356808.103
Quick Start Guide Installation, Operation, Commissioning and Maintenance
DC Power Supply System Integrated Applications
Miscellaneous Communication o CAN Bus Termination (13) o Installing PowerSuite – PC software (13) AC Mains o External AC Fuses ~ Recommended Rating (14) o Mains Feeds versus Rectifier ID (14) Battery Monitoring o Battery Symmetry – Connections (15) o Battery Interface Card ~ Terminals & Pin-out, ( 16) Alarms & Monitoring o Standard Alarm Relays & Digital Inputs (17) o Alarm Interface Card ~ Terminals & Pin-out (17) o Alarm Interface Card, Extd. ~ Terminals & Pin-out (18) Internal Connections o System Interface Card ~ Terminals & Pin-out (19) o LVD Latching Contactors (19) Drawings o Block Diagram Minipack 48VDC, 3.2kW (21) o Block Diagram Minipack 48VDC, 4.8kW (22)
Introduction o The Smartpack based Product Range (2 ) o Brief System Description ⎯ Minipack (2 )
Installation o Installing Smartpack and Rectifier Modules ( 3) o Installation and Maintenance Details
⎯ Opening or Closing the Minipack Drawer Shelf (4) ⎯ Mounting or Removing Minipack Blind Covers (4) ⎯ Removing or Mounting Load MCBs (5) ⎯ Configuring Priority and Non-Priority Load Circuits (5)
o Installation steps; mechanical, electrical (6-7) o Location of Components, GA drawing; 6 and 4 rectifiers systems (8) o Connections, Factory Settings, etc. (9)
Commissioning
o Pre-start check (10 ) o Commissioning steps, Startup (10-11)
Operation o Front keys and display (12) o Software Menus (12)
Check Lists pullout forms o Installation Check List o Circuit Distribution List o Commissioning Procedure o Maintenance Procedure
Minipack, PS System
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 2
The Smartpack based Product Range Eltek Valere's Smartpack based product range utilizes the Smartpack controller, and Flatpack2 rectifiers, Powerpack rectifiers and Minipack rectifiers as building blocks for implementing effective DC power systems, suitable for a wide range of applications and power ratings.
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.
Brief System Description ⎯ Minipack The Minipack PS system is a compact and cost-effective DC power supply system, specifically developed for the telecom industry.
Example of a typical Minipack PS system for DC power supply of telecom equipment. The system is supplied from an external AC mains supply, and is delivered in one power shelf for integration in existing cabinets (integrated). An external battery bank is to be connected.
Introduction
Flatpack2 System, Integrated4U and 1U Distributions
Flatpack2 System, CabinetizedIndoor and Outdoor Cabinets
Powerpack System Minipack System, Integrated
Minipack
Battery string #1
SymmetryAlarm &
Temp. Sensor
LVLD
LVBD
Fuse Alarm
AC Fuses, external (230V)
Telecomequipment
AC Supply (Single- or
three-phase)
BatteryFuses
Load Fuses & MCBs
Smartpack (Ctrl. Unit)
PowerSuiteApplication
USB cable
DC distribution DC Supply
48V
*
CAN Bus
Minipack rectifiers
Alarm Outputs NC-C-NO Digital Inputs Remote
Monitoring
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 3
Installing Smartpack and Rectifier Modules
Smartpack controller
Handle in locked position
Hole to release the handle’s spring mechanism
Handle in unlocked position
Mounting or Removing Smartpack Controller Mounting the Smartpack controller
1. Open the handles by inserting a screwdriver into the holes to release the spring mechanism
2. Insert the module fully into the power shelf, after plugging the cables to the rear panel
3. Lock the handles by pushing the handles up into their housings (locked position), so that the module is securely locked
Removing the Smartpack controller
1. Open the handles by inserting a screwdriver into the holes to release the spring mechanism
2. Remove the module by using both handles to pull the module loose gently; support from underneath; unplug the cables connected to the rear panel
Minipack rectifier
Locking Screw
MountingRail
Front Handle
Device hazard
CAUTION: Do not hand-carry the controller by its handles. Cables and circuit boards are plugged to the controller’s rear panel. Open the handles before inserting the controller into the power shelf.
Device hazard
CAUTION: The modules may be warm. Remove the locking screw before inserting them into the power shelf (hot-pluggable). Do not relocate already hot-plugged rectifiers to other positions in the power shelf. New rectifiers must be hot-plugged in the power shelf, one at time, starting from the left with position 1, 3, 5 and 2, 4, 6.
Mounting or Removing Minipack Rectifier Modules
1. Unlock the module by
using a screwdriver to loosen the locking screw
2. Insert or remove the module by sliding it on its mounting rail fully into the power shelf, so that the module makes proper contact (hot-pluggable) or using the front handle to pull the module loose; support from underneath before the unit is completely free
3. Lock the module by screwing home the locking screw (locked direction). Then, the module will be securely locked in the shelf, or ready for transport
4. Mount blind covers in unused module locations
Electricshock
Controller & Modules Installation
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 4
Installation and Maintenance Details
Installation Details
Mounting or Removing Minipack Blind Covers
1. Unlock the blind cover by
using a screwdriver to loosen the locking screw
2. Insert or remove the blind cover by sliding it on its mounting rail fully into the power shelf or sliding it out, by inserting your fingers in the cover’s front handle and pulling it loose
3. Lock the blind cover by screwing home the locking screw (locked direction). Then, the blind cover will be securely locked in the shelf, or ready for transport
Minipackblind cover
Locking screw to secure the blind cover
Front handle
Fastening screwfor the shelf
frame
Fastening screws for the drawer
Minipack Sliding Drawer Shelf in Operation Position
Opening or Closing the Minipack Drawer Shelf To access the Minipack distribution area, you have to open the sliding drawer shelf. Do following to open or close the drawer:
1. Unlock the drawer shelf by
using a screwdriver to loosen the upper and lower locking screws. Do not loose the screw in the middle!
2. Open or close the drawer shelf by holding the drawer from the side plates and sliding it outwards. The drawer shelf is the in the Maintenance Position. or sliding it on its mounting rail fully into the shelf
3. Lock the drawer shelf by screwing home the upper and lower locking screws. The drawer is then securely locked in the shelf, in its Operation Position
Shelf Frame
Fastening screwfor the shelf frame
Minipack Sliding Drawer Shelfin Maintenance Position
F1, F2…PlasticCover
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 5
Details Installation
Configuring Priority and Non-Priority Load Circuits CAUTION: Power must be OFF during configuration! Only one screw may be removed.
1. Remove the F1, F2… plastic cover by unscrewing the cover’s frontal screw, then inserting a small screwdriver into the cover’s gap and carefully press down and out to release the locking tabs.
2. Switch OFF and unplug the actual MCBs by switching the MCB handle to “0” (upwards), then using your fingers to pull out the MCB
3. Remove the actual Priority Load Screw by using a screwdriver to unscrew the Priority Load Screw (refer to table below). Keep the removed screw in the clip, on the cover’s inside
Plugs for MCB1
Priority Load Screws(accessible with unplugged MCBs)
F3-F10 Screw (Y6)
F5-F10 Screw (Y7)F7-F10 Screw (Y24)
F9-F10 Screw (Y25)
Screw Removed F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 None P P P P P P P P P P
Y25 NP NP NP NP NP NP NP NP P PY24 NP NP NP NP NP NP P P P P
Y7 NP NP NP NP P P P P P PY6 NP NP P P P P P P P PWARNING: Only one screw can be removed at a time. P=Priority Load Circuits NP =Non Priority Load Circuits
Configuration of Priority & Non Priority Load Circuits
Plug for MCB1
MCB1
MCB8
Minipack front
0
1
MCB8(Upper and
lower plugs)
Removing or Mounting Load MCBs CAUTION: Power must be OFF during this operation!
