User’s Guide

Monitoring and Control Unit

Flatpack2 DC Power Supply Systems
350003.013
1 Welcome

Information in this document is subject to change without notice and does not represent
a commitment on the part of Eltek Energy.

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 Energy.

Copyright ©: Eltek Energy, Norway 2006

Certificate no: 900005E Certificate no: 900005Q

Safety Precautions

The equipment described in this manual must only be operated by

Eltek Energy personnel or by persons who have attended a suitable
Eltek Energy 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 manual carefully before using the equipment

350003.013 Issue 3, 2006 Jan

Published 2006-01-09

Mfm

2 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 1 Welcome

Table of Contents

1. Welcome 4
About this Guide ............................................................................................................. 4
System Diagram ⎯ Flatpack2 Power System ................................................................ 4

2. The Smartpack Controller 5

Key Features................................................................................................................... 5
Block Diagram .......................................................................................................5
Typical Applications ........................................................................................................ 6
Location of Connectors & Communication Ports ..............................................6
System & Battery Signals ⎯ Internal Connections ......................................................... 7
Alarm Relay & Digital Input Signals ⎯ Customer Connections ...................................... 8
CAN bus addressing and termination .................................................................9

3. Installation of Smartpack Controller 10

Safety precautions ..............................................................................................10
Mounting and Removing the Controller ............................................................10

4. Front Panel Operation 11

Description of Keys, Display and Indicators.....................................................11
LED indicators............................................................................................................... 11
LCD Display .................................................................................................................. 11
Front Keys.....................................................................................................................11
Modes of Operation.............................................................................................12
Status Mode .................................................................................................................. 12
Menu Mode ................................................................................................................... 12
Operating Menus, Overview ...............................................................................12
User Options ................................................................................................................. 13
Service Options............................................................................................................. 14

5. Technical Specifications 15

6. Functionality Description 16
Alarm Reset .................................................................................................................. 16
Display System Voltages (VoltageInfo)...................................................................... 16
Display Alarm Messages, (Log) (DisplayMessages).................................................. 16
Display Rectifier Information (Rectifier Info)............................................................... 17
Plug-and-Play Rectifier ...........................................................................................................17
Mains Phase Assignment versus Rectifier ID ............................................................... 18
Resetting the Number of Rectifiers ............................................................................... 18
About Battery Banks, Strings and Blocks...................................................................... 19
Battery Symmetry Measurements...........................................................................................19

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 3

1 Welcome

1. Welcome
Congratulations on your purchase of the powerful Flatpack2 DC power supply system,
which uses the new Smartpack controller ⎯ a powerful and cost-effective module
developed for monitoring and controlling your DC power system.

About this Guide

This booklet provides users of Flatpack2 DC power systems with the required information
for operating the system using the Smartpack’s front panel. The booklet also describes
the Smartpack controller’s building blocks, external connections and technical
specifications.

Read also the general and site specific documentation that was delivered with your
Flatpack2 DC power system.

System Diagram ⎯ Flatpack2 Power System

In the Flatpack2 PS system shown in Figure 1, the Smartpack controller monitors and
controls the whole system, and serves as the local user interface between you and the
system. The PowerSuite application is used for remote operation and system
configuration.

Alarm Outputs NC-C-NO PowerSuite

Digital Inputs Application

Flatpack2
USB cable
Cabinetized Smartpack
(Ctrl. Unit) Fuse Alarm

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 or 60V*)
Fuses *Available from 2006

Figure 1 Example of a typical Flatpack2 PS system for DC supply of telecom equipment

4 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 2 The Smartpack Controller

2. The Smartpack Controller

The Smartpack controller is a monitoring and control unit used as the vital nerve center
of the Flatpack2 DC power plant. You operate the system from the elegant front panel,
using three front keys and the LCD-display. They represent the main interface between
you and the system.
You can also operate the system remotely via modem, Ethernet and the Web. The
module then utilizes the USB- or RS-232 ports to interface with SNMP or Web adapters.
See also chapter “Technical Specifications”, on page 15.

