Installation Guide 15U and 8U Modular Flatpack2 MPS B 2064270 1 7

Installation Manual
Modular HE
Modular DC Power System

Doc. No. 2064270, Issue 7
Published 2-Aug-13
DISCLAIMER
Information in this document is believed to be accurate as of the date of publication and is subject
to change without notice. This document and the information contained herein do not represent
either a commitment or any guarantee on the part of Eltek regarding the reliability, fitness, or
compatibility of the products and procedures described.
While every reasonable effort is made to ensure the accuracy and completeness of this
document, Eltek assumes no responsibility or liability for any damages that may be directly or
indirectly attributed to the use of the information contained within or to any errors or omissions.
No part of this document may be reproduced or transmitted in any form or by any means—
electronic or mechanical, including photocopying and recording—for any purpose without the
expressed consent of Eltek.
Copyright © 2013 Eltek
2925 E Plano Pkwy

Plano, TX 75074
USA
Phone: +1 (469) 330-9100

Fax: +1 (469) 330-9101
Technical Support
+1 (800) 435-4872
techsupport.us@eltek.com
www.eltek.com
Doc. No. 2064270, Issue 7, August 2013

Published 02 August 2013
2 Installation Manual Modular HE ~ Doc. No. 2064270, Issue 7, August 2013

Table of Contents
Safety and Recommended Practices .....................................................7
FCC Compliance Statement ................................................................................................ 8
1. Overview ..........................................................................................9
Rectifier Specifications ...................................................................................................... 10
AC Input................................................................................................................................... 11
AC Panel (15U Distribution Only) ......................................................................................... 13
AC Wire Sizing ........................................................................................................................... 14
AC Lug Sizing............................................................................................................................. 14
DC Output ............................................................................................................................... 15
15U Distribution ....................................................................................................................... 15
8U Distribution.......................................................................................................................... 17
DC Reference Ground ............................................................................................................. 17
DC Output Wire Sizing............................................................................................................. 18
Ground ..................................................................................................................................... 19
Controllers.............................................................................................................................. 19
2. Installation.................................................................................... 21
Required Tools ...................................................................................................................... 21
Torque Settings .................................................................................................................... 22
Unpacking............................................................................................................................... 22
Rack Footprint ....................................................................................................................... 22
Mechanical Mounting .......................................................................................................... 24
Grounding ............................................................................................................................... 24
AC Input Connections ......................................................................................................... 25
15U Distribution ....................................................................................................................... 25
8U Distribution.......................................................................................................................... 27
DC Output Connections ...................................................................................................... 30
Fuse/Breaker Installation .................................................................................................. 31
Controller Connections....................................................................................................... 32
3. Turn-Up ......................................................................................... 34
Installing Rectifiers .............................................................................................................. 34
Installing Converters ........................................................................................................... 36
Connecting Batteries .......................................................................................................... 37
4. Replacement Items ....................................................................... 39
Controller ................................................................................................................................ 39
Rectifiers ................................................................................................................................ 39
Converters ............................................................................................................................. 40
5. Troubleshooting ........................................................................... 41
Installation Manual Modular HE~ Doc. No. 2064270, Issue 7, August 2013 3
6. Sample Configurations ................................................................. 43
15U Distribution .................................................................................................................... 43
8U Distribution ...................................................................................................................... 44
7. Revision Table ............................................................................... 45
Appendix A – Turn-up Checklist .......................................................... 46
Appendix B – Alarm Test Guide ........................................................... 47

Table of Figures
Figure 1 - 15U Overview (24V/1200A system with converters) ......................................................... 9
Figure 2 – 8U Overview (24V/1200A system with converters)........................................................... 9
Figure 3 - 8U Overview (48V/600A system) ......................................................................................10
Figure 4 – Individual-Feed AC Wiring Architecture (per power shelf) ................................................11
Figure 5 – Dual-Feed AC Wiring Architecture (per power shelf) ........................................................12
Figure 6 - AC Wiring Architecture for Flatpack2 48V/3000W Power Shelves ..................................12
Figure 7 - 15U Individual-Feed AC Panel Terminal Block ....................................................................13
Figure 8 - Shelf and Rectifier Numbering (Individual Feed)................................................................13
Figure 9 - 15U Dual-Feed AC Panel Terminal Block ............................................................................13
Figure 10 - Shelf and Rectifier Numbering (Dual Feed) ......................................................................14
Figure 11 - 15U Distribution ................................................................................................................15
Figure 12 - XC2010 Controller Product Label Location .....................................................................20
Figure 13 - 23" Nonseismic Rack Footprint ........................................................................................23
Figure 14 - 23" Seismic “S” Rack Footprint ........................................................................................23
Figure 15 - 23" Seismic “G" Rack Footprint........................................................................................23
Figure 16 - Frame Ground Locations on a Seismic "S" Rack ...............................................................24
Figure 17 - Terminal Blocks for an Individual-Feed Shelf (One Shelf Shown)....................................25
Figure 18 – 15U AC Panel ....................................................................................................................26
Figure 19 - Strain Relief Fittings (24/1800 & 48/2000) ....................................................................27
Figure 20 - Flatpack2 Shelf Individual-feed Terminal Block ..............................................................28
Figure 21 - Individual Feed Connector (Cover Removed) ...................................................................28
Figure 22 - Flatpack2 Shelf Dual-feed Terminal Block .......................................................................29
Figure 23 – Dual-feed AC Section (Cover Removed) ..........................................................................29
Figure 24 - Strain Relief Fittings (48/3000) .......................................................................................29
Figure 25 - Flatpack2 48V/3000W Shelf Terminal Blocks .................................................................30
Figure 26 - Terminal Blocks for 48V/3000W Shelf.............................................................................30
Figure 27 - Chassis Ground (Left Side) ...............................................................................................30
Figure 28 - Chassis Ground (Right Side)..............................................................................................30
Figure 29 – Circuit Breaker Orientation ..............................................................................................32
Figure 30 – TPS Fuse and Holder .........................................................................................................32
Figure 31 – XC2010 Controller with Display.......................................................................................33
Figure 32 – Distribution Monitoring (DM) Device ................................................................................33
Figure 33 - Bay 2 ..................................................................................................................................34
Figure 34 - Changing a Flatpack2 Rectifier ID ....................................................................................35
Figure 35 - Release Handles ................................................................................................................35
Figure 36 - Extract Module ..................................................................................................................35
Figure 37 - Bay 1 ..................................................................................................................................36
Figure 38 – Battery Connections ........................................................................................................37
Figure 39 – 15U Distribution Section for 24V System .......................................................................43
Figure 40 - 8U Distribution Section (4 Secondary Voltage Positions) ...............................................44
Figure 41 – 8U Distribution Section (9 Secondary Voltage Positions) ..............................................44
Table of Tables
Table 1 - Rectifier Operation ...............................................................................................................10
Table 2 - Converter Specifications......................................................................................................11
Table 3 - Recommended AC Lugs ........................................................................................................14
Table 4 - Distribution module styles ...................................................................................................16
Table 5 – DC Lug Part Numbers for Unprotected Output Connections .............................................18
Table 6 – Lug Sizes for BG1 Modules...................................................................................................19
Table 9 - Recommended Torque Settings ...........................................................................................22

