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Flatpack2, PS System
DC Power Supply System
Integrated, Cabinetized and Outdoor Applications
Introduction
o The Smartpack based Product Range (2 )
o Brief System Description, Flatpack2 (2 )
Installation
o Installing Smartpack, Rectifier Modules and blind panels ( 3)
o Installation steps; mechanical, electrical (4-5)
Commissioning
o Pre-start check (6 )
o Commissioning steps, Startup (6-7)
Operation
o Front keys and display (8)
o Software Menus (8)
Appendix
Communication
o Installing PowerSuite – PC software (9)
o CAN Bus Termination and Addressing (10)
AC Mains
o External AC Fuses, Recommended Rating (11 )
o Identifying Power Shelves, 4AC, 2AC or 4AC-3kW ( 12)
o I. Mains Reconfiguration, Integrated Systems, 1U DC Distribution ( 12)
o II. Mains Reconfiguration, AC Terminal Block (13)
o III. Mains Reconfiguration, AC Terminal Block with OVP (14)
o About AC, DC Earthing Systems ( 15)
o Mains Phases vs. Rectifier ID – Phase Balancing & Monitoring (16-17)
Battery Monitoring
o Controller’s 48V Battery Symmetry Connections (18 )
o Controller’s 24V Battery Symmetry Connections ( 19)
o Battery Monitor’s 48V Symmetry Connections (20-21)
o Terminals & Pin-out Location, Battery Interface Card ( 22)
Alarms & Monitoring
o Standard Alarm Relays & Digital Inputs – Connections ( 23)
o Terminals & Pin-out Location, Alarm Interface Card ( 23)
Internal Connections
o Terminals & Pin-out Location, System Interface Card (24 )
o LVD Latching Contactors – Connections (24 )
CAN Bus Nodes
o Battery Monitor CAN Node ( 26)
o Load Monitor CAN Node ( 27)
o I/O Monitor CAN Node ( 28)
Flatpack2 Integrated System, 2U
o Location of Major Components ( 31)
Powerpack System Flatpack2 System, Cabinetized Flatpack2 System, Integrated Minipack System, Integrated
Indoor and Outdoor Cabinets 4U and 1U Distributions
Cabinetized systems are suitable for indoor or outdoor applications. In addition to the power
system and the distribution unit, the cabinet may also contain battery banks, additional
distribution and other dedicated equipment. Integrated systems consist of the power system,
which includes rectifiers and controller(s), and the distribution unit (1U or 4U high). Integrated
systems are sold primarily for mounting in existing cabinets.
Powerpack systems are suitable for large Central Office power plants, and use three-phase
rectifier modules. Minipack systems are suitable as small, stand-alone battery chargers and DC
power supplies.
Flatpack2
CAN Bus rectifiers
LVLD
Telecom
equipment
AC mains
supply
AC Fuses, selector
external Load Fuses
(230VAC or & MCBs
400VAC Symmetry LVBD
Alarm & DC
Temp. Sensor distribution
AC Supply DC Supply
(Single- or (24V, 48V)
three-phase) Battery string #1 Battery
Fuses
Example of a typical Flatpack2 PS system for DC power supply of telecom equipment. The
system is fed from an external AC mains supply, and consists of rectifiers in power shelves, a
control unit and DC distribution unit. Battery banks, LVD contactors, etc. are typically also a part
of the system.
Installation Steps
Check off in the Installation Check List, that you find in the pullout section of
this folder. Also, refer to the system’s specific drawings.
For external AC fuses and AC input cable ratings, refer to your site’s AC
supply specification. Read also our external AC fuse recommendations
in section “Appendix”. In general, a site with better AC supply quality
(stable nominal voltage) may use smaller breakers.