Key Features
Front panel LCD and buttons for on-site service without PC.
USB- or RS-232 interface for PC connection locally or remote monitoring
and control via modem, Ethernet, web or SNMP.
Main program upgrade via USB port and the FWLoader application
6 user programmable relay outputs for traditional remote monitoring
6 user programmable inputs for monitoring of other equipment on site
Battery monitoring and testing without site attendance
Temperature compensated charging for increased battery lifetime
Battery lifetime indication
Password protected operator access levels
Alarm/event log with time and date
Windows-based PC communication software

Block Diagram
The microprocessor is the heart of
the system and represents the All customer-specified functions,
intelligence in Smartpack controller. calibration and log data are stored in
The main program and dynamic Smartpack Controller EEPROM chips
data are stored in Flash memory
chips, easily upgraded via the USB Microprocessor EEPROM
FLASH & EEPROM Memory CAN port (2)
or CAN ports 256Kb 512Kb for communication with rectifiers and
DIP switches for other controllers on the CAN bus
configuring the controller’s DIP switch
CAN bus ID number CAN1 Power supply
Power Bus with regulated supply voltages
24 / 48 / 60VDC Input supply for internal and external use
Power supply Step Down
(plug-in PCB)
Flyback rectifier Reg. ±12V
Inputs signals Step Down
(measurements) Reg.+5V
Output signals (control)
for system reference(1), for LVD latching relays (2)
battery current, battery &
load fuse fail (3) CON5
System Connections (internal)
Inputs signals USB 2.0 type B port (1)
(measurements) for battery serial communication interface with
symmetry (4), temperature CON4 USB PCs and computer devices
sense (1) Battery Connections Serial Bus
(internal) Output signals (control)
Inputs signals for Alarm relays (2)
(measurements) for con- CON1
figurable digital inputs (2) Alarm I/O Connections (customer)
(Plug-in PCB)
Inputs signals CON3
(measurements) for battery Battery Connections (customer) (Plug-in PCB)
symmetry (4), temperature
sense (1), battery current
(1), battery fuse fail (1)
CON2 Output signals (control)
Inputs signals Alarm I/O Connections (customer)
(measurements) for con- for Alarm relays (4)
figurable digital inputs (4)

Figure 2 Block diagram of the Smartpack controller showing the module’s main functions

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 5

 2 The Smartpack Controller

Typical Applications
The Smartpack controller employs CAN bus communication with the Flatpack2 rectifiers
⎯ and other bus-connected Smartpack controllers in the system ⎯ thus enabling flexible
expansion of system functionality and number of measuring points. System components
can be set up and upgraded to meet the demand of any tailor-made power solution.

Location of Connectors & Communication Ports

You can easily connect the Smartpack
DIP switches controller to a PC, plugging a standard USB
(CAN ID number) A-B cable to the USB port on the front of the
controller and to any available USB port on
the computer.

The Smartpack controller is configured from

factory ⎯ via DIP switches on the side ⎯ with
an ID number for CAN bus communication.

On the controller’s rear panel ⎯see Figure 4

⎯ you find two identical RJ45 CAN ports (for
incoming and outgoing CAT5 twisted-pair
USB 2.0 type B port
(PC connection) cables) to connect the controller to the CAN
bus. See also chapter “CAN bus addressing
and termination”, on page 9.

Figure 3 Front access USB port, and DIP switches for ID configuration on the side.

The Smartpack controller’s outputs and inputs ⎯ for monitoring and controlling the
system, the batteries, alarm relays and status of external equipment ⎯ are located on
the controller’s rear panel.

Battery Connections ⎯ Extended Alarm I/0 Connections ⎯ Extended

D-sub, 15 pins, male (Internal) D-sub, 26 pins, female (Customer)

CAN port (2)

RJ45, 8 pins connector
(Internal and customer)

Battery Connections Alarm I/0 Connections

D-sub, 15 pins, male (Internal) Mini power connector,
System Connections 10 pins, male (Customer)
D-sub, 15 pins, female (Internal)

Figure 4 Rear plug connections on the Smartpack controller

6 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 2 The Smartpack Controller

System & Battery Signals ⎯ Internal Connections

In standard Flatpack2 DC power systems, the
controller’s internal signals are cabled either directly to
the corresponding monitoring or measuring points, or
to internal terminals, as shown in Figure 5. See also
your system’s specific arrangement drawings.
Smartpack
controller CON5
15 pins D-Sub (female) 10 +

System Specific Interface Terminals

Power Input
FUNCTION SIGNAL PIN-OUT 15 −
14 System Reference
LVD1A +/− 1 4 + System Voltage
LVD2A +/− 2 Interface 5 −
LVD Common +/− 3 Cable 5 6 + Batt. Current 1
5 1 System Voltage + 4 7 −
System Voltage − 5 12 + Batt. Fuse Fail 1
a
*Batt Current 1 + 6 13 −
b
15 11 *Batt Current 1 − 7 9 + Load Fuse Fail 1
NC 8 11 −
CON5 Load Fuse Fail 1 + 9 LVD1A
(female; orange) 1 +/−
Power Input + 10 3 +/− LVD Common LVD1*
Load Fuse Fail 1 − 11 15-pins 2 +/− LVD2*
c
*Batt Fuse Fail 1 + 12 D-Sub LVD2A
d
*Batt Fuse Fail 1 − 13 male
System Reference 14 (Internal Connections)
System Power Input − 15 Notice: the signals available at the
In Out
Connections interface terminals may vary. Read
your system’s specific documents. * To latching relays.