Safety and Recommended Practices
For use in restricted-access locations only.
Suitable for mounting on concrete or other non-combustible surfaces only.
The Modular HE Power System (MPS) operates on single-phase AC voltage between 100 V
and 250 V and 47–63 Hz. The system produces a regulated DC output of 21–29 V and 42–
56 V, depending on the rectifiers and converters deployed. It can deliver a maximum DC
current of 1200 A in an ambient operating temperature range of –40°C to +45°C
(depending on deployed rectifiers and converters).
WARNING: HAZARDOUS VOLTAGE AND ENERGY LEVELS CAN PRODUCE SERIOUS
SHOCKS AND BURNS. Only authorized, qualified, and trained personnel should
attempt to work on this equipment. Refer to datasheets for full product
specifications.
WARNING: For safety, the power supply is required to be reliably connected to
PROTECTIVE GROUND. The equipment is to be connected to supply mains by
qualified personnel in accordance with local and national codes (e.g., NEC, CEC,
etc). Do not disconnect and reconnect rectifiers or converters during lightning storms.
Equipment meets GR-1089 Surge requirements and is intended for deployments where an
external Surge Protective Device (SPD) is utilized. The output of the power supply is not
intended to be accessible due to energy hazards. Rack mounting must be performed in
accordance with instructions provided by the manufacturer to avoid potential hazards.
WARNING: Changes or modifications to this unit not expressly approved by the
party responsible for the compliance could void the user's authority to operate
this equipment.
CAUTION: All rectifiers employ internal double pole/neutral fusing. Fuses are not
field-replaceable.
Observe all local and national electrical, environmental, and workplace codes.
Each power shelf should be fed from a dedicated AC branch circuit of a terra neutral (TN) or
isolated terra (IT) power system.
A readily accessible disconnect device shall be incorporated in the building installation
wiring for all AC connections. Select wall breakers according to national and local electric
codes.
If the plug end of an AC line cord is considered to be the primary disconnection means,
reasonable access must be given to the plug and receptacle area. The receptacle must be
fed with a breaker or fuse according to input current specifications inTable 1.
Use Underwriters Laboratories (UL)-listed, double-hole lugs for all DC connections to
prevent lug rotation and inadvertent contact with other circuits. Terminal strip
connections require only single-hole lugs.
Wire rated for 90°C is recommended for all DC connections. In practice, wires of a size
larger than the minimum safe wire size are selected for loop voltage drop considerations.
Alarm contacts are rated for a maximum voltage of 60 V, SELV (Safety Extra Low Voltage)
and a maximum continuous current of 1A. Connection and mounting torque requirements
are listed in Table 9.
Heat dissipation greater than the objectives listed in GR-63-CORE may occur. Additional
equipment room cooling may be required. To cope with high heat release, aisle spacing
may be increased and high heat-dissipating equipment may be located adjacent to
equipment generating less heat.
It is recommended practice to ensure that all circuit breakers (including those for DC
distribution) are in the OFF position during both installation and removal.
Eltek does not recommend shipping the power shelf with rectifiers installed. Rectifiers
should be shipped in separate boxes provided by Eltek.
WARNING: Protecting personnel against electrical shocks: The power system
cabling must be done by qualified personnel in conformance with local and national
electrical codes. Input voltages to rectifiers are at a dangerous level. Ensure that
circuit breakers are locked in the OFF position at the AC service panel before attempting to
work on the power system. Dangerous voltages may still be present at the terminals even
if the rectifiers are OFF. Use a voltmeter to verify the presence of such voltages. Do not
switch circuit breakers to ON until the entire system has been assembled and you have
been instructed to do so according to the appropriate procedure. Improper wiring can cause
bodily harm and equipment damage. Turn off all power sources before servicing units.
WARNUNG: Schuetzen von Personal gegen elektrische Schocks. Die
Spannungsversorgungs - Leitungen darf nur durch qualifiziertes Personal in
Anpassung mit Oertlichen und nationalen elektrischen Codes ausgefuehrt werden.
Unsachgemaesse Verdrahtung kann koerperliche Verletzung und Schaeden verursachen.
Eingangsspannungen von der Netzspannungs - Versorgung Ihrer Hausanlage koennen
unter Spannung stehen beim Anschluss derLeitungen. Vesorgungsspannungen koennen bei
unsachgemaessen Gebrauch gefeahrliche Schaeden verursachen. Sorgen Sie dafür, dass
die Cirquite Breaker in der aus position sind. Benutzen Sie ein Spannungsmesser um sicher
zu sein das keine Netzspannung mehr vorhanden ist. Vergwissern Sie sich das alle Schalter
an Ihrem Gereat und in der Vesorgung beim Anschluss abgeschaltet sind. Unsachgemaesse
Verdrahtung kann koerperliche Verletzung und an der Ausstattung Schaeden verursachen.
Vor Wartungsarbeiten am Gerät sind alle Netzkabel vom Stromnetz zu trennen, um die
Gefahr eines elektrischen Schlages oder andere mögliche Gefahren zu reduzieren.
FCC Compliance Statement

This device complies with Part 15 of FCC Rules. Operation is subject to the
following two conditions:
1. This device may not cause harmful interference, and
2. This device must accept any interference received, including
interference that may cause undesired operation.

1. Overview
The Modular HE Power System is a high-efficiency DC power plant. It uses Eltek
Flatpack2 HE rectifiers and is available in 48V/600A, 48V/1200A, and 24V/1200A
output. There is an optional converter shelf available for 24V systems, which uses
Eltek 24V-to-48V DCX-series converters. Two distribution styles—named “15U” and
“8U”—are available for both 48V and 24V systems. The 15U distribution is 15U in
height and includes an AC panel; it also makes use of Eltek's "BG" modules for circuit
breakers and fuses. The 8U distribution is 8U in height and does not include an AC
panel; it makes use of two 24-position distribution boards for plug-in circuit
breakers and fuse adapters.
AC Panel (Inside)
Controller Display 15U Distribution
24V Rectifier
Shelves (4)
48V Converter
Shelf
Figure 1 - 15U Overview (24V/1200A system with converters)
24V Rectifier
Shelves (4)
48V Converter
Shelf
Figure 2 – 8U Overview (24V/1200A system with converters)
48V Rectifier
Shelves (4)
Figure 3 - 8U Overview (48V/600A system)
Rectifier Specifications
The Flatpack2 HE rectifiers are high-efficiency modules that typically perform
at a 96% conversion rate. Specifications are listed in Table 1.
Operational Operational
Flatpack2 Input Voltage Input Current Output Voltage Output Current
Rectifier Model (Vac) (A-rms) Range (Vdc) Range (Adc)
120 11.59 43.5-57.6 0-23.6
48V/2000W HE 208 10.46 43.5-57.6 0-41.7
(241115.105) 240 8.98 43.5-57.6 0-41.7
NOTICE: Maximum current draw is 11.88 A(rms) at 185 Vac
120 18.72 43.5-57.6 0-37.4
48V/3000W HE 208 15.66 43.5-57.6 0-62.5
(241119.105) 240 13.48 43.5-57.6 0-62.5
120 10.8 21.7-28.8 0-44.2
24V/1800W HE 208 9.7 21.7-28.8 0-75
(241115.205) 240 8.3 21.7-28.8 0-75
Table 1 - Rectifier Operation
The Modular HE system can also be powered by standard Flatpack2 rectifier

models, but it will not yield the same energy efficiency. Flatpack2 rectifiers
are rated for 100 – 250 VAC input (though they can operate for a time within a
range of 85 to 300 VAC), with a frequency range between 45 and 66 Hz. See
the User’s Guide—Flatpack2 Rectifier Modules (350002.013) for further details.
NOTICE: Flatpack2 rectifier modules are assigned a system ID based on order
of installation. Therefore, it is recommended to install rectifiers AFTER system
AC turn-up, in the order desired.

