C S C S C S
+ - + - 6 5 4 3 2 1 Communications
Bus

J100
J105
J107
NO NC NO NC NO NC NO NC NO NC NO NC

BUS2 BUS1

J110
J109

J117 J106 J115 J113 J108 J104

J102 J101

RLY106
RLY105

RLY104
RLY103

RLY102

RLY101
J103

J112
J112
4 3 2 1 8 7

Internal Systems

MCB-COM
LVDCOM
Connections

GPIP8

GPIP7

MCB2

MCB1
LVD1

J111
J114

J111
Aug 09
COMMS
0V

+5V

PCB-ESM35-02 1 2 10 9 8

Figure 2.6: SM36 External I/O Layout

Relays

Alarms can be mapped to any of the voltage free output relays fitted to the SM36
supervisory module. Output states of either Normally Open or Normally Closed can be
selected (NO and NC states are for the de-energised relay). A jumper is fitted to nominate
the required output state, ensure the jumper is placed in the correct configuration for
installation requirements.

If an alarm is programmed for the relay to be normally energised (such as a low voltage
alarm where loss of power will put the alarm into its “active” state), then be sure to connect
the remote wiring appropriately.

Note: Relay 1 is hardware set as a “Monitor Fail” alarm. This alarm activates if the monitor

has a hardware fault or if software becomes corrupted.

The flexiCompact relays are preconfigured as follows:

Relay 1: Monitor Fail alarm (hardware set, cannot be reconfigured)

Installation Manual Page 22 of 37

Relay 2: Summary Non-urgent alarm

Relay 3: Summary Urgent alarm

Relay 4: User Configured

Relay 5: User Configured

Relay 6: User Configured

Alarm mapping should be completed in the supervisory module software. Please refer to the
SM36 manual for detailed information.

Temperature Sensor

The flexiCompact system is supplied with a 3m battery temperature sensor as standard, a

option to include an ambient temperature sensor can be made during the order process for
factory fitment or kit form to allow fitment during commissioning.

The temperature sensor is supplied coiled behind the SM36 Supervisory monitor attached to
the front door of the system.

During installation, uncoil the battery temperature sensor and place in a location close to the
centre of the battery strings. The purpose of the battery temperature sensor is to monitor the
ambient temperature of the batteries over long periods of time and adjust the rectifier output
(float) voltage accordingly. As a result, it is not necessary to have the temperature sensor
directly touching the batteries.

When fitted, the ambient temperature sensor should be mounted in a location where the air
temperature is representative of the air temperature within the region being monitored.

Both temperature sensors must be installed away from direct sunlight and draughts to
ensure readings are a true representation of the measurement required.

If either temperature sensor is removed or fails, a temperature fault alarm is generated on

the SM36 monitor.

If during installation it is found the lead is not long enough, any ordinary 2-core copper
(approx. 0.75mm2) wire can be used as an extension. Ensure the connections made are
secure and well insulated to prevent temperature readings which could cause unwanted
alarms or damaging temperature compensation errors in the float voltage applied to the
batteries.

Installation Manual Page 23 of 37

General Purpose Inputs (GPIP)

General purpose inputs allow the flexiCompact system to monitor any external equipment
that includes relay or auxiliary outputs. The GPIP inputs are activated by connecting the
system positive (common) to the input terminal (configuration setup in the SM36 can allow
activation by connecting to system live).

General purpose inputs can also be configured as analogue inputs for purposes such as
battery midpoint monitoring and voltage monitoring.

These inputs may be assigned to contribute to alarm states within the monitor. The state
mapping is defined in the monitor configuration file. Alarm mapping should be completed
using the SM3x supervisory module software. Please refer to the SM36 manual for detailed
information.

Installation Manual Page 24 of 37

Circuit Breaker Fail Monitoring

Battery Breaker Monitoring

Battery circuit breakers are monitored via a voltage measurement taken across the breaker to
detect tripping (or manually opened). When a battery breaker is open, there may be very
little voltage difference between the rectifier live bus and the battery live terminal, making
typical electronic fail detection methods problematic.

If no battery is connected, an open breaker will still generate a Battery Breaker Fail alarm.
The breaker must be closed to clear a Battery Breaker Fail alarm.

