Users Guide

Monitoring and Control Unit

350003.013

Flatpack2 DC Power Supply Systems

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 2005

Certificate no: 900005E

Head Office:
Eltek Energy
P.O. Box 2340
Strms
N-3003 DRAMMEN
Norway

350003.013

Certificate no: 900005Q

Phone: (+47) 32 20 32 00
Fax:
(+47) 32 20 32 10
E-Mail: eltek@eltekenergy.com
Internet: http://www.eltekenergy.com

Issue 2, 2005 Jun

Published 2005-06-07
Mfm

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

1 Welcome

Table of Contents
1

WELCOME
4
1.1 ABOUT THIS GUIDE .................................................................................... 4
1.2 SYSTEM DIAGRAM FLATPACK2 DC POWER SUPPLY SYSTEM .................................. 4

THE SMARTPACK CONTROLLER SHORT DESCRIPTION

5
2.1.1 Typical Applications...................................................................... 5
2.2 KEY FEATURES ......................................................................................... 5
2.3 BLOCK DIAGRAM ....................................................................................... 5
2.4 LOCATION OF CONNECTORS & COMMUNICATION PORTS .......................................... 6
2.4.1 System & Battery Signals Internal Connections ............................ 7
2.4.2 Alarm Relay & Digital Input Signals Customer Connections............. 8
2.5 CAN BUS ADDRESSING AND TERMINATION ......................................................... 9

SMARTPACK CONTROLLER INSTALLATION

10
3.1 SAFETY PRECAUTIONS ............................................................................... 10
3.2 MOUNTING THE CONTROLLER ...................................................................... 10
3.3 REMOVING THE CONTROLLER ....................................................................... 10

FRONT PANEL OPERATION

11
4.1 DESCRIPTION OF KEYS, DISPLAY AND INDICATORS ............................................. 11
4.1.1 LED indicators ........................................................................... 11
4.1.2 LCD Display .............................................................................. 11
4.1.3 Front Keys ................................................................................ 11
4.2 MODES OF OPERATION .............................................................................. 12
4.2.1 Status Mode ............................................................................. 12
4.2.2 Menu Mode ............................................................................... 12
4.3 OPERATING MENUS, OVERVIEW ................................................................... 12
4.3.1 User Options ............................................................................. 13
4.3.2 Service Options ......................................................................... 14

SPECIFICATIONS

APPENDIX
16
6.1 FUNCTIONALITY DESCRIPTION FLATPACK2 DC POWER SYSTEMS .......................... 16
6.1.1 Alarm Reset .............................................................................. 16
6.1.2 Display System Voltages............................................................. 16
6.1.3 Display Alarm Messages (Alarm Log) ............................................ 16
6.1.4 Plug-and-Play Flatpack2 Rectifiers (Rectifier Info)........................... 17
6.1.4.1
6.1.4.2

15

Plug-and-Play
System Reset and Rectifier ID Reassignment

17
18

6.1.5 Mains Assignment versus Rectifier ID ........................................... 19

6.1.6 About Battery Banks, strings, etc ................................................. 19
6.1.7 Symmetry Mid-point, Double Mid-point or Block Measurements .... 19

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

1 Welcome

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.

1.1 About this Guide

This booklet provides users of Flatpack2 DC power systems with the required information
for operating the system using the Smartpacks front panel. The booklet also describes
the Smartpack controllers building blocks, external connections and specifications.
Take a look at the table of contents to familiarise yourself with this booklet.
We have also emphasised the use of images and graphics to make the book easy and
interesting to read.
Read also the general and site specific documentation that was delivered with your
Flatpack2 DC power system.