1. Remove the F1, F2… plastic cover by unscrewing the cover’s frontal screw, then inserting a small screwdriver into the cover’s gap and carefully press down and out to release the locking tabs.
2. Switch OFF the MCB by switching the MCB handle to “0” position (upwards)
3. Remove or insert the MCB by using your fingers to pull out and unplug the MCB or pressing the MCB into the upper and lower plugs
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 6
Installation Steps
Check off in the Installation Check List, that you find in the pulloutsection of this folder. Also, refer to the system’s specific drawings.
Installation
For external AC fuses and AC input cable ratings, refer to your site’s ACsupply specification. Read also our external AC fuse recommendationsin section “Miscellaneous”. In general, a site with better AC supplyquality (stable nominal voltage) may use smaller breakers.
Mechanical Installation Power is OFF!
Carry out the following: 4 Remove packaging and check equipment
o Check you have received all the parts and correct documentation o Inspect the equipment for physical damage (report any damages) o Leave rectifier modules in their packaging or in the selves, if
factory installed. To be installed under commissioning 5 Remove the cabinet’s top cover and dummy front panel
o Connection terminals are accesses by opening the drawer shelf o Battery shelves (if any) are placed behind the lower panels
6 Position and fasten the subassembly o Minipack is fastened in existing 19” or in ETSI cabinets, using
brackets 7 Mount the external batteries on the shelves
o Start (if applicable) placing the batteries on the lower shelf first, and continue upwards
o Do not terminate the battery cables yet! 8 Open the Minipack drawer shelf and lift the plastic cover
o Unlock the upper and lower screws and slide the drawer shelf open; read the Installation & Maintenance Details chapter
o Lift the Melenex plastic cover to access the connection terminals
Electricshock
Devicehazard
Minipack PSS, Doc. Chart, Spec. Drawings, CD-ROM
Minipack drawer shelf slid out in the maintenance position
Plastic Cover
Preparing the Installation Site
Begin preparing the following:
1 Organize the installation site o A 2U high spare location in existing 19”, 250 mm cabinet o Min. Clearances: 60 cm in front o Explosive atmospheres are to be avoided. Ensure suitable
ventilation 2 Prepare the installation tools
o Use insulated tools suitable for telecom installations 3 Prepare AC Supply: AC input cable(s) and fuses
o Correct type AC supply is available o External AC fuses have correct rating o AC input cable(s) are sized correctly
EMCregard
600 mm
2U
200 mm
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 7
Installation
Electrical Installation Power is OFF!
Carry out the following: (Refer to the system’s specific drawings)
CAUTION: The cable lengths must be long enough (service loop) to allow opening the Minipack drawer shelf.
9 Make the system completely voltage free o Switch OFF or remove all load fuses (MCB1, MCBx), battery
fuses (Fb1, Fbx) and the AC supply fuses, in external fuse boards
10 AC Connections o Check AC configuration: the external AC supply consists of 3
single phase mains feed and earth (PE) o Connect the AC Earth wires (PE) to the terminals X5:1-2 (PE) o Connect the AC input cables to the terminals X5:3-4, 5-6, 7-8.
Cable and terminal block labeling are to correspond 11 DC Connections ⎯ Load Circuits
o DC Earth (TE); check that the common DC Output Rail is connected to “Telecom Earth” (TE) at only one place (at the cabinet , cable X7A, or at a central distribution point)
o For each DC load, connect one of the cables to the common DC output terminal, and the other to terminal X6B:F1, F2, etc.
12 DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration, or
to the “Miscellaneous, Alarms & Monitoring” section, terminal blocks X1, X2A and or X2B.
o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output
terminals 13 DC Connections ⎯ Battery Cables
Careful! Use correct polarity. For 48V systems using the battery symmetry mid-point measurement, refer to the figure in this page. For other measurement methods, refer to the Battery Symmetry Connections chapters in this guide’s Miscellaneous section. For each battery shelf:
CAUTION: Mount cable lugs upside down on the (+) battery cables
a Mount 3 intercell links to connect in series 4 battery blocks b-c Connect battery cables to fuses (Fb1, Fb2, etc.) and
Common Battery (X7A) and to the battery shelf’s outer terminals; black (+); blue (-)
d-e Connect battery symmetry cables, if applicable, to the input terminals, and to the center terminal of the battery string (+) and to the -48V outer terminal. Deviation from factory settings requires Symmetry reconfiguration via PowerSuite
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
Electricshock
Minipack drawer shelf slid out in the maintenance position
Service LoopCable lengths
enabling to openthe drawer shelf
Devicehazard
—(-48V) Outer
Terminal+
0V Outer Terminal
Link 2 (X7A)(DC Earth)
Common Battery X7A EG Battery
Fuse, Fbx
Intercell Links
BatteryCable S
ymm
etry
1
2-1
Chassis
Card Art.200576
+ -
15 pins D-Sub (male)
Tem
p. s
enso
r Tem
p. S
enso
r cab
le 1
Block1
- + + - + - + -
Block4 Block3
Cable lugs mounted upside down
Common Battery Cables (+)
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 8
Location of Components, GA drawing Refer to the specific drawings included with your Minipack PS system, for information regarding the exact location of components in your system.
Installation
NOTE: For information about connecting Battery Symmetry, Temperature Sensor, Alarm and Monitoring circuits, refer to section “Miscellaneous”, and read the Battery Monitoring, Alarms & Monitoring chapters.
CAN1CAN bus communication with rectifiers (to Smartpack rear)
CON5A, For internal connections (to Smartpack rear)
Common Battery (+) X7A, Battery connections
DC EarthX7A, Exchange Ground (EG) or system ground. Link connected to chassis
Fb1, Fb2 Battery connections (−)
AC MainsAC Mains & Earth (PE) Terminals
Plastic Protective Cover forAC Terminals
Forward sliding drawer shelf
Top view
Minipack Rectifier
Location ofSmartpack controller
Common DC Output (+)Load terminal block
DC Output (−)Load terminal block
Cable Fastening Plate
X5: pin 1
X6B: pin 1
LVLD latching contactor (optional)
LVBD latching contactor
Min
ipac
k, 6
Rec
tifie
rs (4
8V, 4
800W
)
Front view
Battery Fuses
Load MCBs
Smartpack controller
Minipack rectifiers
CAN1 CAN bus communication with rectifiers (to Smartpack rear)
CON5A, For internal connections (to Smartpack rear)
Common Battery (+)X7A, Battery connections
DC Earth X7A, Exchange Ground (EG) or system ground. Link connected to chassis
Fb1, Fb2, Fb3, Fb4Battery connections (−)
AC MainsAC Mains & Earth (PE) Terminals
Plastic Protective Cover forAC Terminals
Forward sliding drawer shelf
Top view
Minipack Rectifier
Location of Smartpack controller
Common DC Output (+)Load terminal block
DC Output (−)Load terminal block
Cable Fastening Plate
X5: pin 1
X6B: pin 1
LVLD latching contactor (optional)
Fb1
LVBD latching contactor
Min
ipac
k, 4
Rec
tifie
rs (4
8V, 3
200W
)
Front view
Battery Fuses
Load MCBs
Smartpack controller
Minipack rectifiers
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 9
Connections, Factory Settings, etc Refer to your system’s specific drawings for the exact connection points.
Installation
Minipack PS System, Integrated
The figure shows the posi-tion of the relay contacts when the PS system is in alarm mode of operation; the relay coils are then de-energized (fail-safe mode). The relay outputs are preprogrammed from factory (Factory Settings).