Note: The Battery MCB Fail alarm relies on the battery voltage being measurably different

to the system bus voltage. Due to measurement tolerances it may take some time

for the alarm threshold to be reached before the alarm is activated when a battery

breaker is physically turned “off” in non-operational test circumstances.

In a true battery breaker trip event, the required current drawn from the battery

required to open the breaker will ensure the battery voltage is sufficiently low that an

alarm isMonitoring
Load Breaker generated immediately following the trip.

Load circuit breakers are monitored electronically via a diode to a general purpose input on the
SM36. The input will trigger an alarm when it is pulled to the system common (positive) rail.
To operate the load breaker fail alarm, a load must be connected to the circuit breaker. In
this way, false alarms are avoided when no load is connected and the load circuit breaker is
in the “off” position.

Note: Because of the connection with a diode, a small residual voltage can be measured

across an open load termination even when the circuit breaker is turned off (when

measured with high sensitivity digital meters). This voltage is high impedance and

does not present a hazard to the user. The voltage is only apparent when a load is

disconnected.

Installation Manual Page 25 of 37

Commissioning

The following set of instructions is meant as a guide for commissioning and testing of the
flexiCompact system. The use of these instructions is recommended unless different
procedures are suggested by local authorities.

Pre-check:

Before commissioning commences, ensure the following processes are completed.

1. All building work on site is complete to avoid concrete and plaster dust being ingested
into rectifiers and systems.

2. System installation is completed. All terminations are made and secure.

3. Battery and load circuit breakers are turned off, and upstream AC has been turned off.

Note: This system is available supplied configured with the AC earth connected to the

internal positive bus (positive earth). Before connecting the Batteries or Rectifiers

ensure that the earthing is correct for your application.

4. Turn on upstream AC and check that voltages from phase to neutral are as expected.

Once measurements are complete, turn off upstream AC supply.

Start-up

Rectifier Modules

1. Initially rectifier modules should be unpacked and fitted into their shelf positions but
pulled forward enough to disconnect them from the system. Packaging should be cleared
from site to prevent tripping hazard.

2. Turn the upstream AC circuits on.

3. Fully insert first rectifier, wait for the rectifier to start and its power on LED to remain
green. The rectifier non-urgent alarm LED (amber) will initially light to indicate rectifier is
soft starting. This will turn off once the module output voltage reaches normal operating
levels (up to 10 seconds depending on the input AC voltage).

Installation Manual Page 26 of 37

4. Check the SM36 powers up and displays the system default float voltage once the
rectifier soft start has completed. The audible alarm will activate indicating alarms are
active in the system. This is expected as load and battery breakers are open, however
ensure that all active alarms are examined before pressing any SM36 button to silence
the buzzer.

5. Fully insert the remaining rectifiers ensuring they power on. The non-urgent alarm LED
(amber) on each unit will initially illuminate to indicate rectifiers are soft starting. Once
started, the non-urgent alarm will be deactivated and each module will have only the
power on green LED illuminated.

6. Check that both the load and battery currents on the SM36 are reading 0 amps (± 1% of
full load).

Monitor Configuration

1. If a different system float voltage or other parameters is required, set these using the
procedure specified in the SM36 Manual. Default settings are appropriate to the system
specification and typical user requirements.

2. Check that all SM36 configuration settings are correct (as per customer specification)
with respect to:
- Voltage levels
- Alarm settings
- Alarm mappings to the volts-free relays

Please refer to the SM36 manual for detailed information.

Battery Start-up

Note: It is recommended that battery circuit breaker connections should be made when

the rectifiers are turned on and the system is “live”. This is because the system

voltage and battery voltages will be similar, minimising any arcing during

connection. This also prevents high current arcing due to the charging of the rectifier

output capacitors.

1. Power up only one rectifier initially (to limit any damage if any connections are incorrect).

Installation Manual Page 27 of 37

2. Measure the voltage across each battery string at the terminals of the Compact System.
Ensure that the reading from the DC Common bus to the Battery Live Terminals is -48V
(approximately) as per system specification.