1.2 System Diagram Flatpack2 DC Power Supply System

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

Alarm Outputs NC-C-NO

Digital Inputs

Flatpack2
Cabinetized

Smartpack
(Ctrl. Unit)

Fuse Alarm

Flatpack2
(rectifiers)
LVLD
AC mains
supply
selector

AC Fuses,
external
(230VAC or
400VAC

Figure 1

LVBD
Load Fuses
& MCBs

Symmetry
Alarm &
Temp. Sensor

AC Supply
(Single- or
three-phase)

Telecom
equipment

Battery string #1

DC distribution

Battery
Fuses

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

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

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

2 The Smartpack Controller ( Short Description

The Smartpack Controller Short Description

The Smartpack module is a monitoring and control unit that serves as the vital
nerve center of the Flatpack2 DC power plant, representing the main interface
between you and the system. The modules elegant front panel enables both
local and remote system monitoring and control, using three front keys and
LCD-display, and USB- or RS-232 interface, as well as via modem, Ethernet, Web and
SNMP. See also chapter Specifications, on page 15.
2.1.1 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.

2.2 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.
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

2.3 Block Diagram

The microprocessor is the heart of
the system and represents the
intelligence in Smartpack controller.
The main program and dynamic
data are stored in Flash memory
chips, easily upgraded via the USB
or CAN ports
DIP switches for
configuring the controllers
CAN bus ID number

Smartpack Controller
Microprocessor
FLASH & EEPROM Memory
256Kb

EEPROM
512Kb

Inputs signals
(measurements)
for system reference(1),
battery current, battery &
load fuse fail (3)
Inputs signals
(measurements) for battery
symmetry (4), temperature
sense (1)
Inputs signals
(measurements) for configurable digital inputs (2)
Inputs signals
(measurements) for battery
symmetry (4), temperature
sense (1), battery current
(1), battery fuse fail (1)
Inputs signals
(measurements) for configurable digital inputs (4)

Figure 2

CAN port (2)

for communication with rectifiers and
other controllers on the CAN bus

DIP switch

CAN1
Power Bus

24 / 48 / 60VDC Input supply

All customer-specified functions,

calibration and log data are stored in
EEPROM chips

Power supply

Step Down
Reg. 12V

Flyback rectifier

Step Down
Reg.+5V

Power supply
with regulated supply voltages
for internal and external use
(plug-in PCB)

Output signals (control)

for LVD relays (2)

CON5
System Connections (internal)

CON4

USB

Battery Connections
(internal)

Serial Bus

USB 2.0 type B port (1)

serial communication interface with
PCs and computer devices
Output signals (control)
for Alarm relays (2)

CON1
Alarm I/O Connections (customer)

(Plug-in PCB)

CON3
Battery Connections (customer)

CON2
Alarm I/O Connections (customer)

(Plug-in PCB)

Output signals (control)

for Alarm relays (4)

Block diagram of the Smartpack controller showing the modules main functions

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

2 The Smartpack Controller ( Short Description

2.4 Location of Connectors & Communication Ports

DIP switches
(CAN ID number)

USB 2.0 type B port

(PC connection)

Figure 3

You can easily connect the Smartpack

controller to a PC, plugging a standard USB
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 switched on the side with
an ID number for CAN bus communication.
On the controllers rear see Figure 4 you
find two identical RJ45 CAN ports (for
incoming and outgoing CAT5 twisted-pair
cables) to connect the controller to the CAN
bus. See also chapter CAN bus addressing
and termination, on page 9.

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

The Smartpack controllers inputs and outputs for monitoring and controlling the
system, the batteries, alarm relays and configurable digital are located in the rear the
controller.

Battery Connections Extended

D-sub, 15 pins, male (Internal)

Alarm I/0 Connections Extended

D-sub, 26 pins, female (Customer)

CAN port (2)

RJ45, 8 pins connector
(Internal and customer)

Battery Connections
D-sub, 15 pins, male (Internal)
System Connections
D-sub, 15 pins, female (Internal)
Figure 4

Alarm I/0 Connections

Mini power connector,
10 pins, male (Customer)

Rear plug connections on the Smartpack controller

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

2 The Smartpack Controller ( Short Description

2.4.1 System & Battery Signals Internal Connections

In
standard
Flatpack2
DC power systems,
the
controllers 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 systems specific arrangement drawings.
CON5

System
Connections

Out

SIGNAL PIN-OUT

LVD1A +/ 1
LVD2A +/ 2
LVD Common +/ 3
System Voltage +
4
System Voltage
5
a
*Batt Current 1 +
6
b
*Batt Current 1
7
NC
8
Load Fuse Fail 1 +
9
Power Input + 10
Load Fuse Fail 1 11
c
*Batt Fuse Fail 1 + 12
d
*Batt Fuse Fail 1 13
System Reference
14
Power Input 15