DC-DC conversion for 24V systems is made possible by Eltek’s DCX-series
converters. Table 2 lists specifications for the available converter module.
Input Voltage Max Input Output Output
Model Range Current Voltage Current
DCX1500BA 20-30 Vdc 100 Adc 42-56 Vdc 30 Adc
Table 2 - Converter Specifications
AC Input
The Flatpack2 power shelves used in the Modular HE plant are designed for
single-phase AC input.
CAUTION: Lightning and surge damage is not covered by Eltek. The
installation site must be equipped with adequate lightning and surge
protection.
NOTICE: AC wiring to a 15U system is terminated at the AC panel at the top of
the distribution (front-access, behind the door). AC wiring to an 8U system is
terminated to the rear of each power shelf.
NOTICE: AC terminal blocks are not labeled in Flatpack2 rectifier shelves.
Refer to the wiring figures provided if AC feeds are to be wired directly to the
shelves.
24V/1800W and 48V/2000W Shelves
Power shelves for 48V/2000W and 24V/1800W Flatpack2 rectifiers
are available in individual- and dual-feed architectures.
FEED D, LINE 2
FEED D, LINE 1
FEED C, LINE 2
FEED C, LINE 1
FEED B, LINE 2
FEED B, LINE 1
FEED A, LINE 2
FEED A, LINE 1
1 2 3 4 5 6 7 8 GND
INDIVIDUAL FEED
AC TERMINAL BLOCK
FEED D FEED C FEED B FEED A
SLOT 4 SLOT 3 SLOT 2 SLOT 1
FLATPACK2 POWER SHELF

FRONT VIEW
Figure 4 – Individual-Feed AC Wiring Architecture (per power shelf)
FEED A, LINE 1
FEED A, LINE 2
FEED B, LINE 1
FEED B, LINE 2
1 2 3 4 GND
AC TERMINAL BLOCK
SHELF REAR
FEED B FEED A

FRONT VIEW
Figure 5 – Dual-Feed AC Wiring Architecture (per power shelf)
NOTICE: When viewing the Flatpack2 power shelf from the front, the
AC feeds (as labeled in the figures) power the rectifier slots from
right to left.
48V/3000W Shelves
Power shelves for 48V/3000W rectifiers are individual-feed only.
FEED 3, LINE 1 FEED 2, GROUND
FEED 3, LINE 2 FEED 2, LINE 2
FEED 3, GROUND FEED 2, LINE 1

GND 2 1 GND 2 1 GND 2 1 GND 2 1
LEFT AC TERMINAL BLOCK RIGHT AC TERMINAL BLOCK
FEED 1 FEED 2 FEED 3 FEED 4

FRONT VIEW
Figure 6 - AC Wiring Architecture for Flatpack2 48V/3000W Power Shelves

AC Panel (15U Distribution Only)
The distribution section of the 15U system contains an AC panel that is
pre-wired to the shelves; all AC input and ground connections are made in
this panel. Always connect a safety or chassis ground before terminating
the lines. Ground wires should be longer in length than AC line wires.
Figure 7 - 15U Individual-Feed AC Panel Terminal Block
Figure 8 - Shelf and Rectifier Numbering (Individual Feed)
Figure 9 - 15U Dual-Feed AC Panel Terminal Block
Figure 10 - Shelf and Rectifier Numbering (Dual Feed)
NOTICE: The 8U distribution section does not have an AC panel, requiring

direct wiring to the rear of each shelf. Always connect a safety or chassis
ground to the Flatpack2 power shelf before terminating the lines.
AC Wire Sizing
To size AC feeds properly, follow the specifications listed in Table 1.
Failure to size the AC breaker and wiring properly can result in nuisance
breaker trips or even fire. If you anticipate growth, size the AC breaker
and wiring for the expected capacity. ALWAYS FOLLOW NEC (NATIONAL
ELECTRICAL CODE) RULES, LOCAL CODES, AND COMPANY PRACTICES
WHEN SELECTING AC WIRES AND PROTECTION DEVICES.
Because two Flatpack2 HE rectifiers are connected to each AC feed, the
current draw on each feed will be a maximum of 23.2A for 48V rectifiers
and 22.50A for 24V rectifiers (see to Table 1). A breaker rated for 30A
should be appropriate, allowing for 25% overhead.
AC Lug Sizing
Power shelves for the Flatpack2 48V/3000W rectifier modules require
ring terminals for AC input. The screw size for each terminal is M4 (close
to size #8). Table 3 lists recommended lugs.
NOTICE: Ground lugs must be double-crimp lugs.
AMP Part Number Description
35605 Single hole ring terminal, stud size #8 (M4)
Table 3 - Recommended AC Lugs

DC Output
Currently, there are 2 distribution sections offered with the Flatpack2 power
core, which are defined by the rack units they occupy: 15U and 8U.
15U Distribution
The 15U DC distribution consists of two rows of distribution modules
arranged in a “waterfall” configuration. The upper section is positioned
closest to the front; the lower section is positioned closer to the back.
This allows for better cable grooming as wires are fed from the top of the
system. Each row is populated with ten (10) distribution modules. The
available styles for the 15U distribution are listed in Table 4.
Figure 11 - 15U Distribution
BG1 BG2 BG3 BG4
1 two-pole 2 one-pole 4 one-pole 10 GMT fuses

breaker breakers breakers
Table 4 - Distribution module styles
1. BG1 accepts one (1) double-pole breaker between 125A and 200A
rating each. Output connections are made onto 5/16” studs with 1”
centers.
2. BG2 accepts up to two (2), single-pole breakers up to 100A rating
each. Output connections are made onto 1/4”-20 studs with 5/8”
centers. This module can also accept a TPS fuse holder (TPSB100,
ordered separately) and fuses up to a 100A rating each.
3. BG3 accepts up to four (4), single-pole breakers up to 50A rating
each. Output connections are made onto #10-32 studs with 5/8”
centers. This module can also accept a TPS fuse holder (TPSB100,
ordered separately) and fuses up to 50A rating each.
4. BG4 accepts up to 10 GMT fuses up to 15A rating each. Wire
connections are made to compression screws.
Each distribution module has both output and load return landings.
Return studs are located on the very top and back of the distribution
modules and match the number of output studs provided.
In 24V systems, the lower distribution bus can be split into two voltage
sections. The leftmost modules are connected to the converter shelf,
providing 48 VDC. The remaining modules are energized by the 24V

