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User's Guide

Smartpack2 Basic Controller

Monitoring and Control Units


Powerpack, Flatpack2 & Minipack
DC Power Supply Systems
.
350021.013

1 Introduction

Information in this document is subject to change without notice and does not represent a
commitment on the part of Eltek Valere.
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
explicit written permission of Eltek Valere.
Copyright : Eltek Valere, 2010

NS-EN ISO 14001 Certified

NS-EN ISO 9001 Certified

Certificate No:
11276-2007-AE-NOR-NA

Certificate No:
4072-2007-AQ-NOR-NA

Safety Precautions

The equipment described in this guide must only be operated by Eltek Valere
personnel or by persons who have attended a suitable Eltek Valere training course

The equipment represents an energy hazard and failure to observe this could cause
terminal injury and invalidate our warranty

There are hazardous voltages inside the power system. As the modules incorporate
large charged capacitors, it is dangerous to work inside the system even if the
mains supply is disconnected

Products into which our components are incorporated have to comply with a
number of requirements. Installation is to be in accordance with the
recommendations herein

Please read the guide carefully before using the equipment

Part number for Smartpack2 Basic Controller:

350021.013

242100.501

Issue 1.0, 2010 Jun

Published 2010-10-06
mafe

User's Guide Smartpack2 Basic Controller

350021.013, Issue 1.0, 2010 Jun

1 Introduction

Table of Contents
1.

Introduction ................................................................................. 4
About this Guide................................................................................................4
System Diagram Flatpack2 Power System w/SP2 ....................................... 4

2.

The Smartpack2 Basic Controller .............................................. 5


Key Features .....................................................................................................5

Block Diagram ............................................................................................... 5


Location of Terminals, Ports, LEDs ............................................................ 6
Installation of Smartpack2 Basic Controller ............................................... 7
Fastening / Unfastening the Controller .............................................................. 7
Connection Drawing ..........................................................................................8
CAN Bus Termination .......................................................................................9

Configuration .............................................................................................. 10
CAN Bus Addressing ......................................................................................10
System Configuration ......................................................................................11

Technical Specifications ............................................................................ 12


Ordering Information ......................................................................................12

Firmware Upgrade Controller .................................................................... 13

User's Guide Smartpack2 Basic Controller

350021.013, Issue 1.0, 2010 Jun

1 Introduction

1. Introduction
The Smartpack2 Basic controllers are powerful and cost-effective modules used as slave
controllers in Smartpack2-based power systems.

About this Guide


This booklet describes the Smartpack2 Basic controllers building blocks, external
connections and technical specifications.
For detailed functionality description, browse and search through the Functionality
Description Help file (or 350020.073) or WebPower Online Help file. The user guide for
the Smartpack2 Master controller (Doc 350020.013) might also be helpful.

System Diagram Flatpack2 Power System w/SP2


The generic Smartpack2 (SP2) distributed control system used in Flatpack2 PS systems
monitors and controls the whole system, and consists of the Smartpack2 Master
controller, the Smartpack2 Basic controller and the I/O Monitor2 CAN node.
The Smartpack2 Master serves as the local user interface between you and the system. The
Smartpack2 Basic monitors and controls the power systems internal wiring and supplies
the CAN bus with power. The I/O Monitor2 CAN node provides the system with input
monitoring and output controlling signals. The WebPower application enables system
configuration via a standard web browser.
WebPower
(web-based
user interface)

Internet

Alarm Outputs NC-C-NO

Ethernet
cable

Config. Inputs
Smartpack2
Master Controller

Flatpack2
System

I/O Monitor2
CAN node

Smartpack2
Basic Controller

Fuse Alarm

CAN Bus
Flatpack2 HE
rectifiers

LVLD
Telecom and
Industrial
equipment

AC Fuses,
external
(230VAC or
400VAC

AC Supply
(Single- or
three-phase)