11
15
(Orange)

Interface
Cable 5

15-pins
D-Sub
male

15-pins
D-Sub
male

Smartpack controller

Battery
Connections

CON4

11

15
(Blue)

Ext. Battery
Connections

In

TB4

SIGNAL PIN-OUT

Batt Sym 1
Temp Sense 1
Batt Sym 1
Temp Sense 1
Batt Sym 2
Batt Sym 2
a
* NC
b
* NC
NC
Batt Sym 3
Batt Sym 3
d
* NC
Batt Sym 4
c
* NC
Batt Sym 4

+
+

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Interface
Cable 4

15-pins
D-Sub
female

15-pins
D-Sub
female

CON3
15 pins D-Sub (male)
FUNCTION

SIGNAL PIN-OUT

Batt Sym 5
Temp Sense 2
Batt Sym 5
Temp Sense 2
1
5
Batt Sym 6
Batt Sym 6
Batt Current 2
Batt Current 2
11
15
NC
(Blue)
Batt Sym 7
Batt Sym 7
Batt Fuse Fail 2
Batt Sym 8
Batt Fuse Fail 2
Batt Sym 8
Smartpack controller

Figure 5

15

15 pins D-Sub (male)

FUNCTION

TB5
+

1
Power Input
2
System Reference
3
+
4
System Voltage
4

5
5
+
6
Batt. Current 1
6

7
7
12 +
Batt. Fuse Fail 1
8

13
9
+
9
Load Fuse Fail 1
10

11
11
LVD1A
+/ 12
1
LVD1
+/ 13 LVD Common
3
LVD2
+/ 14
2
LVD2A
15
(Internal
Connections)
14

+
+

+
+

+
+

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

Interface
Cable 3

15-pins
D-Sub
female

15-pins
D-Sub
female

Terminal Printed Circuit Board, Art. xxxxxx (TB3 & TB4) or Art. yyyyyy (TB4)

10

Terminal Printed Circuit Board, Art. xxxxxx

FUNCTION

In

15 pins D-Sub (female)

1
2
3
5
4
11
5
10
6
15
7
13
8
4
9
2
10
Internal
Connections)
6

Batt. Symmetry 1
Batt. Symmetry 2
Batt. Symmetry 3
Batt. Symmetry 4
Temp. Sense 1

TB3
3

1
2
6
3
5
4
11
5
10
6
15
7
13
8
4
9
2
10
7
11
8
12
14
13
12
14
15
(Internal
Connections)
1

Batt. Symmetry 5
Batt. Symmetry 6
Batt. Symmetry 7
Batt. Symmetry 8
Temp. Sense 2
Batt Current 2
Batt Fuse Fail 2

Overview of internal system and battery connections

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

2 The Smartpack Controller ( Short Description

2.4.2 Alarm Relay & Digital Input Signals Customer Connections

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

CON1
FUNCTION

2
10
(Green)

Ext. Alarm I/O

Connections

26

1
(Green)

Out

TB1

SIGNAL PIN-OUT

Config. Input 1A
1
Config. Input 1B +
2
Config. Input 2A
3
Config. Input 2B +
4
Relay Output 1 COM 5
Relay Output 1 NO
6
Relay Output 1 NC
7
Relay Output 2 COM 8
Relay Output 2
NO
9
Relay Output 2
NC 10

Interface
Cable 1

10-pins
plug
female

10-pins
RJ45
plug

CON2
26 pins D-Sub (female)
FUNCTION

19

In

10 pins Connector (male)

Config. Input 5B
Config. Input 5A
Config. Input 6B
Config. Input 6A
NC
Relay Output 3
Relay Output 4
Relay Output 5
Relay Output 6
Config. Input 4A
NC
NC
NC
NC
Relay Output 3
Relay Output 4
Relay Output 5
Relay Output 6
Config. Input 4B
Config. Input 3A
Config. Input 3B
NC
Relay Output 3
Relay Output 4
Relay Output 5
Relay Output 6