Smartpack
controller
CON4
15 pins D-Sub (male)
FUNCTION SIGNAL PIN-OUT 3 + Batt. Symmetry 1

System Specific Interface Terminals

Batt Sym 1 − 1 1 −
Temp Sense 1 − 2 6 + Batt. Symmetry 2
Batt Sym 1 + 3 5 −
1 5 Interface 11 +
Temp Sense 1 + 4 Cable 4 Batt. Symmetry 3
Batt Sym 2 − 5 10 −
Batt Sym 2 + 6 15 + Batt. Symmetry 4
11 15
a
* NC 7 13 −
CON4
b
* NC 8 4 + Temp. Sense 1
(male; blue) NC 9 2 −
Batt Sym 3 − 10 15-pins 7 a b
8 NC *, *
Batt Sym 3 + 11 D-Sub
d
* NC 12 female 14 c d
NC *, *
Battery Batt Sym 4
c
− 13 12
Connections * NC 14 Internal
Batt Sym 4 + 15 Connections)
In
Smartpack
controller CON3
15 pins D-Sub (male)
FUNCTION SIGNAL PIN-OUT 3 +
System Specific Interface Terminals

Batt. Symmetry 5
Batt Sym 5 − 1 1 −
Temp Sense 2 − 2 6 + Batt. Symmetry 6
Batt Sym 5 + 3 Interface 5 −
1 5 Temp Sense 2 + 4 Cable 3 11 + Batt. Symmetry 7
Batt Sym 6 − 5 10 −
Batt Sym 6 + 6 15 + Batt. Symmetry 8
11 15 Batt Current 2 + 7 13 −
CON3 Batt Current 2 − 8 4 + Temp. Sense 2
(male; blue) NC 9 2 −
Batt Sym 7 − 10 7 + Batt Current 2
Batt Sym 7 + 11 15-pins 8 −
Batt Fuse Fail 2 − 12 D-Sub 14 + Batt Fuse Fail 2
Batt Sym 8 − 13 female 12 −
Ext. Battery Batt Fuse Fail 2 + 14
(Internal
Connections Batt Sym 8 + 15
Connections)
In
Figure 5 Overview of internal system and battery connections

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 7

2 The Smartpack Controller

Alarm Relay & Digital Input Signals ⎯ Customer Connections

In standard Flatpack2 DC power systems, the controller’s customer alarm relay and
digital input signals are cabled to dedicated easy accessible terminals, as shown in
Figure 6. See also your system’s specific arrangement drawings.

Smartpack
controller CON1
10 pins Connector (male) 2 + Input Circuit 1

System Specific Interface

FUNCTION SIGNAL PIN-OUT 1 −
Interface 4 + Input Circuit 2
Config. Input 1A − 1 Cable 1 3 −
1 9
Config. Input 1B + 2 6 NO

i l
Config. Input 2A − 3 5 COM
Config. Input 2B + 4 Alarm Circuit 1
7 NC
2 10 Relay Output 1 COM 5 NO
9

T
CON1 Relay Output 1 NO 6 10-pins 8 COM
(male; green) Relay Output 1 NC 7 plug Alarm Circuit 2
10 NC
Relay Output 2 COM 8 female
Alarm I/O Relay Output 2 NO 9 (Customer
Connections)
Connections Relay Output 2 NC 10
In Out

Smartpack CON2
controller
26 pins D-Sub (female)
FUNCTION SIGNAL PIN-OUT

Config. Input 5B + 1 21 +
Config. Input 5A − 2 Input Circuit 3
20 −
Config. Input 6B + 3 19 +
Config. Input 6A − 4 Input Circuit 4
System Specific Interface Terminals