Battery
Cable f-g Connect the temperature sensor cable, if applicable, to the
- + D-Sub plug or input terminal, and fix the temperature
sensor (at the end of the cable) to a suitable place in the
middle of the installed battery bank
- + - + - + - +
—
(-48V) Outer
Terminal Block1 Block3 Block4
+
Intercell Links 0V Outer
Terminal
1. Disconnect all rectifier modules, without removing them (keep original location)
o Read how to install modules, on page 3 in this guide. Also, read about the correct
rectifier position on page 17, and then,
o If Flatpack2 rectifier modules are installed, unlock the handles and pull the
modules partially out (fan housing visible), but do NOT physically remove them
Device from the power shelves
hazard o If Flatpack2 rectifier modules are not yet mounted, release their handles and insert
them partially into the correct position in the shelves
2. Switch ON the system
o Switch ON the AC input supply (external AC fuses) to the PS cabinet
3. Measure and verify that the AC input voltage is correct
o Measure the AC input voltage at the cabinet’s mains connection box
o Verify the AC voltage is within range
Load Adjustments
Now, you can begin with stage III, where you will adjust again the output voltage to the
Power is ON!
III
battery voltage, and connect the batteries and the load. Carry out the following:
10. Adjust DC output voltage to equal measured battery voltage
o Measure the battery voltage is within range (check connections have correct polarity)
o Adjust DC output voltage — using the controller’s front keys (refer to page 8) or via Device
PowerSuite— to equal the measured battery voltage. hazard
Smartpack Controller — front keys, display Flatpack2 Rectifier Module — front panel
Display: is in Status Mode (displays the system’s Power LED is OFF (mains unavailable), Flashing
status) or in Menu Mode (displays the menu (controller accessing information) or ON (powered).
structure). Warning LED is ON (derating or similar minor
Operation: Press on the key to change from warning), Flashing (over-voltage mode) or OFF
Status Mode to Menu Mode. Press the or (OK)
keys to scroll up or down and navigate to find menu Alarm LED is ON (shutdown or similar major alarm)
options (function or parameter). Press then the or OFF (OK, no alarm)
key to select the function.
Menus: When you “enter” Menu Mode (Level 1),
you access the User Options. You may also scroll Level 2 Level 3
down to password protected Service Options. Service menu <ServiceOption>
Default password <0003> should be changed.
Change Language Æ English ↓↑ 2v0
Level 2 Level 3 NomVolt ↓↑
BoostVolt ↓↑
User menu <UserOption> LoBattMaj ↓↑
VoltAdjustment LoBattMin ↓↑
AlarmResetÆ
HiBattMaj ↓↑
NomVolt HiBattMin ↓↑
BoostVolt
The ”XvX” references, if any, on the right hand of the option, are not shown in the display. They only indicate
LVBD ↓↑
The ”XvX” references, if any, on the right hand of the option, are not shown in the display. They only indicate the
HiBattMin SetManBoostTime Æ ↓↑
LVBD Start/StopBoost Æ
LVLD 1.1 Auto Boost Config. Æ Enable/Disable ↓↑ & Threshold ↓↑
Nxt Test DateTime Date ↓↑ Time ↓↑
the firmware version (402073.009 XvX) the option was first implemented or updated.
DisplayMessagesÆ Message ↓↑
Software Menus ~ Smartpack Controller
End Volt ↓↑
Firmware 402073.009 3v03 Smartpack, Distributed
SoftwareInfoÆ
SerialNumberÆ
Batt Test Setup MaxTestDur ↓↑
Test Int ↓↑
firmware version (402073.009 XvX) the option was first implemented or updated.
1. Install PowerSuite
1 Insert the CD in your PC drive, start the PowerSuite installation and follow &
accept the wizard default steps
2. Switch Smartpack ON and plug USB cable (Part 202073)
2 to Smartpack and to any available USB port in the PC
3. Wait for Windows to install USB drivers
Follow & accept the wizard default steps to automatically install the USB
drivers; the wizard runs twice
3 New hardware 4. Start PowerSuite and establish connection
is ready to use
Select “Start > All Programs > Eltek Valere> PowerSuite”. On the toolbar,
click “Connect” button. On the Connection dialogue box, click the “Connect”
4 button
If PowerSuite fails communicating via the standard COM port, find the COMx assigned to
Smartpack (My Computer/ Properties/ Hardware/ Device Manager) and configure PowerSuite to
communicate via this COMx (read the instructions in the installation CD).
