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: Certificate No:

11276-2007-AE-NOR-NA 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: 242100.501

350021.013 Issue 1.0, 2010 Jun

Published 2010-10-06
mafe

2 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 3
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 controller’s 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 system’s 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 I/O Monitor2
CAN node
Flatpack2
Smartpack2
System Basic Controller
Fuse Alarm
CAN Bus

Flatpack2 HE
rectifiers
LVLD
Telecom and
Industrial
equipment
AC mains
supply
selector
AC Fuses,
external LVBD
Load Fuses
(230VAC or Temp. & MCBs
400VAC Sensors DC
Distribution

AC Supply DC Supply
(Single- or Battery string #1 Battery (24V, 48V
three-phase) Fuses 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

4 User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun
 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 system’s 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 controller’s 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 0
system. Executes measurements and CAN Address
analogue to digital conversions 1 via DIP switches (4)
µP
Flash
Flash & EEPROM Memory
24 / 48 / 60VDC Input supply stores the main program and
EEPROM dynamic data
Power supply
(DC/DC, Internal)
Power supply LVD Control
with regulated supply voltages for internal use Output signals (control)
Inputs ON
for LVD latching and not-latching
OFF contactors (3)
V
Voltage Sense Input
24V, 48V, 60V, 110V systems (1)
CAN
A Power Bus
Current Sense Input
20mV to 60mV shunt (1) CAN port w/Distributed power
for communication with rectifiers and CAN nodes
Supplies CAN nodes with power
Load Fuse Sense Input LEDs
Open/Close, Pull-Up/Down, Diode Matrix (1)
Front LED lamps
green, amber and red (3)
Battery Fuse Sense Input
Open/Close, Pull-Up/Down, Diode Matrix (1)
Cº

Temperature Sense Inputs

Battery temp via external probe (3)
Figure 2 Block diagram
Configurable: Smartpack2 Basic controller
(Open/Close, Pull-Up/Down, Diode Matrix)

User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun 5
2 The Smartpack2 Basic Controller

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

1+ DIP switches
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
LED Lamp (green)
Alarm
LED Lamp (red)

1+
LVD
Control Outputs (6 pins) Smartpack2 Basic
Power
+ 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 Illumination Description

Indicator Status
OFF The controller has NO supply
Power ON green Supply healthy
Flashing Green Distributed Power Fault
OFF No Warning
Warning ON amber Warning (Minor alarm, non-critical alarm)
Flashing amber Communications Fault
OFF No Alarm
Alarm ON red Alarm (Major Alarm, critical alarm)
Flashing red SW Fault / Boot Loader Mode

Table 1 Description of the Smartpack2 Basic controller’s LED illumination status

6 User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun
 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.

CAUTION: For safety reasons, the commissioning and configuration of the equipment is
! only to be performed by Eltek Valere’s personnel or by authorized and qualified persons;
Qualified
personnel
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
Smartpack2
the power system, switch OFF the power system, and
Basic controller
Power is OFF!

1 1. Loosen the top fixing tab screw from the

cw screw hole (D)
Smartpack2
Basic controller 2. Lift the controller carefully upwards,
I/O system
internal cables
(the slot (C) disengage from the lower
4 fixing tab (B)
3. Unplug the cables from the CAN bus
3 CAN sockets sockets

2 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
Flatpack2 4U-Distr. and then, in the inverse order, carry out the opposite
Subassembly
as described above (4, 3, 2, 1).
DIN rail mounting with dedicated plate is also
possible.
Figure 4 Smartpack2 Basic controller’s location in a cabinet or
subassembly. (The pluggable terminals may be black or
green)

User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun 7
2 The Smartpack2 Basic Controller

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
FUNCTION SIGNAL PIN-OUT

X:*
System Connections

(From internal equipment)

Voltage Sense Input 1 + 1 To System Voltage
− 2
Battery Fuse Input 1 + 3 To Battery Fuse
− 4
Load Fuse Input 1 + 5 To Load Fuses
− 6
Smartpack2 Basic + 7 To Current Shunt ^
CAN bus node