NC 5 10 −
1 + Input Circuit 5
Relay Output 3 NC 6
Relay Output 4 NC 7 2 −
Relay Output 5 8 3 + Input Circuit 6
19 26 NC Interface
Relay Output 6 9 4 −
NC Cable 2 15 NO
Config. Input 4A − 10 COM
NC 11 23
1 9 Alarm Circuit 3
NC 12 6 NC
CON2 16 NO
NC 13
(female; green) NC 14 24 COM
Alarm Circuit 4
Relay Output 3 NO 15 26-pins 7 NC
D-Sub 17 NO
Relay Output 4 NO 16 COM
Relay Output 5 17 male 25
NO Alarm Circuit 5
Relay Output 6 NO 18 8 NC
18 NO
Config. Input 4B + 19 COM
Config. Input 3A − 20 26 Alarm Circuit 6
Config. Input 3B + 21 9 NC
NC 22 (Customer
Relay Output 3 COM 23 Connections)
Relay Output 4 COM 24
Relay Output 5 25 In Out
Ext. Alarm I/O COM
Relay Output 6 COM 26
Connections

Figure 6 Overview of customer connections ⎯ alarm relay & digital input signals

8 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 2 The Smartpack Controller

CAN bus addressing and termination

The Smartpack controller is factory configured with a unique CAN bus ID number, using
DIP switches on the side of controller (hardware-assignment).

When Flatpack2 rectifiers are hot-plugged in the power shelves the first time, the
Smartpack controller dynamically assigns the rectifiers with the next available ID number
(software-assignment), and automatically increases the number of communicating
rectifiers on the CAN bus. Also, the controller registers the rectifiers’ ID numbers, or CAN
bus address (01, 02…), together with their serial numbers.

When a previously installed rectifier is hot-plugged in the power shelf again, it retains its
previous ID and serial number.

To ensure a correct bus communication and avoid data reflection, you must always
terminate the CAN bus with two 120Ω resistors at both ends of the line, see Figure 7.

USB A-B cable CAN bus

(standard) (twisted-pair internal CAT5 cable)
1
120Ω
End-of-Line End-of-Line
Resistor Resistor
120Ω
Smartpack assigns ID numbers to the recti-
01 02 n fiers (software-assigned). The Smartpack’s
Flatpack2 ID numbers are assigned by DIP switches
DC Power System on the controller’s side.

Figure 7 CAN bus terminated with a 120Ω resistor on both line ends (60Ω bus impedance)

The example in Figure 8 shows two networked Flatpack2 DC power systems. The CAN
bus must then be terminated with only two 120Ω resistors, one at each end of the line.

End-of-Line
Resistor 1 2 120Ω

120Ω
01 02 n n+1 n+2 m
Flatpack2 Flatpack2
DC Power System 1 DC Power System 2 End-of-Line
Resistor

Figure 8 Two Flatpack2 DC power systems CAN bus connected with CAT5 twisted-pair cables.
Only two 120Ω resistors are to be terminated on both line ends (60Ω total bus impedance)

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 9

 3 Installation of Smartpack Controller

3. Installation of Smartpack Controller

Safety precautions
Get acquantied with the satety precaution on page 2, before installing or handling
the equipment.

Mounting and Removing the Controller

The Smartpack controller incorporates handles that serve both to lock the module
into position and to pull it out of its housing.

CAUTION: Do not hand-carry the controller by its handles. Cables are

Device
plugged to the controller’s rear panel. Open the handles before inserting the
hazard controller into the power shelf.
Mount blind panels in unused module locations.
Electric
shock

Hole to release the

Smartpack handle’s spring Mounting the Smartpack controller
controller mechanism
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
Handle in locked position 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
Handle in using both handles to pull the module loose gently;
unlocked position
support from underneath; unplug the cables connected
to the rear panel

Figure 9 Smartpack controller’s locking mechanism

Removing blind panels

Release the panel’s upper left and right corners by inserting a small screwdriver
into the panel’s upper left gap, and carefully press down and out to release the
locking tabs. Repeat on the upper right gap. Refer to the Flatpack2 system’s quick
start guide for more information.

10 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 4 Front Panel Operation

4. Front Panel Operation

This chapter describes the Smartpack controller’s keys and indicators, and how to
operate the Flatpack2 DC power system from the controller’s front panel.

Description of Keys, Display and Indicators

The Smartpack controller’s front panel consists of two functional areas: the presentation
area (LCD display and LED lamps) and the control area (keys). For information about the
handles and the USB port, read pages 6 and 10.