AC mains
supply
selector

LVBD
Temp.
Sensors

Battery string #1

Load Fuses
& MCBs
DC
Distribution

Battery
Fuses

DC Supply
(24V, 48V
or 60V)

Figure 1 Typical Flatpack2 DC power supply system for telecom and industrial equipment. The system is fed from
an external AC mains supply, and consists of rectifiers in power shelves, master and basic controllers and
DC distribution unit. Battery banks, LVD contactors, etc. are typically also a part of the system

User's Guide Smartpack2 Basic Controller

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2 The Smartpack2 Basic Controller

2. The Smartpack2 Basic Controller


The Smartpack2 Basic controllers are powerful modules used as slave controllers in the
distributed control system of Smartpack2-based power supply systems.
They are developed for monitoring and controlling of the power systems internal
functionality and to supply distributed power for connected CAN nodes. They can also
operate in stand-alone mode, maintaining normal operation of the system, thus providing
redundancy and improving system reliability.

Key Features
A wide range of features are implemented in the Smartpack2 Basic controller:
LEDs for local visual alarming (Major, Minor, Power ON)
Supplies distributed power for CAN bus nodes
2 sense inputs for internal monitoring, 1 voltage sense and 1 current sense
2 configurable inputs for load and battery fuse monitoring
3 configurable multipurpose inputs (temperature, digital inputs or analog signals)
3 LVD control outputs, configurable for latching and non-latching contactors
Up to 8 Smartpack2 Basic controllers may be connected the CAN bus
CAN bus addressing via DIP switches
Configuration via the master controllers front keys or WebPower on a standard
web browser
Firmware upgrade via the CAN bus (page 13)
Read also chapter Technical Specifications, page 12, for more details.

Block Diagram
Smartpack2 Basic Controller
The main processor is the heart of the
system. Executes measurements and
analogue to digital conversions

0
1
P

CAN Address
via DIP switches (4)

Flash
Flash & EEPROM Memory
stores the main program and
dynamic data

24 / 48 / 60VDC Input supply

Power supply
Power supply
with regulated supply voltages for internal use

(DC/DC, Internal)

Inputs

EEPROM

LVD Control
ON
OFF

Output signals (control)


for LVD latching and not-latching
contactors (3)

V
Voltage Sense Input
24V, 48V, 60V, 110V systems (1)
A
Current Sense Input
20mV to 60mV shunt (1)
Load Fuse Sense Input
Open/Close, Pull-Up/Down, Diode Matrix (1)

CAN
Power Bus

LEDs

CAN port w/Distributed power


for communication with rectifiers and CAN nodes
Supplies CAN nodes with power
Front LED lamps
green, amber and red (3)

Battery Fuse Sense Input


Open/Close, Pull-Up/Down, Diode Matrix (1)
C

Figure 2 Block diagram


Smartpack2 Basic controller

Temperature Sense Inputs


Battery temp via external probe (3)
Configurable:
(Open/Close, Pull-Up/Down, Diode Matrix)

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Location of Terminals, Ports, LEDs


For a complete list of signals, pin-out, etc., refer to chapter Connection Drawing, page 8.
CAN port 1&2
Electrically identical

DIP switches

1+

CAN ID address

System Connections
Voltage, current and fuse inputs (8 pins)

1+

Temp Sense

DIP switch #1

Configurable Inputs (6 pins)

Warning
LED Lamp (amber)

Power
Alarm

LED Lamp (green)

LED Lamp (red)

1+

LVD
Control Outputs (6 pins)

Power

Smartpack2 Basic
Controller

Input Supply (3 pins)

Figure 3 Location of pluggable terminal blocks, DIP switches, CAN ports and LED indicators in the
Smartpack2 Basic controller. (The pluggable terminals may be black or green)

CAN port 1 and 2 are electrically identical, and are used to enable connection of the CAN
bus incoming and outgoing CAT5 cables, or the RJ45 CAN bus termination plug.
LED
Indicator
Power