rectifiers. See the section “15U Distribution” on page 43 for an example of
a dual-voltage distribution.
The 15 distribution also features an AC panel that is pre-wired to the
rectifier shelves. See the section “AC Panel” on page 13 for details.
8U Distribution
The 8U DC distribution consists of two rows of plug-in device positions
arranged in a “waterfall” configuration. The upper section is positioned
closest to the front; the lower section is positioned closer to the back.
This allows for better cable grooming as wires are fed from the top of the
system. Each row can be populated with a maximum of 24 distribution
devices (bullet-nosed, plug-in breakers or fuse holders).
In 24V systems, the lower distribution bus can be split into two voltage
sections. Either 4 or 9 of the leftmost positions are connected to the
converter shelf, providing 48 VDC. The remaining positions are energized
by the 24V rectifiers. See the section “8U Distribution” on page 44 for an
example of a dual-voltage distribution.
DC Reference Ground
An external reference or earth ground can be connected to the battery
return bus bar, unless the installation site is fully floating. The ground
connection is made on a 3/8” hole with a 1” center (see the section
“Ground” on page 24). Follow NEC and company guidelines for sizing and
attaching a reference ground.
DC Output Wire Sizing
There are two main considerations for sizing DC wire, ampacity and
voltage drop. Ampacity refers to a safe current carrying level as specified
by non-profit organizations such as Underwriters Laboratories (UL) and
the National Fire Prevention Association (NFPA), which publishes the
National Electric Code (NEC). Voltage drop is simply the amount of
voltage loss in a length of wire due to ohmic resistance of the conductor.
DC wire may be sized for either ampacity or voltage drop depending on
branch load loop length and conductor heating. In general, ampacity
considerations will drive wire selection for short loop lengths (less than
50 feet) and voltage drop will drive wire selection for long loop lengths
(greater than 50 feet). NEC Table 310provides ampacity values for
various sizes, bundles, and insulation temperature rated wire. ALWAYS
FOLLOW NEC RULES, LOCAL CODES, AND COMPANY PRACTICES WHEN
SELECTING DC WIRING AND PROTECTION.
NOTICE: The part numbers listed in Table 5 to Table 8 are for Burndy lugs.
If using another vendor, use the lug descriptions provided to find
corresponding part numbers.
Unprotected Bulk Output Connections
Unprotected DC output wire sizes are based on the total rectifier
capacity for the shelf. Table 5 lists recommended Burndy lug part
numbers for appropriate wire sizes.
Wire Size Burndy Lug Part # Description
2 YAV2C-L2TC38-FX Two-hole lug with 3/8" holes and 1" centers
4/0 YAV29-L2NT38-FX Two-hole lug with 3/8" holes and 1" centers (narrow tongue)
350 MCM YA34-L2NT38-FX Two-hole lug with 3/8" holes and 1" centers (narrow tongue)
500 MCM YA38-L2TC38-FX Two-hole lug with 3/8" holes and 1" centers
750 MCM YA44-L2TC38-FX Two-hole lug with 3/8" holes and 1" centers
Table 5 – DC Lug Part Numbers for Unprotected Output Connections
Fuse/Breaker-Protected Connections
Fuse/breaker protected DC output wire sizes are based on the
protector current rating.
Table 6 lists recommended Burndy lug part numbers for wire sizes
appropriate to BG1 modules.

1/0 YAV25-L2TC516-FX Two-hole lug with 5/16" holes and 1" centers
350 MCM YA31L-2TC38 Two-hole lug with 5/16" holes and 1" centers
500 MCM YA34L-2TC38 Two-hole lug with 5/16" holes and 1" centers
Table 6 – Lug Sizes for BG1 Modules
Use Table 7 lists recommended Burndy lug part numbers for wire
sizes appropriate to BG2 modules.
10 YAV102TC14 Two-hole lug with 1/4" holes and 5/8" centers
8 YA8CL2TC14 Two-hole lug with 1/4" holes and 5/8" centers
6 YAV6C-L2TC14-FX Two-hole lug with 1/4" holes and 5/8" centers
2/0 YA26L2NT14 Two-hole lug with 1/4" holes and 5/8" centers (narrow tongue)
Use Table 8 lists recommended Burndy lug part numbers for wire
sizes appropriate to BG3 modules.
10 YAV102TC10 Two-hole lug with #10 holes and 5/8" centers
8 YA8CL2TC10 Two-hole lug with #10 holes and 5/8" centers
6 YAV6C-L2TC10-FX Two-hole lug with #10 holes and 5/8" centers
4 YAV4C-L2TC10-FX Two-hole lug with #10 holes and 5/8" centers
Ground
Always make safety or chassis ground connections before connecting any
power. AC ground leads should be longer in length than the power leads.
It is recommended that every system rack be grounded. Frame ground
connection points are located along the top of each rack provided by Eltek.
Controllers
The Modular Flatpack2 power plant uses two controllers. The master
controller is the XC2010, which collects all system information and relays it to
the user through the front display and web-based GUI. The EC3010 controller
acts as an interface between the Flatpack2 power shelves and the XC2010
controller.
CAUTION: The XC2010 controller must have the proper profile loaded
in order to operate with the Flatpack2 rectifiers. Using the wrong
voltage profile can cause damage to the rectifiers.
To check the controller profile, locate the controller’s product label for the
model number (see Figure 12). Controllers for 48V systems begin this way:
“XC2010-A”, where the “A” indicates a 48V profile. Controllers for 24V systems
begin this way: “XC2010-B”, where the “B” indicates a 24V profile.
Figure 12 - XC2010 Controller Product Label Location

2. Installation
Before installing the power system, note the following safety requirements:
o Elevated Operating Ambient: If installed in a closed or multi-unit rack
assembly, the operating ambient temperature of the rack environment may
be greater than room ambient. Therefore, consideration should be given to
installing the equipment in an environment compatible with the maximum
ambient temperature (Tma) specified by the manufacturer.
o Reduced Air Flow: Installation of the equipment in a rack should be such
that the amount of air flow required for safe operation of the equipment is
not compromised.
o Mechanical Loading: Mounting of the equipment in the rack should be such
that a hazardous condition does not exist due to uneven mechanical
loading.
o Circuit Overloading: Consideration should be given to the connection of the
equipment to the supply circuit and the effect that overloading of the
circuits might have on over-current protection and supply wiring.
Appropriate consideration of equipment nameplate ratings should be used
when addressing this concern.
o Reliable Earthing: Reliable earthing of rack-mounted equipment should be
maintained. Particular attention should be given to supply connections
other than direct connections to the branch circuit (e.g. use of power
strips).
Required Tools
Eltek power systems are designed to be installed with a minimum number of
commonly available tools:
o #1 and #2 Phillips screwdrivers
o #1 flat-head screwdriver
o Set of box wrenches, ratchet set, or nut drivers
o Wire and cable strippers suitable for the wire size selected
o Wire and cable crimpers suitable for the lugs and wire sizes selected
o Power drill
o Digital voltmeter
Torque Settings
Table 9 shows recommended torque settings for all mechanical and electrical
connections according to screw or nut size. Not all screw sizes listed may be
present on a particular shelf.
Screw or Torque Torque
Nut Size (in-lbs) (N-m)
8-32 22 3
10-32 37 4.25
12-24 50 5.75
1/4"-20 65 7.5
5/16"-18 135 15
3/8"-16 240 28
Table 9 - Recommended Torque Settings
Unpacking
Before unpacking the DC power system, note any physical package damage
that could indicate potential damage to the contents. After removing the
system from boxes and packing material, inspect for any shipping or other
damage. Contact sales or technical support immediately if you notice any
damage.
Have all tools, wires, cables, hardware, and so on within easy reach. To the
extent possible, ensure a clean (free of debris, dust, and foreign material) work
environment. Care should be taken during the installation process to prevent
exposure of the equipment to wire clippings.
If possible, rectifiers should remained sealed in their shipping boxes until the
shelf wiring is complete. Ensure that all AC and DC power sources are off and
disconnected.
Rack Footprint
The following figures show the footprints of the available relay racks in which
the system can be installed. Use the appropriate figure to determine the
location of mounting anchors (captions are below their respective figures).