SIGNAL PIN-OUT

NC
NC
NC
NC

NO
NO
NO
NO

+
COM
COM
COM
COM

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

Interface
Cable 2

26-pins
D-Sub
male

26-pins
D-Sub
male

Terminal Printed Circuit Board, Art. xxxxxx (TB1 & TB2) or Art. yyyyyy (TB1)

Alarm I/O
Connections

1
2
3
3
4
6
NO
5
5 COM 6
NC
7
7
NO 8
9
COM
8
9
NC
10
10
(Customer
Connections)
4

Input Circuit 1
Input Circuit 2

Alarm Circuit 1
Alarm Circuit 2

TB2
21

1
2
19
3
10
4
1
5
2
6
3
7
4
8
NO
15
9
23 COM 10
NC
6
11
NO 12
16
COM
24
13
NC 14
7
NO
17
15
25 COM 16
NC
8
17
NO
18
18
COM
26
19
NC
9
20
(Customer
Connections)
20

Input Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6

Alarm Circuit 3
Alarm Circuit 4
Alarm Circuit 5
Alarm Circuit 6

Smartpack controller

Figure 6

Overview of customer connections alarm relay & digital input signals

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

2 The Smartpack Controller ( Short Description

2.5 CAN bus addressing and termination

The Smartpack controller is factory configured with a unique CAN bus ID number. When
Flatpack2 rectifiers are plugged in the power shelves the first time, the Smartpack
controller automatically assigns the rectifiers with the next available ID number, and
automatically increases the number of communicating rectifiers on the CAN bus.
When a previously installed rectifier is plugged in the power shelf again, it always sends
its previous ID and serial number to the Smartpack controller.
To ensure a correct bus communication and avoid data reflection, you must always
terminate the CAN bus with two 120 resistors at both ends of the line, see Figure 7.

To system & battery terminals

(Internal Connections)

End-of-Line
resistor
120

USB A-B cable

(standard)
WebPower
Application

To systems Alarm I/O terminals

(Customer Connections)
Smartpack
(Ctrl. Unit)

CAN bus
(twisted-pair internal CAT5 cable)

Flatpack2
DC Power System

Figure 7

End-of-Line
resistor
120

Flatpack2
rectifiers

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

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

120
Flatpack2
DC Power System 1

Flatpack2
DC Power System 2

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

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

3 Smartpack Controller Installation

Smartpack Controller Installation

3.1 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

3.2 Mounting the Controller

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

5 Do not hold or hand-carry the Smartpack controller by its handles

5 Open the handles before inserting the module fully into the power shelf

Handel in
unlocked position

1. Open the handles

(insert a screwdriver into the holes to release the
spring mechanism)
2. Insert the module fully into the power shelf
3. Lock the handles
(push the handles up into their housings (locked
position), so that the module is securely locked)

3.3 Removing the Controller

Hole to release the
handles spring mechanism
o

o
Handel in locked position
Figure 9

10

Open the handles

(insert a screwdriver into the holes to release the
spring mechanism)
Remove the module
(use both handles to pull the module loose; support
from underneath)

Smartpack controllers locking mechanism

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

4 Front Panel Operation

Front Panel Operation

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

4.1 Description of Keys, Display and Indicators

The Smartpack controllers 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.
Alarm
LED Lamp (red)
Warning
LED Lamp (yellow)

Graphical Display
16 character x 2 lines
LCD display

Power
LED Lamp (green)

Upper line
Output voltage or
menu options
Lower line
Battery or load current,
alarms, or keys to press
Enter key
Up arrow key
Down arrow key
Figure 10

Smartpack controllers front keys and indicators

4.1.1 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)
4.1.2 LCD Display
The graphic display is an important part of the power supply systems user interface. The
display is in Status Mode (displays the systems status) or in Menu Mode (displays the
menu structure).
Depending on the displays 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.
4.1.3 Front Keys
You can control the whole Flatpack2 DC power system via a network of software menus
accessed with the controllers front keys.
key to change from Status Mode to Menu Mode.
o Press on the
o

or
keys to scroll up or down and navigate to find menu options
Press the
(function or parameter).