Warning

Alarm

Illumination
Status
OFF
ON green
Flashing Green
OFF
ON amber
Flashing amber
OFF
ON red
Flashing red

Description
The controller has NO supply
Supply healthy
Distributed Power Fault
No Warning
Warning (Minor alarm, non-critical alarm)
Communications Fault
No Alarm
Alarm (Major Alarm, critical alarm)
SW Fault / Boot Loader Mode

Table 1 Description of the Smartpack2 Basic controllers LED illumination status

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2 The Smartpack2 Basic Controller

Installation of Smartpack2 Basic Controller


The Smartpack2 Basic controller is always factory installed in all Flatpack2 PS systems
that implement the Smartpack2 Distributed Control System.
If you need to replace the installed Smartpack2 Basic controller with a new one, always
follow the precautions relevant for installation, commissioning and general handling of the
Smartpack and Smartpack2-based DC power systems.

!
Qualified
personnel

CAUTION: For safety reasons, the commissioning and configuration of the equipment is
only to be performed by Eltek Valeres personnel or by authorized and qualified persons;
otherwise the warranty may be invalidated.
Please, read the user documentation carefully before installing and using the equipment,
as installation and operation is to be performed as described in it.

You need standard installation tools and equipment used by an authorized electrician.
NOTE: All tools must be insulated.

Fastening / Unfastening the Controller


You fasten the Smartpack2 Basic controller using
two dedicated fixing tabs (A)(B) inside the DC
power cabinet or subassembly, and a slot (C) and
screw hole (D) on the controller, refer to Figure 4,
page 7.
To unfasten the Smartpack2 Basic controller from
the power system, switch OFF the power system, and

Smartpack2
Basic controller

Power is OFF!
1. Loosen the top fixing tab screw from the
screw hole (D)

cw
Smartpack2
Basic controller

2. Lift the controller carefully upwards,


(the slot (C) disengage from the lower
fixing tab (B)

I/O system
internal cables

4
3

3. Unplug the cables from the CAN bus


sockets

CAN sockets

Flatpack2 4U-Distr.
Subassembly

4. Disconnect the pluggable I/O terminals by


pulling them out
To fasten a new Smartpack2 Basic controller to the
power system, first configure its CAN ID address
and then, in the inverse order, carry out the opposite
as described above (4, 3, 2, 1).
DIN rail mounting with dedicated plate is also
possible.
Figure 4 Smartpack2 Basic controllers location in a cabinet or
subassembly. (The pluggable terminals may be black or
green)

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Connection Drawing
Use this drawing as a connection reference for all cabling. You find the exact location of
connection terminals, plugs and DIP switches, by referring to chapter Location of
Terminals, Ports, LEDs, page 6.
The LVD control outputs may be configured for both latching and non-latching contactors
using the WebPower via a standard web browser. LVD Output 1 is usually configured as
LVBD, and output 2 and 3 as LVLD1 and LVLD2.

Connections ~ Smartpack2 Basic Controller


System sense inputs and LVD control outputs

X:*
Voltage Sense Input 1
Battery Fuse Input 1
Load Fuse Input 1
Current Sense Input 1
(System Reference)

1
2
3
4
5
6
7
8

To System Voltage
To Battery Fuse
To Load Fuses
To Current Shunt ^

Configurable
Inputs

X:**
Temp Sense 1
Temp Sense 2
Temp Sense 3

Temperature
Sensor 1

1
2
3
4
5
6

Temperature
Sensor 2

Temperature
Sensor 3

RJ45, 8 pins
DIP
Switches

LVD Control
Outputs

CAN
port 1&2

LVD Output 1
LVD Output 2
LVD Output 3

1
3
4

1
2
3
4
5
6

To LVD Contator 1
To LVD Contator 2
To LVD Contator 3

X:***

Power
Input

To next
CAN bus node

Or
RJ45 CAN bus termination plug, if the I/O
Monitor2 is the last node in the CAN bus

X:***

(From internal equipment)

Smartpack2 Basic
controller

SIGNAL PIN-OUT

(From area with internal


batteries)

System Connections

From previous
CAN bus node

FUNCTION

Battery +
Battery +/
Battery

+
C

1
2
3

Power Input
2

Max. 1.5 mm ,
(Internal Connections) (14AWG) wire section
Out

In

Figure 5 Connection Drawing Smartpack2 Basic controller

Read also chapter Technical Specifications page 12, for more details.