PowerSuite’s newest version is always available on our FTP server. Call your Eltek Valere’s
contact person.
ID numbers formatted in italics (column 15 and 16 and range 65-78) are not available due to
software constraints. For DIP switch configuration, refer to chapter “CAN Bus Nodes”, page 26.
The figure shows a Flatpack2 DC power system expanded with a slave controller and 3 CAN
nodes to implement additional digital inputs, relay outputs or similar functionality.
Alarm Outputs Alarm Outputs
NC-C-NO NC-C-NO
Notes:
• Use the values in {} brackets in the 176VAC column, if you are unsure or know that the available
AC mains voltage may drop below 205VAC.
• The system is implemented with 4AC-3KW Power Shelves. Systems with more than 3 power
shelves require more than 1 AC Mains Feed Input
• The recommendations apply for use of
- Thermal magnetic circuit breaker (Th/Mag), type Siemens 5SX or 5SY series, MG C60H series
or similar; and
- Hydraulic magnetic breaker (Hy/Mag), type CBI QF frame or QY frame, Airpax or similar.
For more information regarding External AC fuses, please read the document 2052045.
WARNING:
Always replace a rectifier with blown internal AC fuse with a new module, and send the malfunctioning module for servicing.
PE L1 L2 L3
Chassis
Warning:
In Δ Mains Configuration, mount every other fish plate upside down, thus avoiding short circuits, if cut too long.
To To To To To To To To X:******
rectifier 1 rectifier 2 rectifier 3 rectifier 4 rectifier 5 rectifier 6 rectifier 7 rectifier 8
(To internal connections for 2 power shelves)
Flatpack2 DC Power System
2009604, v9
Y Mains, NT
Three-phase & N, 400VAC
(1 Y Mains input will feed 2 power shelves)
Customer
connections
To terminal X*, pin 1 (+)
To Digital
Input 1 To terminal X*, pin 2 (-) 11 14 12
PE PE N L1 L2 L3
X* X** 1 1 2 3 4 5 1 1 2 3 4 5
1
Over Voltage Protection, OVP
Link 2 Chassis
(L1,L2,L3,N)
(DC Earth)
Common AC Earth (PE) and DC Earth (TE) are
AC Mains EG DC Rail TE connected to chassis via “Link 1” and
“Link 2”. Remove the links (“floating
Link 1 . DC Load earth”) for compliance with other local
PE (AC Earth) Cabinet Circuit earthing systems.
Chassis
Refer to your system’s specific drawings to
identify how these links are implemented in
your DC power system.
Common Positive DC Output Rail is usual in 48 and 60V DC supply systems: Negative DC
Distribution. Common Negative DC Output Rail is usual in 24V systems: Positive DC
Distribution.
Common DC Rail + Common DC Rail —
DC Load
DC Load
— +
wires
wires
— +
— +
— +
Negative DC Positive DC
Distribution Distribution
Phase 3
Phase 1
n 09 06 03 N 01 04 07 n
Δ Mains
Three-phase, 230VAC Mains
230VAC
Phase 2
400VAC, 3ph+N
L1
02 05 08 n
Phase 3
Phase 1
AC L2
Mains ID number
n 09 06 03 230VAC 01 04 07 n (Assigned
L3 L2 CAN bus
Flatpack2 rectifier address)
02
Mains
05 One-phase, 230VAC
L(L1)
08
AC
Mains
n 230VAC 01 02 03 n
N(L2)
Phase 2
Form 173-gb-v4-C01_356804-103_qstart_flatpack2-pssyst_6v0.docx_mfm_2008-08-25
www.eltekvalere.com
Headquarters:
Eltek Valere Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, 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
CIRCUIT DISTRIBUTION LIST
System Data
Flatpack2 PSS, type: Article No.:
Site, name:
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
Fb1
Fb2
Fb3
Fb4
BATT.