Press then the

key to select the function.

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

11

4 Front Panel Operation

4.2 Modes of Operation

The controllers display is either in Status Mode or in Menu Mode.

4.2.1 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

4.2.2 Menu Mode

When the front keys are in operation, the controllers 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 any of the keys are not pressed within 30 seconds, the display will switch
from Menu Mode to back to the Status Mode.

4.3 Operating Menus, Overview

The Flatpack2 DC power systems 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
menu structures: the User Options menus and the
Service Options menus (password protected, only
authorised personnel have access to them).
Special not so frequently used options such as
calibration and adjustments are included in the
Service Options sub-menus.

12

Users Guide Smartpack Monitoring & Ctrl Unit,

Display in Status Mode

UserOption
ServiceOption

Art. 350003.013, v2-2005-06

4 Front Panel Operation

4.3.1 User Options

When you enter Menu Mode, you access the User Options.
Level 1
Display in Status Mode

Level 3

UserOption

User menu <UserOption>

ServiceOption

AlarmReset

VoltageInfo

How to browse the display menus

o

Level 2

Menu Mode
key to change from
Press on the
Status Mode to Menu Mode
Browse to Nxt. menu option
key, to scroll down within
Press the
the same menu level, and find the
Next menu options (function or
parameter)

DisplayMessages
SoftwareInfo
Rectifier Info

Mains Info

NomVolt
BoostVolt
LowBatt1
LowBatt2
HighBatt1
HighBatt2
LVD 1
LVD 2

NoOfRects. nn
NoOfPhases nn
Mains Status
Mains Voltage

Select menu option

key to select the
Press on the
displayed menu option or parameter
OR

Browse to Prev. menu option or

level
key to scroll up to the
Press the
Previous menu option, and out to the
previous menu level.

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

13

4 Front Panel Operation

4.3.2 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 Options password is factory-programmed to <0003>. We strongly
recommend that this password is changed as soon as the system is installed
Level 1
Display in Status Mode
UserOption
ServiceOption

Level 2

Level 3

Service menu <ServiceOption>

How to browse the display menus

VoltAdjustment

Menu Mode
key to change from
Press on the
Status Mode to Menu Mode

Browse to Nxt. menu option

key, to scroll down within
Press the
the same menu level, and find the
Next menu options (function or
parameter)

Select menu option

key to select the
Press on the
displayed menu option or parameter

VoltCalibration

VoltCal

ChangePassword
SetBoostTime
Start/StopBoost
Auto Boost Conf.

Password

Batt Test Setup

OR
o

Browse to Prev. menu option or

level
key to scroll up to the
Press the
Previous menu option, and out to the
previous menu level.

Start/Stop Test
Charge Curr Lim.

Enable/Disable
AutoBThrs
Nxt Test DateTime
End Volt
MaxTestDur
Test int
Guard time
Enable/Disable
Max C.Curr

Battery Setup

NumOfBanks

Output Control

Voltage Control
Temp.Comp.

Change Date/Time

RelayTest

14

NomVolt
BoostVolt
LowBatt1
LowBatt2
HighBatt1
HighBatt2
LVD 1
LVD 2

Users Guide Smartpack Monitoring & Ctrl Unit,

Date
Time
Relay 1
Relay 2
:
Relay nn
LVD1 relay
LVD1 relay

Art. 350003.013, v2-2005-06

5 Specifications

Specifications

Remote Monitoring / Control

Local Monitoring / Control

From a PC running Windows-based

communication software (Smartpack
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 a PC running Windows-based

communication software (Smartpack
PowerSuite)
Windows-based comm. software can also
communicate with the Smartpack through an USB
serial or RS-232 cable.

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).
Using alarm relays (voltage free contacts)
6 internal failsafe alarm relays provide voltage free
contacts that can be connected to equipment used
for traditional alarm monitoring.