CANCom
Cable
CA
N b
us
End
-of-L
ine
Plu
g (1
20Ω
)
(Rear)
Smartpack (Front)
USBCom
Cable USB 2.0 Type B serial port
CAN1 portRJ45, 8 pins
CAN1 portRJ45, 8 pins
(For CAN bus termination, see section “Miscellaneous”)
FUNCTION SIGNAL TERM. POINT
X5
AC
Mai
ns In
puts
6 5 4 3 2 1
7 8
PEPEN3L3N2L2N1L1
2.5 mm2, max. wire section M4 terminals
Mains Feed 1
Mains Feed 2
Mains Feed 3
AC Earth (PE)
FUNCTION SIGNAL PIN-OUT
Load
Fus
es
MCB1
MCB2
X6A
2
1
10
8
+
+
+
+
6 m
m2 , m
ax. w
ire s
ectio
n Load Circuit 1X6B
Load Circuit 2
MCB8Load Circuit 8
MCB10 Load Circuit 10
(Minipack systems with 6 rectifiers have 8 DC load outputs available. Systems with 4 rectifiers have 10 DC load outputs)
CommonBattery “Rail”
Bat
tery
Fu
ses Fb1
Fbx
Battery Cables, string 1
Battery Cables, string x
M6 screws, cable lugsmax. 15 mm width
X7A
Interface Cards Connections Refer to the connections for the actual terminal circuit boards
installed in your system
Battery Connections (X4)Terminal Circuit Board, Art. 200576
Battery Symmetry 1-4 and Temp. Sense 1 (See page 15 for pin-out information)
Battery Connections, Extended (X3)Terminal Circuit Board, Art. 200576
Batt. Symmetry 5-8, Temp. Sense 2, Batt. Current and Batt. Fuse Fail
(Not applicable for Smartpack RS232 D-Sub option, on rear panel) (See page 15 for pin-out information)
Alarm Outputs & Digital Inputs (X1)Terminal Circuit Board, Art. 218470
Digital Input 1-2 and Relay Output 1-2 (See page 15 for pin-out information)
Alarm Outputs & Digital Inputs Extended (X2A & X2B)Terminal Circuit Board, Art. 218473
Digital Input 3-6 and Relay Output 3-6
(Not applicable for Smartpack Ethernet option) (See page 15 for pin-out information)
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 10
The Minipack PSS startup consists of following stages:
I. Perform a pre-start check before the PS system is switched ON II. Switch ON the system with disconnected load; adjust output voltage
III. Adjust the nominal output voltage with connected batteries and load
Pre-Start Check Power is OFF! Check off in the Commissioning Procedure, that you find in the pullout section of this folder.
If you have just finished the system installation successfully and filled in the Installation Check List, jump over the Pre-Start Check and continue with stage II.
Before you switch ON the Minipack PS system, verify the following:
1. System installation is completed o Ensure a correctly performed system installation, with correct polarity on all
connections (Installation Check List filled in) o All cabling is securely terminated and supported o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
2. Battery and load fuses are disconnected o Verify that all battery and load MCBs/ fuses are switched OFF
3. AC input cable(s) and AC Earth wire (PE) are terminated o Make sure that the AC input cable(s) are correctly connected to the AC terminals o Verify that the AC input cable(s) and external AC fuses are sized and rated as specified o Check that AC Earth (PE) is terminated, and electrically connected to chassis
4. Site specific parameters and settings are known o Read the site specific drawings and documentation
5. AC supply and all MCBs, fuses are switched OFF o Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF
Commissioning Steps, Startup Check off in the Commissioning Procedure, that you find in the pullout section of this folder.
After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you will switch ON the Minipack PSS — while the batteries and load are disconnected ⎯ then measure the output voltage, and adjust it if required. Carry out the following:
Startup and No-Load Adjustments Power is ON!
1. Disconnect all rectifier modules, without removing them (keep original location) o Verify that all Minipack rectifier modules are disconnected (unplugged) but NOT
physically removed from the power shelf. Also, read about the correct rectifier position, page 14, and how to mount them, on page 3.
2. Switch ON the system o Switch ON the AC input supply (external AC fuses) to the Minipack system
3. Measure and verify that the AC input voltage is correct o Measure the AC terminals’ input voltage at the system’s AC Mains terminals o Verify that the AC voltage is within range
Commissioning
Device hazard
Device hazard
I
II
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 11
4. Mount all Minipack rectifier modules in the power shelves (keep original location)
o Plug all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯ to plug them in the same self location. Secure them with the locking screws. Refer to page 3.
o Mount Minipack blind covers over unused positions
5. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON o Verify correct operation, by monitoring the modules’ LED lamps and display:
No alarm are present on rectifiers. The Smartpack displays fuse alarms
6. Connect the a PC to the PS system (to facilitate operation) o Plug a standard USB A-B cable between the PC and the Smartpack controller o Start PowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite
Refer to chapter “Installing PowerSuite ⎯ PC Application”, page 13, if required o On the toolbar, click the “Connect” button to establish connection
7. Measure and adjust DC output voltage o Read the DC output voltage on the controller’s display o With a multi-meter, measure the DC output voltage at the most accessible point, e.g.
between the common DC rail and the lower connection of one of the priority load MCBs o If required, adjust the voltage using the controller’s front keys or via PowerSuite
8. Verify the alarm relays are working correctly (alarm relay test) o Run the alarm relay test using the controller’s front keys (refer to page 12) or via
PowerSuite (select the menu Go > Output Test)
9. Make sure the System Setup is in accordance with configuration o Verify system settings using the controller’s front keys or via PowerSuite o Use the opportunity to enter site related information, number of used AC phases,
type of batteries, etc.
Load Adjustments Power is ON!
Now, you can begin with stage III, where you will adjust again the output voltage to the battery voltage, and connect the batteries and the load. Carry out the following:
10. Adjust DC output voltage to 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 12) or via
PowerSuite— to equal the measured battery voltage. (Important adjustment to avoid arcing when connecting the batteries)
11. Unplug all rectifiers but one, and connect the battery fuses /MCBs (CAUTION: Have only one rectifier connected, when switching ON the battery fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.)
o Disconnect all rectifiers but one, by unlocking the locking screw and pulling them partially out. Do NOT physically remove them from the power shelf
o Switch ON all battery fuses or MCBs
12. Adjust DC output voltage again to equal the nominal battery voltage o Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to
equal the nominal battery voltage (or the nominal load voltage, when not using batteries)
13. Plug in again all rectifiers, and verify the rectifiers’ current sharing o Connect all rectifiers again by pushing them firmly inwards ⎯ Repeat step 4, in stage II o Wait for about 2 min., and check — using the PowerSuite application —that each of the
rectifiers delivers the same output current. A deviation of 1A is acceptable. 14. Connect the load breakers and verify that no alarms are displayed
o Switch ON all load MCBs/ fuses o Verify correct operation: rectifiers and controller display no alarms
Commissioning
Devicehazard
Devicehazard
III
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 12
Front Keys and display, menus, etc.
Operation
Minipack Rectifier Module — front panel Power LED is OFF (mains unavailable), Flashing (controller accessing information) or ON (powered). Warning LED is ON (derating or similar minor warning), Flashing (over-voltage mode) or OFF (OK) Alarm LED is ON (shutdown or similar major alarm) or OFF (OK, no alarm)
Smartpack Control Unit — front keys, display, etc Display: is in Status Mode (displays the system’s status) or in Menu Mode (displays the menu structure). Operation: Press on the key to change from Status Mode to Menu Mode. Press the or keys to scroll up or down and navigate to find menu options (function or parameter). Press then the key to select the function. Menus: When you “enter” Menu Mode (Level 1), you access the User Options. You may also scroll down to password protected Service Options. Default password <0003> should be changed.