Fb5
Fb6
F1
F2
F3
F4
F5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
LOAD
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Continue
Form 172-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_6v0.docx_mfm_2007-11-01
www.eltekvalere.com
Headquarters:
Eltek Valere Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, 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
CIRCUIT DISTRIBUTION LIST
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
LOAD
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
Form 172-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_6v0.docx_mfm_2007-11-01
www.eltekvalere.com
Headquarters:
Eltek Valere Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, 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
MAINTENANCE PROCEDURE
System Data Flatpack2 PS System
Flatpack2 Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:
WARNING: Maintenance work on live equipment is only to be performed by authorized and
Electric qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.
shock
System Inspection Power is ON!
CARRY OUT FOLLOWING: OK
1. Site specific parameters and settings are known.
User manuals and site specific connection & arrangement drawings are available.
2. The battery bank has been fully charged in advance.
At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration
3. The equipment is free from damage, dust or dirt; verify.
Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.
4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.
5. The Smartpack & all rectifier modules are ON, no alarm present; verify.
Otherwise, correct and put the PS system in normal mode of operation.
6. All rectifier’s functionality & Smartpack’s keys and display work OK; verify
Correct possible abnormalities before continuing.
7. Connect the PS system to a PC (install the PowerSuite application if required)
The PowerSuite program in the PC enables system configuration from the PC.
8. Rectifiers’ load current sharing; verify.
Use the PowerSuite PC application to check all rectifiers output the same amount of current (±1A)
9. Display the stored log of Alarm Messages.
Using the keypad on the Smartpack controller or from the PC.
System Adjustment
CARRY OUT FOLLOWING: OK
1. DC Output Voltage Calibration; ensure correct display readings.
If measured DC output voltage at the load terminals deviates more than ±1% from the display reading, calibrate the
output voltage from the Smartpack’s keypad or the PC.
2. Load & Battery Current Calibration; verify correct display readings.
Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery
current. If the calculated total values deviate more than ±1% from the display readings, calibrate the current from the
PC (calibration value>50% of system’s max. capacity)
3. DC Output Voltage Adjustment; measure and adjust.
Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery manufacturer.
(Voltage measurements to be done at the DC rail, with little load current)
4. Alarm Relay Test; verify all alarm relays are working correctly.
From the Smartpack’s keypad or PC use the Relay Test function; verify activation of external equipment
5. Battery bank control; measure and verify battery specifications.
Follow the recommendations of the actual battery manufacturer.
Approval
Responsible of maintenance control, sign.: Date: Approved by customer, sign.:
Form 171-gb-v3-C01_356804-103_qstart_flatpack2-pssyst_6v0.docx_mfm_2007-11-01
www.eltekvalere.com
Headquarters:
Eltek Valere Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, 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
PULLOUT
COMMISSIONING PROCEDURE
System Data Flatpack2 PS System
Supplier’s Order No.: Flatpack2 Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:
I Pre-Start Check Power is OFF!
CHECK FOLLOWING: OK
1. Flatpack2 system installation is completed; The Flatpack2 Installation Check List is filled in.
All cabling is securely terminated with correct polarity
Device
hazard 2. All battery and load MCBs/ fuses are disconnected
3. AC input cable(s) and AC earth wire (PE) are terminated
4. Site specific parameters and settings are known
5. AC supply and all MCBs/ fuses are switched OFF
Start-up, No-Load & Load Adjustments Power is ON!