Graphical Display Alarm

16 character x 2 lines LCD display LED Lamp (red)
Upper line Warning
Output voltage or LED Lamp (yellow)
menu options
Power
Lower line LED Lamp (green)
Battery or load current,
alarms, or keys to press

”Down” arrow key

”Enter” key
”Up” arrow key

Figure 10 Smartpack controller’s front keys and indicators

LED indicators
The Smartpack controller has the following LED indications:
• “Power” (green) indicates that the power supply is ON or OFF
• Alarm (red) indicates an alarm situation (major alarm)
• Warning (yellow) indicates an abnormal situation (minor alarm)

LCD Display
The graphic display is an important part of the power supply system’s user interface. The
display is in Status Mode (displays the system’s status) or in Menu Mode (displays the
menu structure).
Depending on the display’s mode, the upper line shows the output voltage or menu
options, while the lower line displays battery and load current, alarms, or information
about which key to press. See also chapter “Modes of Operation”, on page 12.

Front Keys
You can control the whole Flatpack2 DC power system via a network of software menus
accessed with the controller’s front keys.
o Press on the key to change from Status Mode to Menu Mode.
o Press the or keys to scroll up or down and navigate to find menu options
(function or parameter).
o Press then the key to select the function.

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 11

4 Front Panel Operation

Modes of Operation
The controller’s display is either in Status Mode or in Menu Mode.

Status Mode
When the front keys are not in operation, the display is in Status Mode. The following
information is then scrolled through the display:

• The upper line continuously displays the battery voltage.

• The lower line continuously scrolls the following information:
o Battery Current
o Load Current
o Active alarms
o Other messages

Menu Mode
When the front keys are in operation, the controller’s display switches to Menu Mode and
the following information is scrolled through the display:

• The upper line shows the name of the active menu or sub-menu
• The lower line indicates which key to press

Notice that if no keys are pressed within 30 seconds, the display will automatically switch
from Menu Mode and to back to Status Mode.

Operating Menus, Overview

The Flatpack2 DC power system’s functionality is accessed via a network of software
menus and submenus, enabling you to configure and control the whole power system.

The functionality is divided in two different hierarchical Level 1

menu structures: the User Options menus and the
Service Options menus (password protected, only Display in Status Mode
authorised personnel have access to them).
UserOption
Special, not so frequently used options — such as ServiceOption
calibration and adjustments — are accessible in the
Service Options sub-menus.

12 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 4 Front Panel Operation

User Options
When you “enter” Menu Mode, you access the User Options.

Level 2 Level 3

The ”XvX” references, if any, on the right hand of the option, are not shown in the display.
How to browse the display menus
User menu <UserOption>

They only indicate in which software vesjon (x) the option was first implemented.
AlarmReset
o Entering Menu Mode NomVolt
Press on the key to change from BoostVolt
LowBatt1
Status Mode to Menu Mode
VoltageInfo LowBatt2
o Browsing “down” to a menu option HighBatt1
HighBatt2
Press the key, to scroll down within LVD 1
the same menu level, and find menu LVD 2
options (functions or parameters) DisplayMessages Message ↓↑
SoftwareInfo
o Selecting a menu option SerialNumber 1v01
NoOfRects. Nn
Press on the key to select the RectCurrent 1v0
displayed menu option or parameter Rectifier Info RectSerialNumber 1v0
Rect.PrimaryVolt 1v0
Rectifier Status 1v0
o Browsing “up” to a menu option Rectifier Temp 1v0
or level NoOfPhases nn
Press the key to scroll up to the Mains Info Mains Status
previous menu option, and out to the Mains Voltage
Temp Level Info-- Level ↓↑ 1v0
previous menu level.

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 13

4 Front Panel Operation

Service Options
When you enter Menu Mode, you access the User Options. You may then scroll down to
the password protected Service Options.

The Service Option’s password is factory-programmed to <0003>. We strongly

recommend that this password is changed as soon as the system is installed

Level 2 Level 3
How to browse the display menus
Service menu <ServiceOption>
o Entering Menu Mode NomVolt ↓↑

The ”XvX” references, if any, on the right hand of the option, are not shown in the display.
BoostVolt ↓↑
Press on the key to change from LowBatt1 ↓↑
VoltAdjustment LowBatt2 ↓↑
Status Mode to Menu Mode