Figure 13 - 23" Nonseismic Rack Footprint
Figure 14 - 23" Seismic “S” Rack Footprint*
Figure 15 - 23" Seismic “G" Rack Footprint
*
May require additional bracing for a Zone 4 seismic rating
Mechanical Mounting
Eltek recommends mounting the system on a floor made of a non-combustible
material and of sufficient strength to withstand an earthquake. Concrete
expansion anchors should meet the following requirements:
o A maximum embedment depth of 90 mm (3.5”)
o A maximum bolt diameter of 13 mm (0.5”)
o Use steel construction
o Be suitable for earthquake zones
See the footprints provided in the section “Rack Footprint”, which begins on
page 22, for bolt locations. Use the following steps for installation:
1. Inspect the floor for compliance.
2. Drill holes 5/8” in diameter.
3. Place anchors into holes.
4. Place the rack over the anchors.
Grounding
For electrical safety, it is recommended to connect a frame ground to one of
the available locations on the system rack. Prepare the connection point by
removing the paint and applying a layer of NO-OX grease.
Grounding Grounding
Location Location
Figure 16 - Frame Ground Locations on a Seismic "S" Rack
Use the following steps to connect the central office (CO) ground:
1. Connect the lugged wire designated for a CO ground to the ground
position on the battery return bus bar (see Figure 38 on page 37).
Connections are made on double 3/8” holes with 1” centers.
2. Secure the connection with the supplied hardware (screw, washer, and
nut).
NOTICE: The CO ground wire must be the same size or larger than the
largest wire used in the system.

AC Input Connections
WARNING: Make sure that all AC breakers are in the OFF position
before making connections.
CAUTION: Lightning and surge damage is not covered by Eltek. The
installation site must be equipped with adequate lightning and surge
protection.
AC input connections differ depending on the distribution section. The 15U
distribution contains an AC panel; the 8U distribution does not have a central
AC junction box, requiring direct wiring to the shelves.
15U Distribution
The 15U distribution AC panel contains four sets of terminal blocks—one
set for each rectifier shelf. The leftmost set of terminals power the
topmost rectifier shelf. Required input voltage ranges for Flatpack2 HE
rectifiers are listed in Table 1.
Individual Feed
In the individual-feed panel, the terminal blocks are grouped
according rectifier feeds. For instance, the terminal blocks for
rectifier 1 are blocks 1 (for Line 1) and 2 (for Line 2/Neutral). Refer to
Figure 8 on page 13 for the rectifier slots powered by each set of
terminal blocks.
Figure 17 - Terminal Blocks for an Individual-Feed Shelf (One Shelf Shown)
Use the following steps to connect AC wiring to a power shelf

through the 15U individual-feed terminal block:
1. Ensure that all AC breakers are in the OFF position.
2. Route cables through knockouts in the AC section of the
system.
3. Connect grounds to the studs just above the terminal blocks.
4. Tighten the ground connections per specifications in Table 9.
5. Strip line wires to a length of 0.4”.
6. Connect Line 1 of the feed for Rectifier 1 to the terminal
labeled “1L1” and tighten compression screw to 15 in-lbs.
7. Connect Line 2 or Neutral of the feed for Rectifier 1 to the
terminal labeled “1L2” and tighten compression screw to 15 in-
lbs.
8. Repeat steps 6 and 7 for the remaining rectifiers, beginning
with terminal “2L1” (for Rectifier 2).
9. Repeat steps 6 – 8 for each shelf remaining.
Dual Feed
A dual-feed AC terminal block is shown in Figure 18. Each terminal is
labeled alphanumerically. The first letter (“A” or “B”) indicates the
feed, and the rest indicates the line (Line 1 or Line 2/Neutral).
Numbered from left-to-right, Feed A powers slots one and two, and
Feed B powers slots three and four. Refer to Figure 10 on page 14
for the rectifier slots powered by each set of terminal blocks.
Figure 18 – 15U AC Panel
Use the following steps to connect AC wiring to a power shelf

through the 15U dual-feed terminal block:
1. Ensure that all AC breakers are in the OFF position.
2. Route cables through knockouts in the AC section of the
system.
3. Connect grounds to studs just above terminal blocks.
4. Tighten the ground connections per specifications in Table 9.
5. Strip line wires to a length of 0.4”.

6. Connect the AC wires of Feed A to terminals AL1 (feed A,
Line 1) and AL2/N (feed A, Line 2/Neutral).
7. Connect the wires of Feed B to terminals BL1 (feed B, Line 1)
and BL2/N (feed B, Line 2/Neutral).
8. Tighten compression screws to 10 in-lbs.
9. Repeat steps 6 – 8 for the remaining rectifier shelves.
8U Distribution
The 8U distribution does not have an AC panel, so AC connections must
be made to the AC terminal blocks on each rectifier shelf. There are two
styles of terminal blocks: compression and screw. The power shelves for
the 48V/2000W and 24V/1800W Flatpack2 rectifiers feature a single
block with compression terminals. The power shelves for the 48V/3000W
Flatpack2 rectifiers feature two terminal blocks with screw terminals.
24V/1800W and 48V/2000W Shelves
Strain-relief fittings are located on the right side of the 24V/1800W
and 48V/2000W power shelf sections (when facing the front of the
system). Feed the AC lines through these before wiring them to the
rectifier shelves.
Strain Relief
Fittings
Figure 19 - Strain Relief Fittings (24/1800 & 48/2000)
A safety or chassis ground connection must also be made to the

power shelf. Use either the PEM stud or the PEM screw hole, which
both accept a #10 lug. See Figure 21 (individual-feed) and Figure 23
(dual-feed).
The terminal block used for 24V/1800W and 48V/2000W Flatpack2
power shelves can be either individual-feed (Figure 20) or dual-feed
(Figure 22). There is one terminal block per rectifier shelf.
To wire the terminal blocks:
1. Remove the Lexan cover located at the rear of the rectifier
shelves.
2. Unscrew and remove the green AC connector using either a
small Phillips or flat blade screwdriver.
3. Use a small flat blade screwdriver to open each terminal and
install AC wiring.
4. Pull a green safety wire in the AC mains conduit and
terminate it to the ground terminal of the connector. It
should be longer in length than the black and white AC wires.
5. Double-check that each connection is secure and replace the
connector.
6. If necessary, terminate additional safety wires to the shelf
ground termination stud located to the right of the
connector.
7. Replace the Lexan cover after AC terminations are complete.
GROUND
FEED D, LINE 1
FEED D, LINE 2
FEED C, LINE 1
FEED C, LINE 2
FEED B, LINE 1
FEED B, LINE 2
FEED A, LINE 1
FEED A, LINE 2
Rectifier Shelf
AC Terminal Block
(numbered left-to-right) 1 2 3 4 5 6 7 8 9
Figure 20 - Flatpack2 Shelf Individual-feed Terminal Block
Ground Nut
Ground Stud
Figure 21 - Individual Feed Connector (Cover Removed)

GROUND
FEED A, LINE 1
FEED A, LINE 2
FEED B, LINE 1
FEED B, LINE 2
Rectifier Shelf
AC Terminal Block
(numbered left-to-right) 1 2 3 4 5
Figure 22 - Flatpack2 Shelf Dual-feed Terminal Block
Ground Nut
Ground Stud
Figure 23 – Dual-feed AC Section (Cover Removed)
48V/3000W Shelves
Strain-relief fittings are on both sides of the 48V/3000W shelves.
Feed the AC lines through these before wiring them to the rectifier
shelves.
Strain Relief
Fittings Strain Relief
Fittings
Figure 24 - Strain Relief Fittings (48/3000)
The terminal blocks used for 48V/3000W Flatpack2 power shelves

are individual-feed and are divided into two blocks per shelf. Each
shelf has a 1/4”-20 chassis ground stud next to the terminal blocks
(see Figure 27 and Figure 28). Use a Phillips screwdriver to remove
the terminal block cover. Screw terminals require the installation of
ring terminals on the AC input wires; screws are size M4 (metric).
Make sure that ground wires are longer in length than AC line wires.
After making all wire connections, replace the cover.