3. Turn on each battery circuit breaker in succession while measuring the each battery
voltage. Ensure that the voltage increases slightly to the system Float Voltage (typically
the voltage will increase from 2-3V below float to float voltage. At this point the batteries
will be drawing some current to bring them to a full state of charge.

Load Start-up

1. Ensure downstream load connections have been made and there are no loose/floating
load cables.

2. Turn on the load circuit breakers. Ensure that the downstream equipment powers up as
expected.

3. Confirm the system float voltage on the SM36 is at the level previously noted.

4. Ensure the load current is as expected for the connected loads.

Note: Prior to leaving the system after it has been commissioned, ensure all AC, DC

loads and battery circuits are off. If it is required that the system is to be left on (to

power load equipment or to float charge batteries), ensure rectifiers are left in their

powered up state and batteries are in circuit. This will prevent leaving the batteries

only powering the load causing them to go flat.

Installation Manual Page 28 of 37

System Monitoring

This section relates primarily to the interface of the SM36 supervisory module contained
within the flexiCompact systems. Configuration of the power system monitor can be made
utilising the LCD and front panel buttons, USB interface with local PC software or over a
network using Ethernet connection.

For full monitor functionality and operation information, please refer to the separate SM36
manual for detailed information.

Interface Options

Front Panel Interface

The flexiCompact can be monitored locally utilising the front panel of the SM36 supervisory
monitor with LCD display, alarm LED’s and keypad. These are used to:

 display metered values

 display active alarms

 access the menu for setting up the system parameters

The display menu is navigated using the three keys next to the display.

The following LED indicators are provided on the monitor front panel:

This green LED indicates the monitor has power and is operating correctly.

This yellow LED indicates an alarm is active. This LED is configured to indicate a
Non-Urgent Alarm state has occurred.

This red LED indicates an alarm is active. This LED is configured to indicate an
Urgent Alarm has occurred.

The monitors are fitted with an audible buzzer which can be configured to alert to any
alarm

Connecting via Computer

Installation Manual Page 29 of 37

The front panel USB port is used for local PC connection to the SM36 supervisory monitor.
The mini-USB connector is protected by a rubber cover, this can be removed by pulling the
side tab gently.

The control parameters of the monitor are set using a configuration file that can be loaded
through this interface. The flexiCompact system is supplied preconfigured from the factory
but configuration setup can be modified using the configuration software supplied on the CD
that is supplied with the DC system.

Network Connection

Access to the SM36 supervisory module Ethernet port is made by undoing the thumb screws
securing the front panel of the flexiCompact system and folding it down to a level sufficient to
give clear and unrestricted access to the connector.

The web interface is opened by typing the IP address of the monitor into the address bar of a
web browser. The web interface allows monitoring and configuration changes to be made
remotely across the connected network.

For full monitor functionality and operation information, please refer to the separate SM36
manual for detailed information.

Installation Manual Page 30 of 37

Maintenance

As Enatel flexiCompact systems are advanced electronic systems, only minor routine
maintenance is required

System

 During normal operation the cable entries to the MCB’s may loosen over time due to
movement in the cable strands. To avoid damage to the MCB’s and cable entries due
to heat build-up and arching, it is recommended that the retaining torque is
periodically checked at least annually. MCB’s should be maintained at a torque of
2Nm.
 All other connections should also be checked at this time.

Monitor

 The monitor will give a good indication of the condition of the system. Alarm logs can
show issues with the system and rectifiers and should be regularly checked.
 Routinely check that the float voltage and load current are as expected.
 If the batteries are fully charged, check the battery current is zero or near to zero
amps.

Rectifiers

 During normal operation some dust will build-up on the front of the rectifiers. This
should be kept to a minimum by regularly wiping the rectifiers to avoid accumulation
within the units and blocking the airflow. The positioning of the system and
surroundings will determine the regularity of this requirement.
 In extremely dusty positions it is recommended that the units are removed and
cleaned with compressed air to prevent airflow blockages.

Batteries

Battery maintenance will depend on the individual manufacturer’s specification, please

contact the battery supplier for recommendations.