II CARRY OUT FOLLOWING: OK
1. Disconnect all rectifier modules, without removing them (keep original location)
Device 2. Switch ON the system (external AC fuses ON)
hazard
3. AC input voltage is correct; Measure and verify
4. Insert all Flatpack2 rectifiers in their original locations in the power shelves
5. The Smartpack and all rectifier modules are working, LEDs are ON; Verify
6. Connect a PC to the PS system Install the PowerSuite software, if required
7. DC output voltage; Measure and adjust
8. Alarm relay test; Verify all alarm relays are working correctly
9. System Setup is in accordance with configuration Enter site spec. info in PowerSuite
III 10. Adjust DC output voltage to equal measured battery voltage Check correct polarity!
11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs
Device
hazard 12. Adjust DC output voltage to equal nominal battery or load voltage
13. Plug in again all rectifiers, and verify the rectifiers’ current sharing
14. Connect all load MCBs/ fuses, and verify no alarms are displayed
Approval
Responsible of commissioning, sign.: Date: Approved by customer, sign.:
Form 170-gb-v5-C01_356804-103_qstart_flatpack2-pssyst_6v0.docx_mfm_2007-11-01
www.eltekvalere.com
Headquarters:
Eltek Valere Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, 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
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
PULLOUT
AC Mains Appendix
Correct Rectifier Positions in Power Shelves
Flatpack2 DC power systems are normally shipped from factory with empty power shelves. The
rectifier modules are shipped in separate packaging, and you have to install the modules in the
correct position in the power shelves, with respect to their ID number (or CAN bus address). Do
not relocate already pre-installed rectifiers.
For first time installations of rectifiers in Flatpack2 systems, follow the scheme below:
1. Find out your system’s power shelf type, by
reading the Identifying Power Shelves section, page12
2. Find out if your system’s AC mains feed is
<230VAC, 3 phase> or <400VAC, 3 phase and N>
3. Insert & hot-plug the rectifiers in the indicated power shelf positions,
one module at a time, allowing a 2s delay between them and starting with ID number 1,
2, 3, and so on. (indifferent after ID# 6)
Follow one of the four figures below:
Flatpack2 Flatpack2
Smartpack rectifier Smartpack rectifier
controller controller
03 04 Position 4 02 05 Position 4
01 02 01 04
Position 1 --- --- Position 8 Position 1 --- --- Position 8
05 06 03 06
--- ---
--- ---
--- --- --- --- --- ---
--- ---
--- --- ---
Position 9 ID number Position 9 --- ID number
(Assigned CAN (Assigned CAN
bus address) bus address)
Flatpack2 Flatpack2
Smartpack rectifier Smartpack rectifier
controller controller
02 03 01 Position 4
02 05 Position 4
01
Position 1 04 --- Position 8 Position 1 04 --- Position 8
05 06 03 06
--- ---
--- ---
--- --- --- ---
--- --- --- ---
--- --- ---
Position 9 ID number Position 9 --- ID number
(Assigned CAN (Assigned CAN
bus address) bus address)
2-1 2-1 3 5 7
X:**** Card, Art. 200576 X:****
Serial Switches
Set all 4
Symmetry 1.3
Symmetry 1.4
Symmetry 1.1
Symmetry 1.2
Symmetry 1.1
switches
OFF (up) Set all 4 switches
ON (down)
- + + + + +
-
- + - + - + - + - + - + - + - +
— —
(-48V) Outer (-48V) Outer
Terminal Block1 Block3 Block4 Terminal Block1 Block3 Block4
+ +
Intercell Links 0V Outer Intercell Links 0V Outer
Terminal Terminal
Battery Symmetry
Double-point Measurement Notice that, if you open the serial switches in
card, Art. 200576 ⎯ setting all to OFF (up) ⎯
Two measurements per string, from the you have to connect the + and – wires of every
middle to the outer terminals symmetry input.