4G 4L2 4L1 3G 3L2 3L1 2G 2L2 2L1 1G 1L2 1L1
Left AC Terminal Block Right AC Terminal Block
Figure 25 - Flatpack2 48V/3000W Shelf Terminal Blocks
Feed 4 Feed 3 Feed 2 Feed 1
Figure 26 - Terminal Blocks for 48V/3000W Shelf
Figure 27 - Chassis Ground (Left Side) Figure 28 - Chassis Ground (Right Side)
DC Output Connections
WARNING: For continued protection against fire, only replace a fuse
with another of the same type and rating. Indicating fuses have
exposed live parts. Use caution when replacing or servicing them.

WARNING: Always verify polarity and voltage before making
connections! Improper connections can cause permanent damage to
electrical equipment.
NOTE: Use the “Distribution Label” card, located on the door of the distribution
bay, to check fuse and breaker locations.
NOTE: Converter shelves are wired to the rectifier shelves and distribution at
the factory; no further connections are necessary.
Follow your company and local standards for connecting lugs to DC wires, heat
shrinking, and dressing wire properly. Wiring can be directed from the top of
the system. DC wire selected should be rated for 90°C. The “waterfall”
configuration enables wires to the bottom distribution row to drop behind the
top distribution row.
Attach lugged wires to proper DC output and corresponding return
connections with supplied washers and nuts. Torque connections in
accordance to specifications outlined in Table 9. DC distributions vary
depending on the type of system. Use the following steps to make DC
connections:
1. Route cables through the top opening in the system and connect
output and return cables to the desired module position.
2. Secure the lugged cable with the supplied hardware (washer and nut).
3. Torque the connections per specifications in Table 9.
4. Repeat procedure for all appropriate module connections.
Fuse/Breaker Installation
Circuit breakers (sold separately) are UL-approved, bullet-nose style breakers
and slide into the breaker positions. Breakers must be installed with the “line”
bullet connector at the top and the “load” bullet connector at the bottom.
“Line” and “Load” are labeled on a sticker on the side of the breaker (Figure 29).
If circuit breakers supplied by Eltek are not used, use UL-approved breakers
with isolated auxiliary output connections. In addition, alarm contacts should
short-circuit between the NC (normally closed) and the C (common)
connections in a tripped state.
Line
NC
Load
Figure 29 – Circuit Breaker Orientation
UL-approved, TPS-style fuses can be used in place of circuit breakers. Fuse

holder must be installed with the alarm tab in the top position. Install the TPS
fuse into the removable part of the fuse holder and return to the fuse holder.
TPS fuse holders install into a single circuit breaker position.
Fuse holder TPS-style fuse
Alarm tab Alarm indicator

fuse (GMT)
Removable
section
Figure 30 – TPS Fuse and Holder
Controller Connections
All rectifier, converter, and distribution module communication connections are
pre-wired. See the XC201x-Series Controller Manual for details about alarm
interface and connections. No controller setup is required for system turn-up.
The controller can be connected to a LAN and monitored remotely through a
browser-based interface. Details can be found in the GUI manual provided with
the controller.
Figure 31 and Figure 32 show the location of the controller and display and the
distribution monitoring (DM) device. The EC3010 module is not shown in the
images because there is no provision for user interface. All information is
relayed to the XC2010 controller.

Controller display
XC-series
controller
Figure 31 – XC2010 Controller with Display
Distribution
Monitoring (DM)
Device
Figure 32 – Distribution Monitoring (DM) Device
3. Turn-Up
Secure and check all input and output connections, then activate all AC input
breakers.
Installing Rectifiers
CAUTION: To avoid breaking the rectifier latches:
1. Do not carry rectifiers by the latches.
2. Open the latches fully before inserting rectifiers into
shelves.
CAUTION: Flatpack2 rectifiers incorporate an AC mains fuse in
each line. Double Pole / Neutral Fusing
NOTICE: The XC2010controller GUI displays rectifiers in order of ID number
under the “Bay 2” tab of the “Modules” page. Rectifier ID number is
determined by order of installation. The first rectifier installed is assigned ID
number “1”. The next rectifier installed is “2”, and so on. Rectifier “1” is always
positioned the far left of the top row, followed by numbers 2 through 4 in the
same row (from left-to-right). Rectifier “5” is positioned in the next row down,
and number continues as before. See Figure 33.
Figure 33 - Bay 2
It is recommended that installation of each rectifier module proceed in

accordance with this default arrangement. Once installed, each rectifier saves
its ID number and continues to use it even if physically installed in another
rectifier slot. The ID number can be changed manually using the GUI. See
Figure 34.

Click here
Figure 34 - Changing a Flatpack2 Rectifier ID
NOTICE: If rectifier ID numbers are manually changed, remember that the GUI
always positions the rectifier with ID number “1” in the left slot of the top row,
followed by numbers 2 through 4 in the same row (from left-to-right)—
regardless of the physical position of the rectifier module.
Once AC power is activated, install each module as follows:
1. Release the latches by inserting a small flat-blade screwdriver into the
release slots and pressing the tip upward; extend each handle.
2. Beginning with the top shelf and leftmost position, slide the first
rectifier firmly into the shelf.
3. Close the latches to lock the rectifier in place.
4. Continue installing rectifiers in the shelf from left-to-right.
5. Once the shelf is fully populated, start from the leftmost slot of the
next shelf below.
6. Repeat steps 1to 5 until all rectifiers to be used are installed.
Handle Release
Figure 35 - Release Handles Figure 36 - Extract Module
NOTICE: Any DC circuit breakers left in the off position may trigger a
distribution alarm after the first rectifier is installed. If the load device can be
powered at this point, simply switch the breaker ON to clear the alarm.
Installing Converters
CAUTION: Converter latches must be open for installation.
Attempting to install converters with latches closed can result in
mechanical damage to the converters and the shelf.
NOTICE: Converter ID number is determined strictly by position in the shelf;
converters do not save ID number. The converter shelf appears under the “Bay
1” tab of the XC2010controller GUI. See Figure 37.
Figure 37 - Bay 1
If the system is configured for DCX-series converters, converter modules

should be installed after rectifiers are installed and operating properly. To
install the DCX-series converters:
1. Release the latch by pushing the latch release button in the center
bottom of the faceplate.
2. Slide the module into the shelf.
3. Close the latch to lock the converter in place.
4. Continue with each remaining converter until all modules are installed.

Figure 11–Converter Module Installation
Converter fans start in high-speed mode and reduce speed according to the
ambient and plant conditions within 10 seconds. As each converter is
installed, the controller automatically identifies the new module and
reconfigures the system. After all converters are installed, and if there are no
alarms, the controller displays “System OK.” If there are alarms, refer to
Section 5 for troubleshooting assistance.
Connecting Batteries
DANGER: Always verify polarity and voltage before making battery
connections! Improper connections can cause permanent damage to
electrical equipment, serious personal injury, and/or death.
Batteries should be connected after making AC connections and activating
rectifiers. The system must be powered to check polarity on the battery bus.
Then, power off the system to connect batteries.
Return
CO Ground bus bar
Charge
bus bar
System
Shunt
Optional
LVLD
Figure 38 – Battery Connections
NOTE: It is recommended that the system be unpowered while making battery
connections, even though such connections can be made on a live system. If
unpowered, however, the controller and any LVD will activate once the first
string of batteries are connected.
After verifying the polarity, connect batteries to the battery termination panel
(shown in Figure 38) by performing the following steps:
1. Connect the “hot” leg of the battery string to the battery charge bus
bar. The controller and any LVD should activate.
2. Secure the connection with the provided 3/8” hardware. (Torque
connections per specifications in Table 9.)
3. Connect the grounded leg of the battery string to the return bus bar.
4. Secure the connection with the provided 3/8” hardware. (Torque
connections per specifications in Table 9.)
5. Repeat the steps for remaining battery connections.