They only indicate in which software vesjon (x) the option was first implemented.
HighBatt1 ↓↑
o Browsing “down” to a menu option HighBatt2 ↓↑
LVD 1 ↓↑
Press the key, to scroll down within LVD 2 ↓↑
the same menu level, and find menu VoltCalibration ------- VoltCal ↓↑
ChangePassword --- Password ↓↑
options (functions or parameters) SetBoostTime--------- ↓↑
Start/StopBoost
o Selecting a menu option Auto Boost Conf. --- Enable/Disable & AutoBThrs ↓↑
Press on the key to select the Nxt Test DateTime
End Volt ↓↑
displayed menu option or parameter Batt Test Setup MaxTestDur ↓↑
Test int ↓↑
Guard time ↓↑
o Browsing “up” to a menu option Start/Stop Test
or level Charge Curr Lim. --- Enable/Disable & Max C.Curr ↓↑
Battery Setup -------- NumOfString ↓↑
Press the key to scroll up to the Output Control ------- VoltageCtrl / TempComp
Change Date/Time
previous menu option, and out to the Alarm Output 1
previous menu level. RelayTest Alarm Output 2
Batt Contactor
Load Contactor
Alarm Output nn
BattLifeTime Rst 1v0

14 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 5 Technical Specifications

5. Technical Specifications

Remote Monitoring / Control Local Monitoring / Control

From a PC running Windows-based
communication software (PowerSuite)
With the Windows-based communication program
installed on a remote computer, the system can be
monitored and controlled via modem or Ethernet
network.
From an NMS via Ethernet (SNMP)
With an SNMP agent connected to the Smartpack, the
system can be monitored and controlled from a
Network Management System (NMS) through
Ethernet on Simple Network Management Protocol
(SNMP).
From a PC running Windows-based
communication software (PowerSuite)
Windows-based comm. software can also
communicate with the Smartpack through an USB
serial or RS-232 cable.
LCD and three keypads for local operations.
If any alarm (major or minor) is activated, a (red or
yellow) LED is lit in the front panel, the alarm text
appears in the LCD and the corresponding alarm relay
is activated.
In normal operation, the front LCD will display the
output voltage, battery current, load current and
charge mode.

Using alarm relays (voltage free contacts)

6 internal failsafe alarm relays provide voltage free Available Alarms
contacts that can be connected to equipment used All alarms can be set up with monitoring of
for traditional alarm monitoring. minor, major, average and peak levels.

System
Mains Failure (individual phases)
Digital Inputs (programmable names)
Load Disconnect (voltage or timer)
Features
Load Fuse
System Load Current
Output Voltage Measurement
Total Load Current Measurement Battery
Load/Battery Disconnect High Battery voltage
Alarm Level Settings (major / minor) Low Battery voltage
Alarm Log (up to 1000 events) High Battery temperature
Low Battery temperature
Real Time Clock with Battery Backup
Battery Capacity
Site Text/ID
Battery Disconnect
Test of Relay Outputs Battery Fuse
Voltage Level setup Symmetry Failure
Battery quality indication
Battery Battery discharge current
Battery Current Measurement
Battery Temperature Measurement (optional) Rectifier
Battery Testing (acc. to discharge table or set time Rectifier Failure
Critical Rectifier Failure (> 1, programmable)
limit)
Rectifier Capacity w. programmable level
Battery Test Information (10 latest tests)
Rectifier Current Limit
Setup of Battery Data Rectifier Over voltage Protection
Battery shunt setup Rectifier Current
Battery quality indication
Battery Boost Charging
Battery Cable Voltage Drop Compensation Specifications
Temperature Compensated Charging Input Voltage 24/48/60 VDC
Protection against Temperature Probe Failure
Firmware The Smartpack main program can
be upgraded via the USB port,
Rectifier
using a PC running the FWLoader
Available information about each rectifier, e.g. serial application
number, version, internal temperature
Dimensions 109 x 44 (1U) x 140mm (wxhxd)
Individual Rectifier Current Measurement
(4.3 x 1.7 x 5.5”)
Individual Rectifier Input Voltage

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 15

6 Functionality Description

6. Functionality Description
In this chapter you can find helpful and more detailed descriptions of expressions,
technical terms, functions, etc. used in Flatpack2 DC power supply systems.

Alarm Reset
You can reset all active alarms by selecting “UserOption>AlarmReset”, via the
Smartpack controller’s front keys. The controller will immediately report alarm conditions
that are still active.

The Flatpack2 DC power system can be configured with automatic or manual alarm reset.

When Automatic Alarm Reset is enabled (default) ⎯ and the alarm condition no longer
exists ⎯ the Smartpack controller will deactivate the alarm lamps and relays to indicate
that normal operation is established.