PowerLED Lamp (green)
Warning LED Lamp (yellow)
AlarmLED Lamp (red)
GraphicalDisplay
16 char. x 2 linesLCD display
”Up” arrow key ”Down” arrow key
”Enter” key
USB0ype B port
Smartpack control unit
Minipack rectifier
PowerLED Lamp (green)
WarningLED Lamp (yellow)
AlarmLED Lamp (red)
Software Menus ~ Smartpack controller
User menu <UserOption> AlarmReset
NomVolt
BoostVolt
LoBattMaj
VoltageInfo LoBattMin
HiBattMaj
HiBattMin
LVBD
LVLD 1.1
DisplayMessages Message ↓↑
SoftwareInfo
SerialNumber
NoOfRects. nn
RectCurrent
Rectifier Info RectSerialNumber
Rect.PrimaryVolt
Rectifier Status
Rectifier Temp
Rect. OutputVolt
Rectifier SW Ver
NoOfPhases nn
Mains Info Mains Status
Mains Voltage
Temp Level Info Level ↓↑
NoOfString Nn
BattStringCurr ↓↑
Battery Info BattStringTemp ↓↑
BattBlockVolt ↓↑
Level 2 Level 3
…
Firm
war
e 40
2073
.009
2v0
0 S
mar
tpac
k, D
istri
bute
d
Service menu <ServiceOption> Change Language English ↓↑ 2v0
NomVolt ↓↑
BoostVolt ↓↑
LoBattMaj ↓↑
VoltAdjustment LoBattMin ↓↑
HiBattMaj ↓↑
HiBattMin ↓↑
LVBD ↓↑
LVLD 1.1 ↓↑ VoltCalibration VoltCal ↓↑ ChangePassword Password ↓↑ SetManBoostTime ↓↑ Start/StopBoost Auto Boost Config. Enable/Disable ↓↑ & Threshold ↓↑
Nxt Test DateTime Date ↓↑ Time ↓↑
End Volt ↓↑ Batt Test Setup MaxTestDur ↓↑
Test Int ↓↑
Guard Time ↓↑ Start/Stop Test NoOfRects. ; nn Reset Charge Curr Lim. Enable/Disable ↓↑ & Max C.Curr ↓↑
Battery Setup NumOfString ↓↑
CellCap Ah nn ↓↑ Output Control VoltageCtrl / TempComp ↓ Change Date/Time Date ↓↑ Time ↓↑
Alarm Output 1 ↑ RelayTest Alarm Output 2 ↑
Batt Contactor ↑
Load Contactor ↑
Alarm Output nn ↑ BlockOutputs Enter OutpBlocked/Exit OutpBlocked 2v0 BattLifeTime Rst
Level 2 Level 3
The
”XvX
” ref
eren
ces,
if a
ny, o
n th
e rig
ht h
and
of th
e op
tion,
are
not
sho
wn
in th
e di
spla
y. T
hey
only
indi
cate
th
e fir
mw
are
vers
ion
(402
073.
009
XvX
) the
opt
ion
was
firs
t im
plem
ente
d.
Firm
war
e 40
2073
.009
2v0
0 S
mar
tpac
k, D
istri
bute
d
PU
LLOU
T
Check Lists Pu
llout
Pull o
ut th
e pag
es with
the g
ray outer b
and,
and u
se them
as check lists
Form 174-gb-v1-C
01_356808-103_qstart-inst-comm
-oper_minipack-pss_1v1ev.doc_m
fm_2006-12-29
INSTALLATION CHECK LIST System Data Minipack PS System Minipack 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: Installation carried out by, name:
Site Preparations CARRY OUT FOLLOWING: OK 1. Organize the installation site
o Prepare a 2U high spare location in existing 19”, 250 mm cabinet; Check min. clearance: front access, 60 cm o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere.
2. Prepare the installation tools o Check that insulated tools suitable for telecom installations are used
3. Prepare AC Supply: AC input cable(s) and fuses o Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated
Mechanical Installation Power is OFF! CARRY OUT FOLLOWING: OK 4. Remove packaging and check equipment
o Check you have received all the parts and correct documentation. o Inspect the equipment for physical damage (report any damages) o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
5. Remove the cabinet’s top cover and dummy front panels o Check that cable entry from the top is possible o Connection terminals are accesses by opening the drawer shelf
6. Position and fasten the subassembly o Subassemblies in existing 19” or in ETSI cabinets, using brackets.
7. Mount the external batteries on the shelves o Start (if applicable) on the lower shelf first, and continue upwards o Do not terminate the battery cables yet!
8. Open the Minipack drawer shelf and lift the plastic cover o Unlock the upper and lower screws and slide the drawer shelf open, then lift the Melenex plastic cover
Electrical Installation Power is OFF! CARRY OUT FOLLOWING: OK 9. Make the system completely voltage free
o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses 10. AC Connections
o Check AC configuration: Make available 3 single phase mains feed and earth (PE) o Connect the AC Earth wire (PE) to the terminals AC Earth (PE) o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
11. DC Connections ⎯ Load Circuits o Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place o For each DC load, connect one of the cables to the common DC output terminal; the other to the fuse terminal
12. DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration, or to the Quick Start Guide o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output terminals
13. DC Connections ⎯ Battery Cables Careful! Use correct polarity. For each battery shelf,
o Mount 3 intercell links to connect in series 4 battery blocks o Connect battery cables to fuses and Common Battery, and to the shelf’s outer terminals; black (+); blue (-) o Connect battery symmetry cables, if applicable, to the input terminals o Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the
end of the cable) to a suitable place in the middle of the installed battery bank
Approval Responsible of installation, sign.: Date: Approved by customer, sign.:
EMC regard
Electric shock
Device hazard
Electric shock
www.eltekvalere.com
Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101
Eltek ValereGråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
CIRCUIT DISTRIBUTION LIST System Data Minipack PSS, type: Article No.:
Site, name:
CIRC. NO. FUSE
- TYPE
MCB LVLD
CONTROLLED DESCRIPTION FUSE
AMPERECABLE
mm2
Fb1 Fb2 Fb3 Fb4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
LOA
D
BA
TT.
Form 175-gb-v1-C
01_356808-103_qstart-inst-comm
-oper_minipack-pss_1v1ev.doc_m
fm_2006-12-29
www.eltekvalere.com
Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101
Eltek ValereGråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
COMMISSIONING PROCEDURE System Data Minipack PS System Supplier’s Order No.: Minipack 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:
Pre-Start Check Power is OFF! CHECK FOLLOWING: OK 1. Minipack system installation is completed; The Minipack Installation Check List is filled in.
All cabling is securely terminated with correct polarity 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! CARRY OUT FOLLOWING: OK 1. Disconnect all rectifier modules, without removing them (keep original location)
2. Switch ON the system (external AC fuses ON)
3. AC input voltage is correct; Measure and verify
4. Insert all Minipack 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 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 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.:
Device hazard
I
II
Device hazard
III
Device hazard
Form 176-gb-v1-C
01_356808-103_qstart-inst-comm
-oper_minipack-pss_1v1ev.doc_m
fm_2006-12-29
www.eltekvalere.com
Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101
Eltek ValereGråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
PU
LLOU
T
WARNING: Maintenance work on live equipment is only to be performed by authorized and qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury. Electric
shock
MAINTENANCE PROCEDURE System Data Minipack PS System Minipack 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:
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 177-gb-v1-C
01_356808-103_qstart-inst-comm
-oper_minipack-pss_1v1ev.doc_m
fm_2006-12-29
www.eltekvalere.com
Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101
Eltek ValereGråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
PU
LLOU
T
Check Lists Pu
llout
Pull o
ut th
e pag
es with
the g
ray outer b
and,
and u
se them
as check lists
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 13
CAN Bus Termination Minipack systems are shipped from factory with the CAN bus already terminated with 120Ω resistors.
To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120Ω resistors, one at each end of the line. The figure shows a Minipack system, with its controller communicating with the rectifiers via the CAN bus.
Smartpack assigns ID numbers to the rectifiers (software-assigned). The Smartpack’s ID numbers are assigned by DIP switches on the controller’s side.