4. Replacement Items
The controller and rectifiers are designed as modular, field-replaceable units. The
following sections outline the procedure to replace these items.
Controller
To remove the XC2010 controller and install a new one, use the following
steps: (See the manual for wire location).
1. Disconnect all wires from the controller. Remove the I2C cable first and
then remove the power cable. Removal of wire will cause alarm from
all output relays.
2. Remove the screw attaching the controller to the bay.
3. Connect wires to the new controller. Connect the power cable first
and then connect the I2C cable.
4. Replace the controller and tighten screws.
If it is necessary to remove the EC3010 controller, use the same steps as the
XC2010 controller.
Rectifiers
To replace a rectifier, perform the following steps:
1. Use a small flat blade screwdriver to release the latches on the front
of the rectifier that needs to be removed, and pull the latches until the
unit slides out of the slot.
IMPORTANT: Do not carry Flatpack2 rectifiers by the latches; they are
only for removal assistance.
2. Open the latches of the new rectifier and slide it into the open slot
until it connects with the backplane.
IMPORTANT: Failing to open the latches before inserting the rectifier
module can damage the shelf or the rectifier faceplate. Do not press on
the latches while inserting the rectifier into the shelf.
3. After the rectifier is inserted, close the latches. The rectifier will
power up and the controller will configure automatically. No further
setup procedure is required.
Converters
To replace a converter, perform the following steps:
1. Press the latch button on the bottom center of the module to release
the latch and pull the latch until the unit slides out of the slot.
2. Open the latch of the new converter and slide it into the open slot until
it connects with the backplane.
3. After the converter is inserted, close the latch. The converter will
power up and the controller will configure it automatically.
IMPORTANT: Failing to open the latch before inserting the converter
module can damage the shelf or the converter faceplate.

5. Troubleshooting
This section features common problems and solutions. If problems persist after
following the suggestions provided, please contact Eltek Technical Support at +1
(800) 435-4872.
In case of an alarm from the controller, verify the following:
o All AC and DC connections are secured properly.
o All rectifiers are installed and seated properly.
o The controller is installed and properly connected.
Problems Solutions
Minor Alarm Summary for multiple alarms including single rectifier failure, single
converter failure, distribution alarm, etc.
Major Alarm Summary for multiple alarms including Multiple rectifier failure , multiple
converter failure, LVD Open, etc.
AC Fail Check to see if commercial AC circuit breaker or fuse has tripped. If so,
reset the AC CB(s), or replace the AC fuse(s) in the AC Service Cabinet.
If commercial AC service is lost, seek an alternative energy source such as

a UPS or a generator.
Battery Discharge Verify the system output voltage is at the correct level. If it is correct,
Alarm then check the battery discharge set point (BD Alarm), and if necessary
adjust accordingly.
This alarm is normally present after commercial power failure or due to

the incorrect set point for this alarm.
LVD Open – Low Low Voltage Disconnect contactor has been opened in the battery
Voltage Disconnect termination panel, and / or distribution panel(s). This alarm is normally
Open present during deep battery discharge.
If batteries are not in discharge, reset the disconnect voltage of the

contactor to a lower value, by going into LVD config Menu under Modules.
See Controller Menu Tree.
Check to make sure if the contactor is open or close by going into LVD
Review under Modules, and checking contactor state. See Controller Menu
Tree
Dist Alarm Reset the DC circuit breaker(s), or replace tripped fuse in the distribution
section.
Power Device Comm Rectifier / Converter module(s) is(are) not communicating, or has been
Fail Alarm removed. Replace the removed module(s) in the shelf slot(s).
This alarm can be cleared by going to Alarms under main menu, and then
acknowledging the power device comm Fail alarm. See Controller Menu
Tree.
Problems Solutions
Dist Device Comm Distribution module(s) is(are) not communicating, or has been removed.
Fail Alarm Replace the removed module(s) in the distribution panel(s).
This alarm can be cleared by going to Alarms under main menu, and then
acknowledging the dist device comm Fail alarm. See Controller Menu Tree.
I Share Alarm – Load One or more rectifier(s) is not sharing the total system load equally.
Share Alarm Replace the faulty rectifier(s).
NOTE: AC OK, and DC OK LEDs of the Faulty Rectifier(s) (not sharing the
load), may still be GREEN
Redundancy Alarm The total load current has exceeded the summed current capacity of “N”
number of rectifiers in an “N+1” redundant system. Add more rectifiers, or
reduce system load to maintain redundancy.
Ctrl Alarm Indicates a contact closure at the Temp / Aux input terminals 1-4, or
contact closure at the relay alarm aux input terminals of the controller.
Check if the alarm cable is connected properly, looks ok physically, and
the input terminals at the controller are not shorted.
Thermal Probe Alarm Temperature probe(s) have been removed from the Temp / Aux input
terminals of the controller. Insert the temperature probes back into
proper positions.
Thermal Runaway Battery Temperature has exceeded the Thermal Runaway Temperature
set point, and the plant voltage has been reduced to the thermal runaway
voltage set point. Check to make sure the proper ventilation is available
for the batteries.
Unknown System Controller is displaying Unknown System. During new installation / turn up
of the plant, make sure at least one rectifier module is inserted in the
shelf.
Rectifier Alarms LED Rectifier’s Alarms LED is Red. AC OK, & DC OK LEDs are off. Make sure
(Red) rectifier shelves are not wired for 120V, 1 Phase AC input.
Voltage present Voltage between battery termination panel ground bar (+ve for -48V
between ground bar, system, -ve for +24V system), and chassis ground is not 0V. Make sure
and chassis ground the system is properly frame grounded, and the battery termination panel
ground bar is tied to the central office ground bar using a properly sized
cable.
NOTE: Verify the voltage between battery termination panel battery bar (-
ve for -48V system, +ve for +24V system), and chassis ground. It should
be close to the plant voltage.

6. Sample Configurations
Configurations of the Modular HE Power Systems are powered by 4 rectifier shelves
(up to 16 modules) and an optional converter shelf (up to 4 modules, 24V systems
only).
15U Distribution
Figure 39 shows a 24V system with a 15U distribution. The configuration
shown here consists of ten (10) BG1 modules and eight (8) BG3 modules on the
primary voltage (from the rectifiers), and two (2) BG3 modules on the
secondary voltage (from the converters).
Figure 39 – 15U Distribution Section for 24V System
In order of left-to-right, the top row consists of five BG3 and five BG1 modules
on primary voltage (+24V, blue labels). The bottom row has two BG3 modules
on secondary voltage (-48V, orange labels), three BG3 on primary voltage, and
five BG1 modules on primary voltage.
8U Distribution
The 8U distribution consists of two plug-in breaker boards, each of which
contains 24 breaker positions. In 24V systems, the bottom row can be divided
into primary (rectifier) and secondary (converter) voltage sections. Secondary
voltage can consist of either 4 or 9 breaker positions; the remaining positions
are connected to primary voltage. Figure 40 and Figure 41 feature 24V
systems with converter output. There is no converter option for 48V systems.
Figure 40 - 8U Distribution Section (4 Secondary Voltage Positions)
Figure 41 – 8U Distribution Section (9 Secondary Voltage Positions)