When Manual Alarm Reset is enabled ⎯ and the alarm condition no longer exists ⎯ the
operator must reset the alarm manually.

Display System Voltages (VoltageInfo)

You can display important system voltages by selecting “UserOption>VoltageInfo”,
via the Smartpack controller’s front keys.

Following voltages may be displayed selecting the VoltageInfo sub options (level 3):

Option Description
NomVolt Nominal output voltage
BoostVolt Battery boost-charging voltage
LowBatt1 Voltage limit for Low Battery Alarm 1
LowBatt2 Voltage limit for Low Battery Alarm 2
HighBatt1 Voltage limit for High Battery Alarm 1
HighBatt2 Voltage limit for High Battery Alarm 2
LVD 1 Voltage limit for Low Voltage Disconnect unit 1

Display Alarm Messages, (Log) (DisplayMessages)

You can browse through the stored system alarm messages (alarm log) by selecting
“UserOption>DisplayMessages”, via the Smartpack controller’s front keys.

The Smartpack controller’s alarm log may store up to 1000 chronological events. Each
log entry contains event text, event action, time and date. When the log is full, the oldest
value is overwritten. The log is stored in EEPROM.

16 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 6 Functionality Description

Display Rectifier Information (Rectifier Info)

You can display information about the Flatpack2 rectifiers communicating in the system,
by selecting “UserOption>Rectifier Info”, via the Smartpack controller’s front keys.

Following information may be displayed selecting the Rectifier Info sub options (level 3):

Option Description
NoOfRects. Number of rectifiers installed in the system.
RectCurrent Rectifier current
RectSerialNumber Rectifier ID and serial number
Rect.PrimaryVolt Rectifier input voltage
Rectifier Status Rectifier status
Rectifier Temp Rectifier temperature

While the controller is accessing information from a specific rectifier, the green LED on
the rectifier’s front panel flashes.

The Smartpack controller sends out status messages every 200ms to all the Flatpack2
rectifiers connected to the CAN bus, such as:
o The Smartpack controller’s status
o Current Limit Reference
o Measured Output Voltage
o Reference Output Voltage
o Over-voltage Protection Reference
o Etc.

Plug-and-Play Rectifier
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”. This ID
number (or CAN bus address) and the rectifier’s serial number are stored in both
modules.

When a previously installed (hot plugged) Flatpack2 rectifier is inserted in a power

shelf, the Smartpack controller “recognises” the module, and assigns the same ID to
rectifier.
In other words, the controller and the rectifier “remember” the assigned ID and serial
numbers, even after removing and reinserting the rectifier in the shelf.

To achieve a more controlled ID assignment, you should always insert & hot-plug new
Flatpack2 rectifiers in the power shelves, one module at a time, starting with shelf
position 1, 2, 3 and so on. The sequence is indifferent after positions 9. Read chapter
“Mains Phase Assignment versus Rectifier ID”, page 18.

The power shelf position numbers vary with the type of AC mains and the type of power
shelves installed in your system. Refer to your system’s quick start guide and specific
documentation for more information.

Do not relocate already pre-installed rectifiers.

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 17

6 Functionality Description

Mains Phase Assignment versus Rectifier ID

In systems with 3 phase AC feed, the Smartpack controller can be configured to report a
warning if one phase fails, and to report an alarm if two phases fail, for example.
The 230V phases of Flatpack2 systems’ mains AC feed are routed to the rectifiers’ inputs
in a special pattern that loads the 3 phases evenly. The routing of the phases is
implemented via internal wiring and the use of either 4AC Power Shelves 1 or 2AC
Power Shelves 2 . Refer to your system’s quick start guide and specific documentation
for more information.
To be able to display correct information about the phases, the Smartpack controller
must “know” which phase is connected to which rectifier ID number.
Flatpack2 DC power systems are shipped from factory with the rectifier modules already
installed in the correct position in the power shelves, with respect to their ID
number (or CAN bus address).
This relationship is very important, as the Smartpack controller always uses rectifier ID
01, 02 and 03 to monitor mains phase L1, L2 and L3 respectively. If these rectifiers
malfunction, rectifier ID 04, 05 and 06 will automatically take over. If these fail, the
controller uses rectifier ID 07, 08 and 09.
For example: accidentally inserting a rectifier with ID 02 in a power shelf position
internally connected to mains phase L1, will cause the controller to monitor L1 “thinking“
it monitors L2.