Installation Manual Page 31 of 37

 Priority Non-priority
AC Input Terminations Load & Battery Common (+ve) Terminations Battery Live (-) Terminations Load Live (-) Terminations Load Live (-) Terminations
(Direct into breakers/terminals) (Direct to Busbar Terminals) (Direct into breakers) (Direct into breakers) (Direct into breakers)

E L1 L2 L3 N B1- B2- B3- B4-

L1 L2 L3 N 4k7
12
Priority 4k7 Non-priority
Red (+ve)
Battery LVD White Load LVD*
11

Red1
Battery

Black1
White2
Green2
V V V
14 Yellow2 Shunt

Installation Manual
PLYSW Fuse Fail
GDT Red (+ve)
PCB Red (+ve)
Yellow1 Red2

- 4k7
+ 4k7
Orange1 Violet1 Blue1 Brown2 Black2
E

+
+
SPD* - -

Grey1

White1
Green1

Brown1
AC Distribution

NC
NC
NC
NC
NC
NC
L1 N E L2 N E L3 N E L1 N E

RECTIFIER 1 RECTIFIER 2 RECTIFIER 3 RECTIFIER 4

J12

Serial Communication
AC Linking PCB J11 J10 Connection to SM3x
J14
4-way Backplane PCB
J13

L2 N E L3 N E L1 N E L2 N E
Appendix 1 - System Wiring Diagram

RECTIFIER 5 RECTIFIER 6 RECTIFIER 7 RECTIFIER 8

J12

AC Linking PCB J11 J10

Red
Red

Blue
Grey
Black
Black

Violet
White
White

Green
Green

Brown
Brown

Yellow
Yellow

J14 Orange
4-way Backplane PCB
J13
I1-

J102
J101
J111
J112
I2-
I3-

I1+
I2+
I3+

LVD1
LVD2

BUS2
BUS1
MCB2
MCB1
MCB3
MCB4

GPIP7
GPIP8
GPIP9
GPIP10

LVD Com

ENTER
LVD Com

MCB Com

Aux Power

L3 N E L1 N E L2 N E L3 N E

RY1
RY2
RY4
RY5

RY3
RY6
Temp 2
Temp 1

RECTIFIER 9 RECTIFIER 10 RECTIFIER 11 RECTIFIER 12

J12
- ve
+ve
- ve
+ve

NC
NC
NC
NC
NC
NC

NO
NO
NO
NO
NO
NO
GPIP1
GPIP2
GPIP3
GPIP4
GPIP5
GPIP6

A high resolution copy of the schematic is also included on the system CD

J13 J105 J107 J109 J110 J100
J11 J10
Customer Alarms
J14
4-way Backplane PCB
(Optional)

flexi1 flexi2 flexi3

Batt. Temp.

Amb. Temp.

System Ratings:
Nominal Output Voltage: -48Vdc -48Vdc -48Vdc
Max. Output Current (RM2048): 167A/-48V, 148A/-54V 333A/-48V, 296A/-54V 500A/-48V, 444A/-54V
**AC Input (total):
TITLE DRAWN
3Ph, 175Vin (Ph-N) & 230Vin (Ph-N): 24Amax & 19A 36Amax & 28A 49Amax & 37A
flexiCompact System Generic Schematic LDS
1Ph, 175Vin & 1Ph, 230Vin : 49Amax & 37A 97Amax & 74A 246Amax & 111A REVISION
Output Power (total): DRAWING NUMBER SYSTEM NUMBER DATE:05Aug13 1.1

Page 32 of 37
With Max # RM2048: 8.0kW 16kW 24kW SHEET
130420 flexi# SCALE: NTS 1 of 1
Appendix 1 - Enatel Essential System Set-up Parameters

The following steps are system settings that must be checked at the time of commissioning
for each system installed. You can print this section and fill it out for each site
commissioned.

Failure to correctly follow the items below may cause incorrect system functionality and in
some cases ruin your battery (without the ability to claim battery replacement under
warranty).

Note: Any values shown below are indicative only. If the values in your system differ from

those shown here, write in the values relevant to your system.

Refer to the SM36 Supervisory Monitor manual for more details.

1. Check/Set Float Voltage

Consult battery manufacturer’s data for proper setting.

The Float voltage is for 25°C reference temperature in Enatel systems.