7. Revision Table
Revision Release Description CO
1 05/29/09 Initial release NA
2 07/15/09 Revised AC terminal block descriptions 090701UC
3 12/10/09 48V system option added; individual-feed 091118UA
AC added
4 03/16/09 Rectifier numbering description and 100316UF
procedure added, pp. 26-30
5 07/29/10 Add Flatpack2 48V/3kW rectifiers and 100518UC
power shelves. “XC2010F” controller
changed to “XC2010”.
6 06/07/11 Corrected 15U individual feed terminal 110510UA
block labels. Added more details for wiring
an 8U 24V/1800W or 48V/2000W shelf.
Added table of figures and table (list) of
tables. Revised torque values in table 9.
7 08/02/13 Updated formatting and branding. Added 130722UC
more details about difference between 15U
and 8U systems and AC wiring. 15U
individual-feed terminal block labels
updated.
Appendix A – Turn-up Checklist
Quick Start Turn-up Checklist
Pre-start Check (Power is OFF)
Installation site prepared
o Mounting location is well-ventilated and provides adequate room for airflow
o Floor is level and capable of supporting the system (Individual system weights vary;
see product flyer for more information)
o Suitable insulated tools available
AC input supply prepared
o AC supply is compatible with rectifier shelves
o Supply fuses and/or circuit breakers and wires are properly rated
System components inspected
o All parts, equipment, documentation, etc. accounted for
o Components checked for damage; if damaged, contact Eltek
Rack anchored to suitable location
Distribution circuits open
o Circuit breaker actuators switched OFF
o Fuses REMOVED
AC input connections made with power OFF
o Circuit breaker actuators switched off or fuses removed

o AC ground connections terminated (always connect ground first)
o AC supply lines are correctly configured to the rectifier shelf terminals
DC load connections made (EXCEPT BATTERIES)

o Load cables properly connected to system output and return bus bars
System alarm cable connected to “Alarm” port on controller
External devices connected to controller (if applicable)
o PM device(s) (use provided terminators in any open CAN ports)

o Battery thermal probe cables
o Auxiliary alarms terminated
Turn-up Procedure
Turn on AC breakers and verify proper AC voltage at back of shelf
Insert rectifiers; system will power up
Insert converters (if applicable)
Verify system turn-up
o Controller display turns on

o Controller and rectifier LEDs turn on
o Rectifier fans activate
Check controller interface
o Check display functionality
o Connect crossover cable from laptop to LAN port on controller
o Insert provided CD into laptop (program will automatically start)
o Verify controller appears in LAN Configuration Utility (no need to log in at this time)

Quick Start Turn-up Checklist
Initial controller setup
o Log in to controller from front display
o Set date and time
o Set appropriate preset value (if necessary)
o If desired, adjust voltage reading to match a metered reading using the ”Calibrate”
function

o Log out of front display
o Log in to controller using web browser
o Check controller detection of all installed rectifiers, LVDs, distribution cards (DM), and
PM devices on the ”Modules” page
o Configure distribution and peripheral monitoring device(s) (if applicable)
o Adjust default alarm mappings for controller relays, if necessary
Once alarms are cleared, run relay/alarm tests
Battery Connections (if applicable)
Measure battery string voltage; adjust system DC output voltage to equal battery voltage
Disconnect (but do not remove from shelves) all but one rectifier
CHECK POLARITY and attach batteries to system
o Terminate cable connections to designated battery landings
o Switch battery circuit breaker actuators ON and/or insert battery fuses (if applicable)
Reconnect all rectifiers
Adjust DC output voltage to equal required battery float voltage
Configure battery settings (if desired) via front display or graphical interface
o Battery boost

o Thermal compensation
o Battery current limit
Load Distribution
Once battery management is configured, activate load distribution circuits
o Switch circuit breaker actuators to the ON position
o Insert fuses
Appendix B – Alarm Test Guide

Quick Start Alarm Test Guide
Alarm Test Procedure Expected Result Restore Procedure
Distribution Turn OFF a distribution The controller display LED will Turn the breaker to the
Failure breaker with a black turn RED. The display will say ON position, or insert
actuator or remove a “Dist Alarm in Panel x Module y.” the removed fuse. The
distribution fuse alarms should turn off.
AC Fail Turn an AC breaker Controller LED turns Red. Turn AC breaker to the
feeding a rectifier Controller display indicates ON position. The
shelf to the OFF severity (Major or Minor), DC alarms should turn off.
position Fail, and AC Fail (Shelf x /
Module y) Alarms.
Doc. No. 2064270, Issue 7
Published 2-Aug-13
www.eltek.com
US Office: International:
Eltek, Inc. Eltek AS
2925 E Plano Pkwy, Plano, TX 75074, USA Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway
Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101 Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

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2925 E Plano Pkwy

Phone: +1 (469) 330-9100

Doc. No. 2064270, Issue 7, August 2013

2 Installation Manual Modular HE ~ Doc. No. 2064270, Issue 7, August 2013

4 Installation Manual Modular HE ~ Doc. No. 2064270, Issue 7, August 2013

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FCC Compliance Statement

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Controller Display 15U Distribution

Figure 1 - 15U Overview (24V/1200A system with converters)

Controller Display 8U Distribution

Figure 2 – 8U Overview (24V/1200A system with converters)

Figure 3 - 8U Overview (48V/600A system)

The Modular HE system can also be powered by standard Flatpack2 rectifier

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FEED D FEED C FEED B FEED A

SLOT 4 SLOT 3 SLOT 2 SLOT 1

FLATPACK2 POWER SHELF

Figure 4 – Individual-Feed AC Wiring Architecture (per power shelf)

SLOT 4 SLOT 3 SLOT 2 SLOT 1

FLATPACK2 POWER SHELF

Figure 5 – Dual-Feed AC Wiring Architecture (per power shelf)

FEED 4, LINE 1 FEED 1, GROUND

GND 2 1 GND 2 1 GND 2 1 GND 2 1

LEFT AC TERMINAL BLOCK RIGHT AC TERMINAL BLOCK

FEED 1 FEED 2 FEED 3 FEED 4

SLOT 4 SLOT 3 SLOT 2 SLOT 1

FLATPACK2 POWER SHELF

Figure 6 - AC Wiring Architecture for Flatpack2 48V/3000W Power Shelves

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Figure 7 - 15U Individual-Feed AC Panel Terminal Block

Figure 8 - Shelf and Rectifier Numbering (Individual Feed)

Figure 9 - 15U Dual-Feed AC Panel Terminal Block

NOTICE: The 8U distribution section does not have an AC panel, requiring

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Figure 11 - 15U Distribution

1 two-pole 2 one-pole 4 one-pole 10 GMT fuses

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Table 5 – DC Lug Part Numbers for Unprotected Output Connections

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Table 6 – Lug Sizes for BG1 Modules

Table 7 – Lug Sizes for BG2 Modules

Table 8 – Lug Sizes for BG3 Modules

Figure 12 - XC2010 Controller Product Label Location

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Figure 14 - 23" Seismic “S” Rack Footprint*

Figure 15 - 23" Seismic “G" Rack Footprint

Figure 16 - Frame Ground Locations on a Seismic "S" Rack

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Figure 17 - Terminal Blocks for an Individual-Feed Shelf (One Shelf Shown)

Use the following steps to connect AC wiring to a power shelf

Figure 18 – 15U AC Panel

Use the following steps to connect AC wiring to a power shelf

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Figure 19 - Strain Relief Fittings (24/1800 & 48/2000)