Resetting the Number of Rectifiers

When a rectifier reset is activated, the number of rectifiers is recalculated, and only the
number of communicating modules at the moment will be counted.
For instance: in a DC power system equipped with 10 rectifiers, rectifier with ID number
“04” malfunctions. If you insert rectifier ID#10 in the position of the failing ID#04, and
then activate a rectifier reset, the Smartpack controller recalculates the number of
communicating rectifiers to only 9. At the same time the controller reassigns rectifier
with ID#10 to ID#04, thus filling the gap.

Example: DC power system with malfunctioning rectifier;

3 power shelves with 10 rectifiers (rectifier ID #04 malfunctions)
ID “04”
Rectifier ID 01 Rectifier ID 02 Rectifier ID 03 Rectifier ID 04 SNo.: 04
Serial No. 01 Serial No. 02 Serial No. 03 Serial No. 04 04
Rectifier ID 05 Rectifier ID 06 Rectifier ID 07 Rectifier ID 08 01 02 03 Flatpack2
Serial No. 05 Serial No. 06 Serial No. 07 Serial No. 08 07 08 rectifier
05 06
Rectifier ID 09 Rectifier ID 10
Serial No. 09 Serial No. 10 10
09 ---
---ID “10”
--- --- SNo.: 10

After rectifier reset:

3 power shelves with 9 rectifiers ID “04”
(rectifier ID #10 reassigned to #04) SNo.: 10
Rectifier ID 01 Rectifier ID 02 Rectifier ID 03 Rectifier ID 04 04
Serial No. 01 Serial No. 02 Serial No. 03 Serial No. 10 01 02 03 Flatpack2
07 08 rectifier
Rectifier ID 05 Rectifier ID 06 Rectifier ID 07 Rectifier ID 08 06
Serial No. 05 Serial No. 06 Serial No. 07 Serial No. 08 05
Rectifier ID 09 09 ---
Serial No. 09 ---
--- ---

1
4AC Power Shelves (Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier).
2
2AC Power Shelves (Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers).

18 User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01

 6 Functionality Description

About Battery Banks, Strings and Blocks

Battery Normally, battery banks are implemented by
Block (12V)
connecting in parallel several battery strings; each
string is formed by battery blocks connected in series.
Battery
String #1
(48V) Figure 11 Example of a 48V battery bank
implemented with two 48V battery strings; each
Battery string consists of four 12V battery blocks
48V Battery Bank String #2
(48V)

Battery Symmetry Measurements

Symmetry measurement is a battery monitoring

method for automatically detecting unbalanced battery
Battery Symmetry blocks. Symmetry monitoring of a battery string may
Card, Art. 200576
Block Measurement be performed after three different methods:
Diff. Switches Symmetry o Block measurement method
1 2 3 4
Measuring each battery block
— (-48V)

- + - + - + - +
+ (0V)

o Mid-point measurement method

Measuring from the mid-point of the battery
Set all 4 switches string to one end
OFF (up)
Four measurement points per string o Double mid-point measurement method
(Diff. measurement) Measuring from the mid-point of the string to
both ends

Battery Symmetry The mid-point measurement method requires 2

Mid-point Measurement symmetry wires per battery string; the double mid-
Card, Art. 200576
Diff. Switches Symmetry 1 point measurement method requires 4 symmetry wires
— (-48V)

per battery string, while the block measurement

+ (0V)

- + method requires 8 symmetry wires per battery string.

Refer to the system’s quick start guide for connections
Set all 4 switches using fewer wires, setting the switches to ON.
OFF (up)
One measurement point per string
Flatpack2 cabinetized systems are normally delivered
with the symmetry measurement method and the
Battery Symmetry number of measurement points already
Double Mid-point Measurement preprogrammed in the Smartpack controller. Any
Card, Art. 200576 Symmetry Symmetry
Diff. Switches 1 2 deviation from factory settings requires Symmetry
— (-48V)

reconfiguration via the PowerSuite PC program.

+ (0V)

- + - +

Each Smartpack controller is equipped with 8 battery

Set all 4 switches
symmetry inputs (on CON4 and CON3), enabling
OFF (up) Two measurement points per string, symmetry measurement of:
from the middle to the outer terminals o 2 battery strings (block meas. method)
o 4 battery strings (double mid-point meas. method)
o 8 battery strings (mid-point meas. method)

Figure 12 Example of terminal connection points for Symmetry Block, Mid-point and
Double Mid-point measurement methods

User’s Guide Smartpack Monitoring & Ctrl Unit, 350003.013, v3-2006-01 19

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