Features
System
Output Voltage Measurement
Total Load Current Measurement
Load/Battery Disconnect
Alarm Level Settings (major / minor)
Alarm Log (up to 1000 events)
Real Time Clock with Battery Backup
Site Text/ID
Test of Relay Outputs
Voltage Level setup
Battery
Battery Current Measurement
Battery Temperature Measurement (optional)
Battery Testing (acc. to discharge table or set time
limit)
Battery Test Information (10 latest tests)
Setup of Battery Data
Battery shunt setup
Battery quality indication
Battery Boost Charging
Battery Cable Voltage Drop Compensation
Temperature Compensated Charging
Protection against Temperature Probe Failure
Rectifier
Available information about each rectifier, e.g. serial
number, version, internal temperature
Individual Rectifier Current Measurement
Individual Rectifier Input Voltage

Users Guide Smartpack Monitoring & Ctrl Unit,

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.

Available Alarms
All alarms can be set up with monitoring of
minor, major, average and peak levels.
System
Mains Failure (individual phases)
Digital Inputs (programmable names)
Load Disconnect (voltage or timer)
Load Fuse
Load Current
Battery
High Battery voltage
Low Battery voltage
High Battery temperature
Low Battery temperature
Battery Capacity
Battery Disconnect
Battery Fuse
Symmetry Failure
Battery quality indication
Battery discharge current
Rectifier
Rectifier Failure
Critical Rectifier Failure (> 1, programmable)
Rectifier Capacity w. programmable level
Rectifier Current Limit
Rectifier Overvoltage Protection
Rectifier Current

Specifications
Input Voltage

24/48/60 VDC

Dimensions

109 x 44 (1U) x 140mm (wxhxd)

(4.3 x 1.7 x 5.5)

Art. 350003.013, v2-2005-06

15

6 Appendix

Appendix

6.1 Functionality Description Flatpack2 DC Power Systems

In this chapter you can find helpful and more detailed descriptions of expressions,
technical terms, functions, etc. used in Flatpack2 DC power supply systems.
6.1.1 Alarm Reset
You can reset all active alarms with the Smartpack controllers front keys (e.g.
UserOption>AlarmReset). 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 switch the alarm indicators 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.

6.1.2 Display System Voltages

You can display important system voltages with the Smartpack controllers front keys
(e.g. UserOption>VoltageInfo), as listed below:
o
o
o
o
o
o
o
o

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
LVD 2
Voltage limit for Low Voltage Disconnect unit 2

6.1.3 Display Alarm Messages (Alarm Log)

You can browse through the stored alarm messages using the Smartpack controllers
front keys (e.g. UserOption>DisplayMessages).
The Smartpack controllers 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

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

6 Appendix

6.1.4 Plug-and-Play Flatpack2 Rectifiers (Rectifier Info)

You can display the number of communicating Flatpack2 rectifiers in the system by using
the Smartpack controllers front keys (e.g. UserOption>Rectifier Info).
The following rectifier information is available in the Smartpack controller:
o Number of rectifiers installed in the system.
o Rectifier ID and serial number
o Rectifier current
o Rectifier input voltage
o Rectifier temperature
o Rectifier status
The green LED on the rectifier front panel will flash while the controller is accessing
information from a specified rectifier.
The Smartpack controller sends out status messages every 200ms to all the Flatpack2
rectifiers connected to the CAN bus, such as:
o The Smartpack controllers status
o Current Limit Reference
o Measured Output Voltage
o Reference Output Voltage
o Over-voltage Protection Reference
o Etc.

6.1.4.1

Plug-and-Play

When a previously installed Flatpack2 rectifier is inserted in a power shelf, it always

sends its previous ID and serial number to Smartpack controller, which checks if this ID
is below the number of rectifiers installed.
The following communication sequence is followed when a new Flatpack2 rectifier is
inserted in a Flatpack2 power shelf:
o
o
o

The installer inserts Flatpack2 rectifier

The rectifier module sends a log-on request to the Smartpack controller
If the rectifiers serial number is already present in the controller:
Send to rectifier the same ID as previously assigned to the serial number
Else
If any ID is not responding to the controller:
Take this ID and send it to the rectifier
Else
Take next free ID (last ID+1) and send it to the rectifier
Increment the number of modules communication in the CAN bus