Installing PowerSuite ⎯ PC Application The PowerSuite software application enables you to configure and operate the Minipack Power Supply System from a personal computer.
Communication Miscellaneous
3. Wait for Windows to detect the Smartpack controllerIf required, a wizard will automatically install necessary USB drivers. Follow & accept the wizard default steps New hardware
is ready to use 3
If PowerSuite fails communicating via the standard COM port, find the COMx assigned to Smartpack, by selecting menu option “Tools > Options” (click on the Find COMx button).
PowerSuite’s newest version is always available on our FTP server. Call your Eltek Valere’s contact person.
Minipack system configuration from a PC running MS Windows XP
2. Switch Smartpack ON and plug USB cable (Part 202073)to Smartpack and to any available USB port in the PC 2
1. Install PowerSuite Insert CD in your PC drive and follow & accept the wizard default steps to install PowerSuite 1
4. Start PowerSuite and establish connection Select “Start > All Programs > Eltek > PowerSuite”. On the toolbar, click “Connect” button. On the Connection dialogue box, click the “Connect” button
4
120Ω
Minipack DC Power System
End-of-Line Resistor
End-of-LineResistor
120Ω
CAN bus(twisted-pair internal CAT5 cable)
USB A-B cable(standard)
1
02 n01
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 14
External AC Fuses ⎯ Recommended Rating The site’s AC supply quality is of great importance. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.
Mains Feeds versus Rectifier ID Mains Monitoring The Minipack system is fed with 3 One-phase 230VAC Mains input circuits. Each input circuit is internally connected to feed 2 rectifiers, in such a pattern that loads the 3 circuits evenly.
Plug-and-Play Rectifiers versus Mains Monitoring
When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller assigns the next available ID number to the rectifier, starting with “01”.
When a previously installed (hot plugged) Minipack rectifier is inserted in a power shelf, the Smartpack controller “recognizes” the module, and assigns the same ID to the rectifier. In other words, the controller and the rectifier “remember” the assigned ID number, even after removing and reinserting the rectifier in the shelf.
To achieve a more controlled ID assignment, you should always insert & hot-plug new Minipack rectifiers in the power shelf, one module at a time, in following shelf position order: 1, 3, 5 and 2, 4, 6.
This position-versus-ID number relationship is very important for the correct monitoring of the mains circuit, as the Smartpack controller always uses rectifier ID01, 02 and 03 to monitor the Mains Feed 1, 2 and 3 respectively. If these rectifiers malfunction, rectifier ID 04, 05 and 06 will automatically take over.
For example: accidentally inserting a rectifier with ID02 in a power shelf position internally connected to mains feed 1, will cause the controller to monitor mains feed 1 “thinking“ it monitors mains feed 2.
Miscellaneous AC Mains
Position # 1 2 3 4 5 6 ID # 01 04 02 05 03 06
Mains Feed 1One-phase, 230VAC
N(L2) 230VAC
AC Mains
L(L1) 01 02
Mains Feed 2One-phase, 230VAC
N(L2)
230VAC
AC Mains
L(L1)
03 04
Mains Feed 3One-phase, 230VAC
N(L2) 230VAC
AC Mains
L(L1) 05 06
Distribution of Minipack rectifiers (ID #) on the 3 AC Mains Input Circuits
01
Mai
ns F
eed
2 M
ains
Fee
d 1
Mai
ns F
eed
3
02 03
Minipack System
Position 6
ID number (Assigned CAN bus address)
04 05 06
Position 1
205V
AC
In
puts
AC Mains No of Current Max. (A) Ext. Fuse Type Rectifiers per Input Type
230VAC1 phas
4 17.5 20A-C
626.3 32A-C
AC Mains No of Current Max. (A) Ext. Fuse Type Rectifiers per Input Type
230VAC1 phas
4 19.4 20A-C
629.5 32A-C
Minipack Rectifiers 48 VDC, 800W
Each mains input feeds 2 rectifiers
Note: The recommendations ap-ply for use of Thermal mag-netic circuit breaker, type Siemens 5SX or 5SY se-ries, MG C60H series or similar. For more informa-tion regarding External AC fuses and other types of fuses, please read the arti-cle 2024398 on the CD, 356808.CD3. 18
5VA
C
Inpu
ts
Use the recommenda-tions in the 205VAC ta-ble, if you are sure the available AC mains voltage will not drop below 205VAC.
OR If you are unsure ⎯ or know that the voltage may drop below 205VAC ⎯ use the 185VAC table recom-mendations.
Doc 2024398, v1
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 15
Battery Symmetry Connections Connections Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors CON4 and CON3), enabling symmetry measurement of:
• 8 battery strings using the Mid-Point Measurement Method
• 4 battery strings using the more accurate Double Mid-Point Measurement Method
• 2 battery strings using the even more accurate Block Measurement Method
You can implement any of these methods using one or two Battery Connection Kits (see the illustration next page) and the appropriate number of Battery Symmetry Kits, which contain a single cable strand with suitable cable eyes, etc.
Battery Terminology
Battery Block, Battery String and Battery Bank
48V Battery Bank
Battery String #1 (48V)Batt.
Battery Block (12V)
Battery String #2 (48V)
Battery Symmetry Mid-point Measurement
One measurement per string
—(-48V) Outer
Terminal+
0V Outer Terminal
Intercell Links
2-1 X:****
Sym
met
ry 1
+-
Card, Art. 200576 Serial Switches
Set all 4 switches OFF (up)
Block1
- + + - +B+−
−(From
Notice that, if you open the serial switches in card, Art.200576 ⎯ setting all to OFF (up) ⎯ you have to connect the+ and – wires of every symmetry input.
Battery Symmetry Block Measurement
Four measurements per string (Serial measurement)
—(-48V) Outer
Terminal+
0V OuterTerminal
Intercell Links
X:****
Block1
- + + - + -+-
Block4 Block3
Card, Art. 200576Serial Switches
Set all 4 switches ON (down)
7
Sym
met
ry 4
+
2-1
Sym
met
ry 1
+-
5
Sym
met
ry 3
+
3
Sym
met
ry 2
+
Battery Symmetry Double-point Measurement
Two measurements per string, from the middle to the outer terminals
—(-48V) Outer
Terminal+
0V Outer Terminal
Intercell Links
X:****Card, Art. 200576 Serial Switches
Set all 4 switches ON
(down)
3
Sym
met
ry 2
+
2-1
Sym
met
ry 1
+-
Block1
- + + - +- + -
Block4 Block3
Bat
t. S
ymm
etry
Kit,
Art.
200
830
Cable Eyes
Sin
gle
Cab
le S
trand
Battery Monitoring Miscellaneous
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 16
Battery Interface Card ~ Terminals & Pin-out The Smartpack controller’s battery monitoring signals are accessible on D-Sub connectors CON4 and CON3, on the controller’s rear panel.
Using the Battery Connection Kit ⎯ which consists of a Battery Interface Card (Art. 200576) and a standard 15 pins D-Sub cable ⎯ you can make the signals on CON4 accessible at any suitable location inside your system, e.g. near the battery blocks.
When extra battery monitoring signals are required, you can use an extra Battery Connection Kit connected to the controller’s CON3.
For detailed information about the card’s pin-out location and terminal block connections, see the figures in this section.
For temperature monitoring of the battery compartment, we recommend the use of the Temperature Sense Kit, instead of connecting the sensor cable directly to the terminals, pin 9-10.
The Temperature Sense Kit is connected to the Battery Interface Card (Art. 200576), or directly to the controller’s CON3 or CON4, if unused.