Card, Art. 200576 2-1 3
Serial Switches
X:****
Symmetry 1.1
Symmetry 1.2
Set all 4
Battery Terminology
switches ON
(down) Battery Block, Battery String and Battery Bank
Battery
Block (12V)
- + +
Battery
String #1
- + - + - + - + (48V)Batt.
—
(-48V) Outer
Terminal Block1 Block3 Block4
Battery
+ String #2
Intercell Links 0V Outer 48V Battery Bank
(48V)
Terminal
Battery Symmetry
Mid-point or Block Measurement
Example of Battery Symmetry Connections on the Smartpack controller, 24V Systems
Set all 4
switches
OFF (up)
- +
- + - +
—
0V Outer
Terminal Block1 Block2
+
Intercell Link 24V Outer
Terminal
Battery Terminology
Battery
String #1
(24V)
Battery
24V Battery Bank String #2
(24V)
2
The Mid-Point and the Block Measurement Methods are identical in 24V systems.
Symmetry 1.3
Symmetry 1.4
Symmetry 2.1
Symmetry 2.2
Symmetry 2.3
Symmetry 2.4
Symmetry 1.1
Symmetry 1.2
+ + + + + + + +
Battery Battery
String 1 String 2
- + - + - + - + - + - + - + - +
— —
(-48V) Outer (-48V) Outer
Terminal Block1 Block3 Block4 Terminal Block1 Block3 Block4
+ +
Intercell Links 0V Outer Intercell Links 0V Outer
Terminal Terminal
Symmetry 3.2
Symmetry 3.3
Symmetry 3.4
Symmetry 4.1
Symmetry 4.2
Symmetry 4.3
Symmetry 4.4
Notice:
+ + + + + + + + Always connect Battery
Monitor with ID#<33> to
Battery Battery battery string 1 (lowest), with
String 3 String 4 ID#<34> to string 2, and so
- + - + - + - + - + - + - + - + on. PowerSuite will then refer
— — to the correct battery string.
(-48V) Outer (-48V) Outer
Terminal Block1 Block3 Block4 Terminal Block1 Block3 Block4
+ +
Intercell Links 0V Outer Intercell Links 0V Outer
Terminal Terminal
Mid-point Measurement
One measurement per string, four strings
Battery Monitor
Part 242100.300
ID# <33>
DIP 1234
switches
for CAN
bus addr.
+ + + +
Battery String 4
Symmetry 1.4
Symmetry 1.3
Battery String 3
Symmetry 1.2
Battery String 2
Symmetry 1.1
Battery String 1
- + - + - + - +
—
(-48V) Outer
Terminal Block1 Block3 Block4
+
Intercell Links 0V Outer
Terminal
Notice:
Always connect Battery Monitor with ID#<33> to battery strings 1 (lowest),
2, 3 and 4. Then Battery Monitor with ID#<34> to string 5, 6, 7 and 8. And
so on. PowerSuite will then refer to the correct battery string.
In X:****
Single Wire
1
Batt. Symmetry 1 +
− 2
3
Batt. Symmetry 2 +
(From internal
− 4
Batt. Symmetry 3 + 5
Card Art.200576
batteries)
− 6
Cable
Lugs + 7
internal batteries)
Batt. Symmetry 4 −
internal batteries)
15-pins
− 4
Batt. Symmetry 7 + 5
batteries)
− 6
+ 7
internal batteries)
Batt. Symmetry 8 −
(From area with
Inputs Card, Art. 105954 Smartpack Card, Art. 200576 CON3A or Batt Fuse Fail 2 sensor
CON4A 14
To Smartpack,
CON3
15-pins
D-Sub female (Internal Connections)
CON3A or CON4A For Temp.
Sense Kit 2
1.5 mm , max.
X**/X* 1 5
wire section
X**/X*
X***/X**** 15-pins D-Sub male
Serial Switch 11 15
internal batteries)
15-pins
(From area with
D-Sub female
1 1 Temperature Sense 2
14
(Alternative use of Temp. Sense Kit,
Battery Interface Card, Art. 200576 instead of connecting to X:***, 9-10) Temperature
The Temperature Sense Kits may also be connected directly to the sensor
Smartpack controller’s CON3 or CON4, if these connectors are unused.