SM3x Config Page: Power Module Control

Example:

Site Setting: Done:

2. Set Battery Temperature Compensation

You must consult the battery manufacturer’s data to obtain the correct Slope setting. Note
that in many Hybrid applications where the battery is constantly being cycled, having
temperature compensation enabled may not be necessary as the voltage on the battery is
constantly changing anyway.

SM3x Config Page: Charge

Example:

Installation Manual Page 33 of 37

Site Settings:

Done:

If you choose not to enable Temperatue Compensation, then set the Rectifier Float Voltage
to that required by the battery manufacturer for the average long-term temperature you
anticipate your system to operate at.

3. Set Battery Capacity

Consult battery manufacturer’s data for correct battery capacity settings.

For the SM3x to set the correct Battery Current Limit current, it is essential that this is filled
out correctly. These figures are also used for estimating the Battery Time Remaining during
a discharge.

For Telecom applications, the 10 hour rate is usually the name-plate rating of the battery.
However, once again, check the battery manufacturer’s data sheets as some manufacturers
state the 20 hour rate (which is usually a little more “optimistic”).

The second rate is required specifically for the time-remaining algorithm. A 4 hour rate is
usually a good one to use. This information is available from the battery manufacturer’s data
sheet.

The Battery SoC adjust can be used at the time of installation (or for testing purposes) in
case the installed battery is not initially fully charged. If you think the battery is only 80%
charged, then simply enter that value. The value displayed here will correct itself once the
battery has been on charge for some time or gone through a few charge/discharge cycles.

SM3x Config Page: Charge

Example:

Installation Manual Page 34 of 37

Site Settings:

Done:

Note: Both the 10 hour and secondary battery capacity hour rates should be set at the
same time. The SM36H compares rates to ensure the battery data is accurate and may not
accept the setting if an inaccuracy is detected.

4. Set Battery Current Limit

Consult battery manufacturer’s data for maximum battery recharge current settings.

The Battery Current Limit is set as a percentage of the 10 hour rate entered in step 3.

It is recommended this value is set at the highest rate allowable to ensure the battery is
recharged as fast as possible.

In some systems, especially larger systems, this may require limiting further because of the
number of rectifiers available, rather than the maximum setting.

SM3x Config Page: Control

Example:

Site Settings:

Done:

For telecom settings, this limit is often set to 10% (or 0.1C10, i.e. a 10A current limit for a
100Ahr battery). This is more typical of a design parameter than the need for the setting to
be at this level but a setting higher than this level should be considered to enable the fastest
recharge possible without exceeding the battery manufacturer’s maximum value.

Ensure sufficient rectifier capacity is available to cover battery recharge and load
requirements.

Installation Manual Page 35 of 37

5. Low Voltage Disconnect Settings

The LVD disconnect set points are usually a customer generated setting.

As the discharge time increases, the higher the end voltage should be set. For a discharge
of <1hr, this may be as low as 1.75Vpc (42.0V for a “48V” battery), or for an 8 hour
discharge, it may be 1.85Vpc (44.4V for a “48V” battery).

Note that if only one LVD is fitted, LVD2 and LVD3 thresholds are set outside of possible
tripping voltages. This avoids any confusion over which LVD signal is being used by the
SM3x monitor.

SM3x Config Page: Alarms (Levels)

Example:

Site Settings:

Done:

Installation Manual Page 36 of 37

Notice of Copyright

Copyright © 2013 Enatel Ltd.

No part of this document may be reproduced in any form or disclosed to third parties without
the express written consent of Enatel.

Enatel reserves the right to revise this document and to periodically make changes to the
content without obligation to give notification of such changes, unless required to do so by
prior arrangement.

Exclusion for Documentation

Unless specifically agreed to in writing, Enatel makes no warranty as to the accuracy,

sufficiency, or suitability of any technical or other information provided in its manuals or other
documentation.

Enatel assumes no responsibility or liability for losses, damages, costs or expenses, whether
special, direct, indirect, consequential or incidental, which might arise out of the use of such
information. The use of any such information will be entirely at the user’s risk.

Contact Information

Tel: +64-3-366 4550

Fax: +64-3-366 0884
Email: [email protected]
Web: www.enatel.net

Installation Manual Page 37 of 37