15 pins D-Sub cable
Card Art.200576
Battery Connection Kit
Temp. sensor
Temp. Sensor cable
Temperature Sense Kit
In
1.5 mm2, max.wire section
Battery Connections (Internal) Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
(Internal Connections)
4 3 2 1
5
9 8 7 6
10
14 13 12 11
X4Batt. Symmetry 1 +
−+−+−+−
Batt. Symmetry 2
Batt. Symmetry 3
Batt. Symmetry 4
(Fro
m in
tern
al
batte
ries)
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperaturesensor
+−Temperature Sense 1
(NA)
(NA)
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperaturesensor
15-pins D-Sub female
(Alternative use of Temp. Sense Kit, instead of connecting to X4: 9-10)
Temperature Sense 1
X**/X*15-pins D-Sub male
1 5
11 15
Card Art.200576 To
Sm
artp
ack,
CO
N4
CON3A or CON4A 15-pins D-Sub female
1 11
5 15
In
1.5 mm2, max.wire section
Battery Connections (Internal) Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
(Internal Connections)
4 3 2 1
5
9 8 7 6
10
14 13 12 11
X3+−+−+−+−
(Fro
m in
tern
al
batte
ries)
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperaturesensor
+−
(Fro
m a
rea
with
in
tern
al b
atte
ries)
Temperaturesensor
15-pins D-Sub female
(Alternative use of Temp. Sense Kit, instead of connecting to X3: 9-10)
Temperature Sense 2
X**/X*15-pins D-Sub male
1 5
11 15
Card Art.200576
To S
mar
tpac
k,C
ON
3
CON3A or CON4A 15-pins D-Sub female
1 11
5 15
The Temperature Sense Kits may also be connected directly to the Smartpack controller’s CON3 or CON4, if these connectors are unused.
Batt. Symmetry 5
Batt. Symmetry 6
Batt. Symmetry 7
Batt. Symmetry 8
Temperature Sense 2
Batt Current 2
Batt Fuse Fail 2
Miscellaneous Battery Monitoring
Battery Interface Card, Art. 200576 14
1
Serial Switch
For Temp. Sense Kit CON3A or CON4A
X3/X4X**/X*
1
Terminals & Pin-out Location CON3
CON2
CON4 CON5
CON1
PCB 200576
PCB 200576
Smartpack
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 17
Standard Alarm Relays & Digital Inputs Connections
The alarm outputs in Minipack systems use the Fail-Safe Operation Mode (relay coils energized in the system’s normal operation mode). When the system is in alarm mode, the alarm relay coils are de-energized.
In order to implement monitored fail-safe digital inputs circuits, the external relay coil must be energized and the contact closed in the system’s normal mode of operation. See the figures.
Alarm Interface Card ~ Terminals & Pin-out
The Smartpack controller’s alarm and digital input monitoring signals are accessible from the controller’s rear panel, on mini power connector CON1 (2 outputs & 2 inputs).
Using the Alarm Interface Card (Art. 218470) plugged to Smartpack’s CON1, you can make the signals on CON1 accessible on terminal block X1.
For detailed information about the card’s pin-out location and terminal block connections, see the figures in this section.
Standard Relays & Digital Inputs
Correct Use of Digital Inputs (example)
Normal ModeExternal Relay Y(Energized coil)
+—
Digital Input X (Normal mode)
Alarm ModeExternal Relay Y
(De-energized coil) +
—Digital Input X (Activated)
Minipack PS System
Correct Use of Alarm Outputs (example) Minipack PS System
—
+
NC
NOCom
Normal ModeRelay X
(Energized coil)
+—
Alarm Mode
Relay X(De-energized coil) NC
NOCom
Alarms & Monitoring Miscellaneous
Terminals & Pin-out Location
CON3CAN1
Smartpack
CON2
CON4CON5
CON1
10
1X1
Card neck for cable fastening
Alarm Outputs & Digital Inputs Card Art. 218470
Card 218470
4 3 2 1
5
9 8 7 6
10
X1
(Customer Connections)
Input Circuit 1
Input Circuit 2
Alarm Circuit 1
Alarm Circuit 2
OutIn
(To
and
from
ex
tern
al e
quip
men
t)
1.5 mm2, max.wire section
Relay 1Common Alarm
+−
NOCOM
NC
NOCOM
NC
+−
Digital Input 1
Digital Input 2
Alarm Outputs & Digital InputsVoltage free relay outputs and Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
To S
mar
tpac
k,
CO
N1
Card Art.218470To CON1
1
10X1
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 18
Alarm Interface Card, Extd. ~ Terminals & Pin-out
Additional alarm and digital input monitoring signals are accessible from the Smartpack controller’s rear panel, on D-Sub connector CON2 (4 outputs & 4 inputs).
Using the Alarm Interface Card, Extended (Art. 218473) plugged to Smartpack’s CON2, you can make the signals on CON2 accessible on terminal blocks X2A and X2B.
For detailed information about the card’s pin-out location and terminal block connections, see the figures in this section.
Miscellaneous Alarms & Monitoring
(Customer Connections)
OutIn
1.5 mm2, max.wire section
Alarm Outputs & Digital Inputs, ExtendedVoltage free relay outputs and Configurable monitoring digital inputs
FUNCTION SIGNAL PIN-OUT
Input Circuit 3
Alarm Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6
Alarm Circuit 4
Alarm Circuit 5
Alarm Circuit 6
X2A
4321
5
9876
10
+−
+−
+−
+−
Digital Input 3
Digital Input 4
Digital Input 5
Digital Input 6
(To
exte
rnal
equ
ipm
ent)
(Fro
m e
xter
nal e
quip
men
t)
NOCOM
NC
NOCOM
NC
NOCOM
NC
NOCOM
NC
Relay 3Fuse Alarm
Load & Battery
Relay 5Low Battery Alarm
Relay 6Rectifier Alarm
Relay 4High Battery Alarm
To S
mar
tpac
k,
CO
N2
14131211
151617181920
X2B
Card Art. 218473To CON2
1
10
X2A
11
20X2B
Terminals & Pin-out Location
CON3CAN1
Smartpack
CON2
CON4CON5
CON1
Card 218473
1 10
X2A
1120X2B
Card neck for cable fastening
Alarm Outputs & Digital Inputs Card, ExtendedArt. 218473
(NA for Smartpack Ethernet option)
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 19
System Interface Card ~ Terminals & Pin-out Minipack systems are shipped from factory with the CON5 signals already connected.
Some of the Smartpack controller’s internal system signals are accessible on D-Sub connector CON5, on the controller’s rear panel.
Using a standard 15 pins D-Sub cable, the signals on CON5 are routed to the Minipack system’s main circuit board. See the figure in this section for an overview of the signals on CON5,
LVD Latching Contactors Connections
Minipack systems’ LVBD and LVLD functionality (Low Voltage Battery Disconnect; LV Load Disconnect) is implemented by the Smartpack controlling magnetically latching contactors.
The coil of latching contactors is not energized in any state. They change state from open to close, or vice versa, when a reversed pulse is applied to the coil.
Internal Connections Miscellaneous
SystemConnections
CON515 pins D-Sub (female)
LVD1A +/− 1LVD2A +/− 2
LVD Common +/− 3System Voltage + 4System Voltage − 5a*Batt Current 1 + 6b*Batt Current 1 − 7
NC 8Load Fuse Fail 1 + 9
Power Input + 10Load Fuse Fail 1 − 11
c*Batt Fuse Fail 1 + 12d*Batt Fuse Fail 1 − 13
System Reference 14Power Input − 15
FUNCTION SIGNALPIN-OUT
5 1
15 11CON5
(female; orange)
Smartpackcontroller
Latching Contactors, LVD1 & LVD2
Correct Use of Latching Contactors (example)
A latching contactor changes state only when a reversed pulse voltage is applied to its coil
+ Pulse
ON
- Pulse
OFF
10
89
X:*****
+
—
LVD1A
LVD2A LVD Common
Smartpack controller
Minipack PS System (internal)
11
LVD Common
Latching Contactor LVD2
Y
X
Latching Contactor LVD1
Y
X
Minipack Main PCB
Latching Contactor
Y
X
Bidirectional diode
Warning! The bidirectionaldiode must always bemounted to avoid dam-aging the controller.