Flatpack2 PS System
Correct Use of Digital Inputs (example)
signals on CON1 & 2 accessible at any suitable Card Art.105954 FUNCTION SIGNAL PIN-OUT
external equipment)
Digital Input 2 + 3 Input Circuit 2
−
Alarm Circuit 4
NC 14
NO 15
Relay 5
The figure shows the position of the relay Low Battery Alarm COM 16 Alarm Circuit 5
NC 17
contacts when the relay coils are de-energized Relay 6 NO 18
(PS system in alarm mode. Factory Settings in Rectifier Alarm COM 19 Alarm Circuit 6
NC 20
bold) (Customer Connections)
2
1.5 mm , max.
wire section
Some of the Smartpack controller’s internal system signals are accessible on D-Sub connector
CON5, on the controller’s rear panel.
Using the System Interface Card (Art. 200625) and a standard 15 pins D-Sub cable, the signals on
CON5 may be accessible at any suitable location inside your system.
For detailed information about the card’s pin-out location and terminal block connections, refer to
the figures in this section.
In Out X:*****
Terminals & Pin-out Location 10 + 1 Power Input
System Connections
15 2
JP2
LVD1A
11−,Pos.D. 8 LVD Common LVD1
Pos. Distr. 9
1+/− LVD2A
JP1 Neg. Distr. 3+/− 10 LVD Common
JP2 3 LVD2
JP1
JP2 2+/− 11
2 (To latching contactors
1 1 LVD1 & LVD2)
2
X***** 3 (Internal Connections)
Neg. Distr.
1 11 CON5A Pos. Distr. JP1 and JP2 are used to configure the
System Connections Card, Art. 200625 system for Negative DC distribution (48 and
60V systems) or Positive DC distribution
(24V systems)
Flatpack2 systems’ LVBD and LVLD 3 functionality is implemented by the Smartpack controlling
magnetically latching contactors.
The coil of latching contactors is not
Latching Contactors, LVD1 & LVD2 energized in any state. They change state from
A latching contactor changes state only when a open to close, or vice versa, when a reversed
reversed pulse voltage is applied to its coil pulse is applied to the coil.
ON OFF Y
Bidirectional
+ Pulse - Pulse diode
PCB Art. Warning! The
200625 LVD1A
+ X
bidirectional
Latching diode must
Contactor always be
X:***** LVD1
X mounted to
8 Y avoid dam-
9 LVD Common
LVD2A
aging the
10 X controller.
11 Latching
Contactor Latching Contactor A
— LVD2
Smartpack
Unit
Y
X
LVD Common
3
LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect
Warning
Alarm LED Lamp (yellow)
LED Lamp (red)
CAN port 1&2
Electrically identical Pin 8 Power
LED Lamp (green)
Pin 1
Battery Monitor
Battery Monitor
DIP switches
CAN ID address Monitor Inputs
Terminal Block
DIP switch #1
Battery Monitor
DIP switch configuration
ID <33>
Battery ID DIP Switch Position (All switches OFF)
Monitor # 1 ⎯2 ⎯3 ⎯4
1st Monitor 33 OFF⎯OFF⎯OFF⎯OFF
2nd Monitor 34 ON ⎯OFF⎯OFF⎯OFF
3rd Monitor
To next CAN bus
35 OFF⎯ ON⎯OFF⎯OFF
4th Monitor 36 ON ⎯ ON⎯OFF⎯OFF Note:
5th Monitor 37 OFF⎯OFF⎯ON ⎯OFF • The Battery Monitor Connections
6th Monitor 38 ON ⎯OFF⎯ ON⎯OFF monitor’s Part 242100.300
7th Monitor 39 OFF⎯ON⎯ ON ⎯OFF ID # Battery FUNCTION SIGNAL PIN-OUT
corresponds Monitor
8th Monitor 40 ON ⎯ ON⎯ ON⎯OFF to the DIP X:*
node
− 6
14th Monitor 46 ON ⎯OFF⎯ ON ⎯ON
Or Batt. Current + 7
RJ45 CAN bus − 8
termination plug,
if the Battery 2
1.5 mm , max.