Current Sense Input 1

From previous

controller (System Reference) − 8

X:** Temperature

(From area with internal

Sensor 1
Configurable

Temp Sense 1 + 1
−
Inputs

batteries)
+ 3 Temperature
Temp Sense 2
− 4
Sensor 2

Temp Sense 3 + 5
− 6
Temperature
Sensor 3
X:***
LVD Control

LVD Output 1 + 1 To LVD Contator 1

Outputs

CAN − 2
RJ45 CAN bus termination plug, if the I/O
Monitor2 is the last node in the CAN bus

port 1&2 LVD Output 2 + 3 To LVD Contator 2

RJ45, 8 pins − 4
To next
CAN bus node

DIP LVD Output 3 + 5 To LVD Contator 3

Switches − 6
1
2
X:***
1
Power

Battery + +
Input

3
4 Battery +/− C 2 Power Input
Battery − − 3
2
Max. 1.5 mm ,
(Internal Connections) (14AWG) wire section
Or

Out In

Figure 5 Connection Drawing Smartpack2 Basic controller

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

8 User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun
 2 The Smartpack2 Basic Controller

CAN Bus Termination

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

Ethernet cable (LAN)

Smartpack2
Master Controller Smartpack2 120Ω
Basic Controller End-of-Line
Resistor

Flatpack2 HE
Rectifiers
1
CAN bus 01 02 n
(twisted-pair CAT5 cable) Internal System Monitoring
ID Number
81 82 120Ω
End-of-Line
Resistor

I/O Monitor2 I/O Monitor2

Alarm Outputs NC-C-NO Alarm Outputs NC-C-NO

Config. Inputs 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.

User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun 9
2 The Smartpack2 Basic Controller

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 system’s 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 controller’s ID numbers (1, 2…8) are assigned by DIP switches on
the controller’s top.
A maximum of 8 Smartpack2 Basic controllers may be connected to the CAN bus.

Smartpack2 Basic controller’s

DIP switch configuration
ID <1>
(All switches OFF)

Smartpack2 Basic ID DIP Switch Position

Controller** # 1 2 3 4
1st Controller 1 OFFOFFOFFOFF
2nd Controller 2 ON OFFOFFOFF
3rd Controller 3 OFF ONOFFOFF Terminal Blocks
4th Controller 4 ON  ONOFFOFF
Note:
5th Controller 5 OFFOFFON OFF The controller’s ID #
6th Controller 6 ON OFF ONOFF corresponds to the
7th Controller 7 OFFON ON OFF DIP switch’s binary
8th Controller 8 ON  ON ONOFF value plus 1
** The DIP switch positions apply also to
Smartpack controllers, but do not apply to
Smartpack2 Master controllers

Table 2 Smartpack2 Basic controller’s 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 system’s 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 system’s 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 task-
oriented 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.

User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun 11
2 The Smartpack2 Basic Controller

Technical Specifications
Specifications – Basic
Input Voltage Tolerances: 20-75 VDC
Shutdown: < 18 VDC
Temperature Range -40 to +65˚C (-40 to 140˚F)

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 24V, 48V, 60V systems
• Battery Fuse Battery fuse sense, Open/Close
• Load Fuse Battery fuse sense, Open/Close,
Pull-Up/Down, Diode Matrix
• Current Sense 0-20mV and 0-60mV shunt ranges
Max Basic nodes 8 units on a single CAN-bus
Dimensions 155 x 35 x 80mm
(WxHxD) 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 User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun
 2 The Smartpack2 Basic Controller

Firmware Upgrade Controller

Upgrade of the Smartpack2 Basic controller’s firmware is performed via the power
system’s 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 controller’s 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 controller’s 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 system’s CAN bus ends, and move the end-of-line resistor to one of
the converter’s 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

Smartpack2 Basic 120Ω
A Controller Flatpack2 HE
Rectifiers
End-of-Line
Resistor
B SD Card
Firmware (with Firmware
Source File)
Source File 1
01 02 n
Internal System Monitoring
FW Loader
120Ω ID Number
End-of-Line
Resistor 81

USB A-B cable USB to CAN I/O Monitor2

(standard) Converter

CAN bus Alarm Outputs NC-C-NO

(twisted-pair CAT5 cable) Config. Inputs
Flatpack2
DC Power System

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

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2 The Smartpack2 Basic Controller

14 User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun
 2 The Smartpack2 Basic Controller

User's Guide Smartpack2 Basic Controller 350021.013, Issue 1.0, 2010 Jun 15
www.eltekvalere.com
Headquarters:
Eltek Valere
Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10