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 20
Rev
.D
raw
. N
o.
Pag
eF
orm
at
Blo
ck D
iag
ram
Min
ipa
ck 4
8V
dc
3,2
kW
Consu
ltan
t
Rep
lace
for
Rep
lace
d b
y
Co
py
rig
ht
A/S
Elt
ek.
All
rig
hts
res
erved
Eltek
2023227
2007
-01-0
3
SH
WIN
OC
R 0
7010
3N
A2
Sy
m.
Dat
e/S
ign
Alt
erat
ion
A3
Pro
ject
ion
Sca
leA
pp
roved
FR
NO
NO
Dra
w
OR
SK
NO
Des
ign
OR
SK
NO
Dat
e
07 D
ec. 2006
21 o
f 1
--
-
YX
LV
BD
-F
B1
-F
Bn
Battery Strings
Circuits -48Vdc
0V
Customer
connections
Customer
connections
Load circuits -48Vdc
DC
Ea
rth (
TE
)
Customer connections
1:
Op
tio
nal9 p
inD
-su
b R
S23
2 c
onn
ectio
n.
Can b
e m
ounte
d in fro
nt
or
on r
ear
sid
e o
f
Sm
art
pack. R
ep
laces ”
Ext.
Batt
ery
Co
nn
ecti
on
s”
when
mounte
d o
n th
ere
ar
sid
e o
fS
mart
pa
ck
2:
Op
tio
nal W
eb/S
NM
P (
EN
ET
) conne
ction
.
Repla
ces
”E
xt.
Ala
rm I/O
Co
nn
ecti
on
s”
Custo
mer
connections
CO
N5
Syste
m C
on
nec
tio
ns
CO
N4
Ba
ttery
co
nn
ecti
on
s
CO
N2
Ext.
Ala
rm I/O
Co
nn
ec
tio
ns
2: O
ptio
nal: W
eb/S
NM
P (
EN
ET
)
CO
N1
Ala
rm I/O
Co
nn
ecti
on
s
US
B 2
.0 t
yp
e B
po
rt
(PC
con
nection)
9
1:
Optiona
l:R
S2
32
Sm
art
pa
ck
monitorin
g a
nd
contr
ol u
nit
10
CA
N p
ort
15
15
9/1
5C
ON
3
Ext.
Batt
ery
co
nn
ec
tio
ns
1: O
ptio
nal: R
S 2
32
8/2
6
CA
N p
ort
US
B
Re
ar
conne
ctio
ns
Fro
nt con
nection
s
88
See Std.Documentation
356804.10x
See Std.Documentation
356804.10x
NA for Smartpack Web/SNMP
NA
for
Sm
art
pack R
S232
re
ar
1 2 3 4 5 6 7 8 9
10
*X3
Batt
ery
Co
nn
ecti
on
s
Co
n 3
A*
Ba
ttery
Co
nn
ec
tio
ns
Batt
ery
Co
nnections
2005
76
15
SE
RIA
L
DIF
F
S1
+ -B
att.
Sym
me
try
5
+ -B
att.
Sym
me
try
6
+ -B
att.
Sym
me
try
7
+ -B
att.
Sym
me
try
8
+ -T
em
pe
ratu
re S
ense
2
12
13
14
+ - + -
11
Batt
ery
Curr
en
t2
Ba
tte
ry F
use
Fail
2
15
*Co
n 7
Te
mp
se
ns
e
1 2 3 4 5 6 7 8 9
10
*X4
Ba
ttery
Co
nn
ec
tio
ns
Co
n 4
A*
Batt
ery
Co
nn
ecti
on
s
Ba
ttery
Con
nections
20057
6
15
SE
RIA
L
DIF
F
S1
+ -B
att. S
ym
me
try
1
+ -B
att. S
ym
me
try
2
+ -B
att. S
ym
me
try
3
+ -B
att. S
ym
me
try
4
+ -T
em
pera
ture
Se
nse 1
12
13
14
+ - + -
11
No
t C
onn
ecte
d
No
t C
onn
ecte
d
15
*Co
n 6
Tem
p s
en
se
CO
M
NO
NC
1
Ala
rm O
utp
uts
an
d
Dig
ital In
puts
218470
10
2 3 4 5 6 7 8 9 10
+ - + -
Dig
ita
l In
pu
t1
Dig
ita
l In
pu
t2
Rela
y 1
CO
M
NO
NC
Re
lay 2
Co
n 1
A*
Ala
rm I
/O
Co
nn
ec
tio
ns
X1*
Ala
rm I
/O C
on
ne
cti
on
s
Ala
rm O
utp
uts
and
Dig
ital In
puts
218473
26
1 2 3 4 5 6 7 8 9 10
11
12
13
14
15
16
17
18
19
20
+ -D
igita
l In
pu
t3
+ -D
igita
l In
pu
t4
+ -D
igita
l In
pu
t5
+ -D
igita
l In
pu
t6
CO
M
NO
NC
Rela
y 3
CO
M
NO
NC
Rela
y 4
CO
M
NO
NC
Rela
y 5
CO
M
NO
NC
Rela
y 6
Co
n 2
A*
Ext.
Ala
rm I/O
Co
nn
ec
tio
ns
X2A
*
Ext.
Ala
rm I/O
Co
nn
ecti
on
s
X2B
*
Ext.
Ala
rm I/O
Co
nn
ecti
on
s
Customer
connections
Mains input
terminals
*T
o b
e la
bele
d
8
pin
1-8
8 7 6 5 4 3 2 1
L1 N L2 N L3 N
PE
PE
2133
33
Un
derw
irin
gM
PB
B 6
pos 3
AC
X5*
Pow
er
outp
ut
+ Y
7
Pow
er
outp
ut – Y
8
Pow
er
mo
dule
1P
E
N L
+ -
Pow
er
mo
dule
2P
E
N L
+ -
Pow
er
mo
dule
3P
E
N L
+ -
Pow
er
mo
dule
4P
E
N L
+ -
CA
N1
Sm
art
pa
ck
Po
wer
-/C
AN
bu
s
Inte
rco
nn
ecti
on
s
217
915
Dis
t board
1 M
inip
ack S
yste
mM
CB
10 p
os loa
d
4 p
os b
att
Co
n5A
*S
mart
pa
ck C
on
nec
tio
n
21
32
13
JP
1JP
2
NEG. DIST.
POS. DIST.
NEG. DIST.
POS. DIST.
15
1 2 3 4
Batt. F
use F
ail
+B
att. F
use F
ail
-LV
D 1
ALV
D C
om
mon
TB
1S
yste
m c
on
ne
cti
on
s
3 4 5 6
X6A
*D
C o
utp
ut
+
7 8 910
SH
1
Y1 P
ow
er
input
+
Y2 P
ow
er
input
-
Y7
Y6
Y5
Y4
Y3Y9
To b
attery
con
tacto
r
To
Dis
t
bo
ard
2
Op
tio
na
l
YX
LV
LD
K1
Y1
2
Y1
8
Y1
9
Y2
0
X7A
*
To b
attery
+
1 2
215792
Dis
t.B
oa
rd2 M
PB
B 1
00A
10pos G
1X
6B
*D
C o
utp
ut
-Y
5 low
pri
load
Y4
Y3 F
use
ala
rm
Y2 h
igh
pri loa
d
Y1
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
Y6
Y7
Y24
Y25
10 9 8 7 6 5 4 3 2 1
2
Rev
.D
raw
. N
o.