(From the current shunt)
Monitor is the
last node in the
CAN port 1&2 wire section
(From the current shunt)
CAN bus
RJ45, 8 pins
From previous CAN
bus node
Built-in Battery
Temperature Sensor
Read also the “Installation Guide Battery Monitor CAN Node”, document 351507.033.
Load Monitor
Load Monitor
+
– Input Circuit 3
Config. Input 3
+
– Input Circuit 4
Config. Input 4
+
– Input Circuit 5
Config. Input 5
+
RJ45 CAN bus termination plug, if the Load
RJ45, 8 pins +
To next
CAN bus node
– Input Circuit 7
Load Monitor Config. Input 7
DIP switch configuration
+
– Input Circuit 8
Config. Input 8
+
DIP
Switches X:**
Load ID DIP Switch Position ID <49> 1 – Input Circuit 1
Sense Input 1
Monitor # 1 ⎯2 ⎯3 ⎯4 (All switches OFF) 2 +
– Input Circuit 2
1st Monitor 49 OFF⎯OFF⎯OFF⎯OFF 3 Sense Input 2
+
Current Sense Inputs
Sense Input 3 –
(From current shunts)
I/O Monitor
I/O Monitor
Input 6 Relay 1
monitoring and output controlling Voltage free relay outputs and Configurable monitoring inputs
signals in your Smartpack based DC I/O Monitor FUNCTION SIGNAL PIN-OUT
351503.033. X:**
Relay 1 NO
C Alarm Circuit 1
DIP NC
Switches Relay 2 NO
C Alarm Circuit 2
Alarm Relay Outputs
1
NC
(To external equipment)
2
Relay 3 NO
3
C Alarm Circuit 3
4 NC
Or
Relay 4 NO
(5-8 always
OFF) C Alarm Circuit 4
I/O Monitor
DIP switch configuration NC
Relay 5 NO
C Alarm Circuit 5
NC
Relay 6 NO
I/O ID DIP Switch Position C Alarm Circuit 6
ID <81>
NC
Monitor # 1 ⎯2 ⎯3 ⎯4 (All switches OFF)
– (To be shorted)
1st Monitor 81 OFF⎯OFF⎯OFF⎯OFF Not in use
+
2nd Monitor 82 ON ⎯OFF⎯OFF⎯OFF Temperature
3rd Monitor 83 OFF⎯ ON⎯OFF⎯OFF X:*** Sensor 1
4th Monitor 84 ON ⎯ ON⎯OFF⎯OFF Temperature Sense 1 + 1
Inputs & Outputs
Note: − 2
5th Monitor 85 OFF⎯OFF⎯ON ⎯OFF • DIP switch
Fan Control
3 Temperature
6th Monitor 86 ON ⎯OFF⎯ ON⎯OFF positions 5 Temperature Sense 2 + Sensor 2
− 4
7th Monitor 87 OFF⎯ON⎯ ON ⎯OFF through 8 are
always to be OFF Tachometer Input 1 5
(To and from
external fans
Smartpack
Control Unit
LVLD position
(not displayed) CAN bus
DC Load
Terminals
(+, −)
Interface I/O
Terminals
Rear view
AC Terminals
Bus Bars
Common Battery Supply Battery
Connections Connections
Front view
USB 2.0 type B port DC Distribution (1U high) with built-in Smartpack
PC connection, etc controller, load fuses and MCBs
1U
1U
www.eltekvalere.com
Headquarters:
Eltek Valere Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, 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