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CAN Bus Termination


To ensure a correct bus communication and avoid data reflection, you must always
terminate the CAN bus with two 120 resistors, one at each end of the line (60 bus
impedance).
Smartpack and Smartpack2-based DC power systems are shipped from factory with the
CAN bus already terminated with 120 resistors. The CAN bus termination is
implemented with a special RJ45 plug with built-in 120 end-of-line resistor.
WebPower
(web-based user interface)

Ethernet cable (LAN)


Smartpack2
Master Controller

120

Smartpack2
Basic Controller

End-of-Line
Resistor
Flatpack2 HE
Rectifiers

CAN bus
(twisted-pair CAT5 cable)

01
02
Internal System Monitoring

ID Number
81

120

82

End-of-Line
Resistor

I/O Monitor2

I/O Monitor2

Alarm Outputs NC-C-NO


Config. Inputs

Alarm Outputs NC-C-NO


Config. Inputs

Flatpack2
DC Power System

Figure 6 Example of CAN bus addressing and termination in a Flatpack2 power system with
Smartpack2-based control system and two I/O Monitor2 nodes connected the CAN bus

When connecting more CAN nodes to the bus, you have to remove the CAN bus
termination plug from one of the CAN bus ends, and plug it in one of the CAN ports on the
last connected CAN node.

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Configuration
By the default, Smartpack2-based power systems are shipped from factory with one or
several Smartpack2 Basic controllers correctly installed and configured inside the power
system.

CAN Bus Addressing


The power systems master controller dynamically software-assigns ID numbers to
rectifiers. The master controller registers the rectifiers ID numbers or CAN bus address
(01, 02) together with their Serial Numbers (software assignment).
Other control units make use of DIP switches for configuring their unique CAN bus ID
number (hardware assignment).
The Smartpack2 Basic controllers ID numbers (1, 28) are assigned by DIP switches on
the controllers top.
A maximum of 8 Smartpack2 Basic controllers may be connected to the CAN bus.
Smartpack2 Basic controllers
DIP switch configuration

ID <1>
(All switches OFF)

Smartpack2 Basic ID
DIP Switch Position
Controller**
#
1 2 3 4
1st Controller
1
OFFOFFOFFOFF
2nd Controller
2
ON OFFOFFOFF
3rd Controller
3
OFF ONOFFOFF
4th Controller
4
ON ONOFFOFF
5th Controller
5
OFFOFFON OFF
6th Controller
6
ON OFF ONOFF
7th Controller
7
OFFON ON OFF
8th Controller
8
ON ON ONOFF
** The DIP switch positions apply also to
Smartpack controllers, but do not apply to
Smartpack2 Master controllers

Terminal Blocks
Note:
The controllers ID #
corresponds to the
DIP switchs binary
value plus 1

Table 2 Smartpack2 Basic controllers DIP switch addressing

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2 The Smartpack2 Basic Controller

System Configuration
By the default, Smartpack2 Basic controllers are shipped from factory correctly configured
inside the power system.
The Eltek Valere DC power supply systems functionality represents a vast set of
functions, characteristics or capabilities implemented in the hardware and software of
the controllers, control units and nodes connected to the systems CAN bus.
You can use following types of user interfaces to access the functions and parameters:

The controllers front panel keypad


using software menus and submenu options

A standard web browser


to access the WebPower firmware, a platform-independent graphical user
interface (GUI) built-in the controllers