Pag
eF
orm
at
Blo
ck D
iag
ram
Min
ipa
ck 4
8V
dc
4,8
kW
Consu
ltan
t
Rep
lace
for
Rep
lace
d b
y
Co
py
rig
ht
A/S
Elt
ek.
All
rig
hts
res
erved
Eltek
2021886
2007
-01-0
3
SH
WIN
OC
R 0
7010
3N
A2
Sy
m.
Dat
e/S
ign
Alt
erat
ion
A3
Pro
ject
ion
Sca
leA
pp
roved
HA
HA
NO
Dra
w
OR
SK
NO
Des
ign
OR
SK
NO
Dat
e
31
oct
.2
00
6
21 o
f 1
--
-
Mains input
connection terminals
YX
LV
BD
-F
B1
-F
B2
Battery Strings
Circuits -48Vdc
0V
Customer
connections
Customer
connections
Load circuits -48Vdc
DC
Ea
rth (
TE
)
Customer connections
213
335
Dis
t board
1 M
inip
ack S
yste
mM
CB
8 p
os load
2 p
os b
att
Co
n5A
*
Sm
art
pa
ck C
on
nec
tio
n
21
32
13
JP
1JP
2
NEG. DIST.
POS. DIST.
NEG. DIST.
POS. DIST.
15
1 2 3 4
Batt. F
use F
ail
+B
att. F
use F
ail
-LV
D 1
ALV
D C
om
mon
TB
1S
yste
m c
on
ne
cti
on
s
1 2 3 4
X6A
*
DC
ou
tpu
t +
5 6 7 8
SH
1
Y1 P
ow
er
input
+
Y2 P
ow
er
input
-
Y7
Y6
Y5
Y4
Y3
X7
A*
To b
att
ery
+ Y
9
To b
attery
con
tacto
r
To
Dis
t
bo
ard
2
Op
tio
na
l
YX
LV
LD
K1
Y8
1:
Op
tio
nal9 p
inD
-su
b R
S23
2 c
onn
ectio
n.
Can b
e m
ounte
d in fro
nt
or
on r
ear
sid
e o
f
Sm
art
pack. R
ep
laces ”
Ext.
Batt
ery
Co
nn
ecti
on
s”
when
mounte
d o
n th
ere
ar
sid
e o
fS
mart
pa
ck
2:
Op
tio
nal W
eb/S
NM
P (
EN
ET
) conne
ction
.
Repla
ces
”E
xt.
Ala
rm I/O
Co
nn
ecti
on
s”
Custo
mer
connections
CO
N5
Syste
m C
on
nec
tio
ns
CO
N4
Ba
ttery
co
nn
ecti
on
s
CO
N2
Ext.
Ala
rm I/O
Co
nn
ec
tio
ns
2: O
ptio
nal: W
eb/S
NM
P (
EN
ET
)
CO
N1
Ala
rm I/O
Co
nn
ecti
on
s
US
B 2
.0 t
yp
e B
po
rt
(PC
con
nection)
9
1:
Optiona
l:R
S2
32
Sm
art
pa
ck
monitorin
g a
nd
contr
ol u
nit
10
CA
N p
ort
15
15
9/1
5C
ON
3
Ext.
Batt
ery
co
nn
ec
tio
ns
1: O
ptio
nal: R
S 2
32
8/2
6
CA
N p
ort
US
B
Re
ar
conne
ctio
ns
Fro
nt con
nection
s
88
Custo
mer
conne
ction
s
See Std.Documentation
356804.10x
See Std.Documentation
356804.10x
NA for Smartpack Web/SNMP
NA
for
Sm
art
pack R
S232
re
ar
1 2 3 4 5 6 7 8 9
10
*X3
Batt
ery
Co
nn
ecti
on
s
Co
n 3
A*
Ba
ttery
Co
nn
ec
tio
ns
Batt
ery
Co
nnections
2005
76
15
SE
RIA
L
DIF
F
S1
+ -B
att.
Sym
me
try
5
+ -B
att.
Sym
me
try
6
+ -B
att.
Sym
me
try
7
+ -B
att.
Sym
me
try
8
+ -T
em
pe
ratu
re S
ense
2
12
13
14
+ - + -
11
Batt
ery
Curr
en
t2
Ba
tte
ry F
use
Fail
2
15
*Co
n 7
Te
mp
se
ns
e
1 2 3 4 5 6 7 8 9
10
*X4
Ba
ttery
Co
nn
ec
tio
ns
Co
n 4
A*
Batt
ery
Co
nn
ecti
on
s
Ba
ttery
Con
nections
20057
6
15
SE
RIA
L
DIF
F
S1
+ -B
att. S
ym
me
try
1
+ -B
att. S
ym
me
try
2
+ -B
att. S
ym
me
try
3
+ -B
att. S
ym
me
try
4
+ -T
em
pera
ture
Se
nse 1
12
13
14
+ - + -
11
No
t C
onn
ecte
d
No
t C
onn
ecte
d
15
*Co
n 6
Tem
p s
en
se
CO
M
NO
NC
1
Ala
rm O
utp
uts
an
d
Dig
ital In
puts
218470
10
2 3 4 5 6 7 8 9 10
+ - + -
Dig
ita
l In
pu
t1
Dig
ita
l In
pu
t2
Rela
y 1
CO
M
NO
NC
Re
lay 2
Co
n 1
A*
Ala
rm I
/O
Co
nn
ec
tio
ns
X1*
Ala
rm I
/O C
on
ne
cti
on
s
Ala
rm O
utp
uts
and
Dig
ital In
puts
218473
26
1 2 3 4 5 6 7 8 9 10
11
12
13
14
15
16
17
18
19
20
+ -D
igita
l In
pu
t3
+ -D
igita
l In
pu
t4
+ -D
igita
l In
pu
t5
+ -D
igita
l In
pu
t6
CO
M
NO
NC
Rela
y 3
CO
M
NO
NC
Rela
y 4
CO
M
NO
NC
Rela
y 5
CO
M
NO
NC
Rela
y 6
Co
n 2
A*
Ext.
Ala
rm I/O
Co
nn
ec
tio
ns
X2A
*
Ext.
Ala
rm I/O
Co
nn
ecti
on
s
X2B
*
Ext.
Ala
rm I/O
Co
nn
ecti
on
s
8
pin
1-8
8 7 6 5 4 3 2 1
L1
N1
L2
N2
L3
N3
PE
PE
2133
33
Un
derw
irin
gM
PB
B 6
pos 3
AC
CA
N1
Sm
art
pa
ck
Po
wer
-/C
AN
bu
s
Inte
rco
nn
ecti
on
s
X5*
Pow
er
outp
ut
+ Y
7
Pow
er
outp
ut – Y
8
Pow
er
mo
dule
1P
E
N L
+ -
Pow
er
mo
dule
2P
E
N L
+ -
Pow
er
mo
dule
3P
E
N L
+ -
Pow
er
mo
dule
4P
E
N L
+ -
Pow
er
mo
dule
5P
E
N L
+ -
Pow
er
mo
dule
6P
E
N L
+ -
Customer
connections
Mains input
terminals
*T
o b
e la
bele
d
213
336
Dis
t.B
oard
2 M
PB
B 1
00
A
8pos G
1X
6B
*D
C o
utp
ut
-Y
5lo
w p
ri load
Y4
Y3 F
use
ala
rm
Y2 h
igh
pri
lo
ad
Y1
F1
F2
F3
F4
F5
F6
F7
F8
Y6
Y7
Y24
8 7 6 5 4 3 2 1
2
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 23
www.eltekvalere.com
Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101
Eltek ValereGråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
This product is CE marked andcomplies with all current requirementsfor relevant standards and directives.
Copyright © Eltek Valere, 2007This document may be changed without notice
Art. No. 356808.103, Issue 1.1ev, 2007 MarPublished 2007-03-19