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

17

6 Appendix

6.1.4.2

System Reset and Rectifier ID Reassignment

When a system reset is activated, the number of rectifiers is recalculated, and only the
number of communicating rectifiers at the moment will be counted.
If for instance rectifier number 4 of a total of 10 rectifiers is in error, nine will be
reported and rectifier 10 will be assigned ID 4.
Rectifier alignment before Reset: 10 rectifiers, ID 4 is in error
RectID # 01
Serial # 01
RectID # 06
Serial # 06

RectID # 02
Serial # 02
RectID # 07
Serial # 07

RectID # 03
Serial # 03
RectID # 08
Serial # 08

RectID # 04
Serial # 04
RectID # 09
Serial # 09

RectID # 05
Serial # 05
RectID # 10
Serial # 10

Rectifier alignment after Reset: 9 rectifiers, ID 10 is moved to position 4

RectID # 01
Serial # 01
RectID # 06
Serial # 06

18

RectID # 02
Serial # 02
RectID # 07
Serial # 07

RectID # 03
Serial # 03
RectID # 08
Serial # 08

RectID # 04
Serial # 10
RectID # 09
Serial # 09

Users Guide Smartpack Monitoring & Ctrl Unit,

RectID # 05
Serial # 05

Art. 350003.013, v2-2005-06

6 Appendix

6.1.5 Mains Assignment versus Rectifier ID

Normally, the rectifier ID number 1 is assigned to mains phase 1, the rectifier ID number
2 is assigned to mains phase 2 and rectifier ID number 3 is assigned to mains phase 3.
If rectifiers with ID number 1, 2 and 3 fails, the rectifier with ID number 4, 5, and 6 will
take their positions.
An alarm monitor is used for the mains phases. In a three phase system, the alarm
monitor can e.g. be configured to report a warning if one phase fails, and to report an
alarm if two phases fail.

6.1.6 About Battery Banks, strings, etc

Battery
Block (12V)

Battery
String #1
(48V)
Battery
String #2
(48V)

48V Battery Bank

Normally, battery banks are implemented by

connecting in parallel several battery strings; each
string is formed by battery blocks connected in series.
Figure 11 Example of a 48V battery bank
implemented with two 48V battery strings; each
string consists of four 12V battery blocks

6.1.7 Symmetry Mid-point, Double Mid-point or Block Measurements

Symmetry Block Measurement
Four measurement point per string

Symmetry Mid-point Measurement

One measurement point per string

The mid-point measurement method requires one

symmetry cable per battery string, the double midpoint measurement method requires two symmetry
cable per battery string, while the block measurement
method requires 4 symmetry cables per battery string.

Double Symmetry Mid-point Measurement

Two measurement point per string

Symmetry measurement is a battery monitoring

method of automatically detecting unbalanced battery
blocks. Symmetry monitoring of a battery string may
be performed by measuring each battery block (block
measurement method), by only measuring from the
mid-point of the battery string to one end (mid-point
measurement method) and by measuring from the
mid-point of the string to both ends (double midpoint measurement method).

Flatpack2 cabinetized systems are normally delivered

with the symmetry measurement method and the
number measurement points already preprogrammed
in the Smartpack controller. Any deviation from factory
settings requires Symmetry reconfiguration via the
PowerSuite PC program.

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

Users Guide Smartpack Monitoring & Ctrl Unit,

Art. 350003.013, v2-2005-06

19

ELTEK Energy
P-O- BOX 2340 Stms
N-3003 DRAMMEN
NORWAY
Phone:
Telefax:
Internet:

e-mail:

Location
Norway
Americas
Asia/Pacific
China
Europe
Middle East

+47 32203200
+47 32203210
http://www.eltekenergy.com
eltek@eltekenergy.com

Company
Eltek Energy AS
Eltek Energy, LLC
Eltek Energy Pte Ltd.
Eltek Energy Ltd.
Eltek Energy UK Ltd.
Eltek Middle East

Telephone
+47 32 20 32 00
+1 815 459 9100
+65 6 7732326
+852 28982689
+44 1442 219355
+971 4 887 1176

Fax
+47 32 20 32 10
+1 815 459 9118
+65 6 7753602
+852 28983189
+44 1442 245894
+971 4 887 1175

www.eltekenergy.com