The PowerSuite program


A PC application run on computers using MS Windows operating systems

All the mentioned functions, characteristics and parameters are fully configurable, and are
organized in following system-oriented logical groups:

Power System
Mains
Generator
Rectifiers
Battery
Load
Control System

Also, these functions, characteristics and parameters are presented in following taskoriented logical groups:
1. System Status
2. System Configuration
3. Alarm Configuration
4. Commands
5. Logs and Reports
6. Statistics
7. Commissioning
8. Up/Download
For detailed functionality description, browse and search through the Functionality
Description Help file (or 350020.073) or WebPower Online Help file.

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2 The Smartpack2 Basic Controller

Technical Specifications
Specifications Basic
Input Voltage

Tolerances: 20-75 VDC


Shutdown: < 18 VDC

Temperature Range

-40 to +65C (-40 to 140F)

Power Consumption

Max 1.5A
Max 4.5A (3x LVD max loaded)

Contactor Outputs

3 x LVD control outputs

Configurable Inputs

3x NO/NC/Temperature: NTC probe

System Connections
Voltage Sense
Battery Fuse
Load Fuse

Current Sense

24V, 48V, 60V systems


Battery fuse sense, Open/Close
Battery fuse sense, Open/Close,
Pull-Up/Down, Diode Matrix
0-20mV and 0-60mV shunt ranges

Max Basic nodes

8 units on a single CAN-bus

Dimensions
(WxHxD)

155 x 35 x 80mm
6.4 x 1.4 x 3.3

Specifications are subject to change without notice


242100.50X.DS3 v2

Ordering Information

Part no.

Description

242100.501 Smartpack2 Basic Controller


242100.500 Smartpack2 Master Controller
242100.502 I/O Monitor2 CAN node (type 2 G2)

12

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2 The Smartpack2 Basic Controller

Firmware Upgrade Controller


Upgrade of the Smartpack2 Basic controllers firmware is performed via the power
systems CAN bus, while the system is live. Upgrading the firmware does not delete or
change any of the configuration and calibration values stored in the Smartpack2 Basic
controller.
You can upgrade the Smartpack2 Basic controllers firmware using one of the following
two methods. Refer to Figure 7, page 13.
A. From the Smartpack2 Master controller.
Insert in the Smartpack2 Master controller an SD card containing the
Smartpack2 Basic controllers firmware source file <SP2BAS_x.xx.MHX>.
Use then the front keys to download the firmware.
Refer to the Functionality Description Help file (or guide 350020.073) for a
detailed description.
B. From a Personal Computer.
You must connect a PC via an USB-to-CAN Converter (art. 208565) to one
of the power systems CAN bus ends, and move the end-of-line resistor to one of
the converters CAN ports.
Run then the FWLoader program on the PC to download the firmware
<SP2BAS_x.xx.MHX> to the Smartpack2 Basic controller.
You find a detailed description by browsing and searching through the FWLoader
Online Help file.

Smartpack2 Master Controller

120

Smartpack2 Basic
Controller

End-of-Line
Resistor

Flatpack2 HE
Rectifiers

SD Card
(with Firmware
Source File)

Firmware
Source File

01

02

Internal System Monitoring

FW Loader
ID Number

120
End-of-Line
Resistor
USB A-B cable
(standard)

USB to CAN
Converter
CAN bus
(twisted-pair CAT5 cable)

81
I/O Monitor2
Alarm Outputs NC-C-NO
Config. Inputs

Flatpack2
DC Power System

Figure 7 Example Smartpack2 Basic controllers firmware upgrade via SD card (A) or via PC (B)

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www.eltekvalere.com
Headquarters:
Eltek Valere
Grterudv. 8, Pb 2340 Strms, 3003 Drammen, Norway
Phone: +47 32 20 32 00
Fax: +47 32 20 32 10