081 022 Minipack System

356808.103

Quick Start Guide Installation, Operation, Commissioning and Maintenance

DC Power Supply System Integrated Applications

Miscellaneous Communication o CAN Bus Termination (13) o Installing PowerSuite – PC software (13) AC Mains o External AC Fuses ~ Recommended Rating (14) o Mains Feeds versus Rectifier ID (14) Battery Monitoring o Battery Symmetry – Connections (15) o Battery Interface Card ~ Terminals & Pin-out, ( 16) Alarms & Monitoring o Standard Alarm Relays & Digital Inputs (17) o Alarm Interface Card ~ Terminals & Pin-out (17) o Alarm Interface Card, Extd. ~ Terminals & Pin-out (18) Internal Connections o System Interface Card ~ Terminals & Pin-out (19) o LVD Latching Contactors (19) Drawings o Block Diagram Minipack 48VDC, 3.2kW (21) o Block Diagram Minipack 48VDC, 4.8kW (22)

Introduction o The Smartpack based Product Range (2 ) o Brief System Description ⎯ Minipack (2 )

Installation o Installing Smartpack and Rectifier Modules ( 3) o Installation and Maintenance Details

⎯ Opening or Closing the Minipack Drawer Shelf (4) ⎯ Mounting or Removing Minipack Blind Covers (4) ⎯ Removing or Mounting Load MCBs (5) ⎯ Configuring Priority and Non-Priority Load Circuits (5)

o Installation steps; mechanical, electrical (6-7) o Location of Components, GA drawing; 6 and 4 rectifiers systems (8) o Connections, Factory Settings, etc. (9)

Commissioning

o Pre-start check (10 ) o Commissioning steps, Startup (10-11)

Operation o Front keys and display (12) o Software Menus (12)

Check Lists pullout forms o Installation Check List o Circuit Distribution List o Commissioning Procedure o Maintenance Procedure

Minipack, PS System

Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03 2

The Smartpack based Product Range Eltek Valere's Smartpack based product range utilizes the Smartpack controller, and Flatpack2 rectifiers, Powerpack rectifiers and Minipack rectifiers as building blocks for implementing effective DC power systems, suitable for a wide range of applications and power ratings.

Cabinetized systems are suitable for indoor or outdoor applications. In addition to the power system and the distribution unit, the cabinet may also contain battery banks, additional distribution and other dedicated equipment.

Integrated systems consist of the power system, which includes rectifiers and controller(s), and the distribution unit (1U or 4U high). Integrated systems are sold primarily for mounting in existing cabinets.

Powerpack systems are suitable for large Central Office power plants, and use three-phase rectifier modules.

Minipack systems are suitable as small, stand-alone battery chargers and DC power supplies.

Brief System Description ⎯ Minipack The Minipack PS system is a compact and cost-effective DC power supply system, specifically developed for the telecom industry.

Example of a typical Minipack PS system for DC power supply of telecom equipment. The system is supplied from an external AC mains supply, and is delivered in one power shelf for integration in existing cabinets (integrated). An external battery bank is to be connected.

Introduction

Flatpack2 System, Integrated4U and 1U Distributions

Flatpack2 System, CabinetizedIndoor and Outdoor Cabinets

Powerpack System Minipack System, Integrated

Minipack

Battery string #1

SymmetryAlarm &

Temp. Sensor

LVLD

LVBD

Fuse Alarm

AC Fuses, external (230V)

Telecomequipment

AC Supply (Single- or

three-phase)

BatteryFuses

Load Fuses & MCBs

Smartpack (Ctrl. Unit)

PowerSuiteApplication

USB cable

DC distribution DC Supply

48V

*

CAN Bus

Minipack rectifiers

Alarm Outputs NC-C-NO Digital Inputs Remote

Monitoring


Installing Smartpack and Rectifier Modules

Smartpack controller

Handle in locked position

Hole to release the handle’s spring mechanism

Handle in unlocked position

Mounting or Removing Smartpack Controller Mounting the Smartpack controller

1. Open the handles by inserting a screwdriver into the holes to release the spring mechanism

2. Insert the module fully into the power shelf, after plugging the cables to the rear panel

3. Lock the handles by pushing the handles up into their housings (locked position), so that the module is securely locked

Removing the Smartpack controller

1. Open the handles by inserting a screwdriver into the holes to release the spring mechanism

2. Remove the module by using both handles to pull the module loose gently; support from underneath; unplug the cables connected to the rear panel

Minipack rectifier

Locking Screw

MountingRail

Front Handle

Device hazard

CAUTION: Do not hand-carry the controller by its handles. Cables and circuit boards are plugged to the controller’s rear panel. Open the handles before inserting the controller into the power shelf.

Device hazard

CAUTION: The modules may be warm. Remove the locking screw before inserting them into the power shelf (hot-pluggable). Do not relocate already hot-plugged rectifiers to other positions in the power shelf. New rectifiers must be hot-plugged in the power shelf, one at time, starting from the left with position 1, 3, 5 and 2, 4, 6.

Mounting or Removing Minipack Rectifier Modules

1. Unlock the module by

using a screwdriver to loosen the locking screw

2. Insert or remove the module by sliding it on its mounting rail fully into the power shelf, so that the module makes proper contact (hot-pluggable) or using the front handle to pull the module loose; support from underneath before the unit is completely free

3. Lock the module by screwing home the locking screw (locked direction). Then, the module will be securely locked in the shelf, or ready for transport

4. Mount blind covers in unused module locations

Electricshock

Controller & Modules Installation


Installation and Maintenance Details

Installation Details

Mounting or Removing Minipack Blind Covers

1. Unlock the blind cover by

using a screwdriver to loosen the locking screw

2. Insert or remove the blind cover by sliding it on its mounting rail fully into the power shelf or sliding it out, by inserting your fingers in the cover’s front handle and pulling it loose

3. Lock the blind cover by screwing home the locking screw (locked direction). Then, the blind cover will be securely locked in the shelf, or ready for transport

Minipackblind cover

Locking screw to secure the blind cover

Front handle

Fastening screwfor the shelf

frame

Fastening screws for the drawer

Minipack Sliding Drawer Shelf in Operation Position

Opening or Closing the Minipack Drawer Shelf To access the Minipack distribution area, you have to open the sliding drawer shelf. Do following to open or close the drawer:

1. Unlock the drawer shelf by

using a screwdriver to loosen the upper and lower locking screws. Do not loose the screw in the middle!

2. Open or close the drawer shelf by holding the drawer from the side plates and sliding it outwards. The drawer shelf is the in the Maintenance Position. or sliding it on its mounting rail fully into the shelf

3. Lock the drawer shelf by screwing home the upper and lower locking screws. The drawer is then securely locked in the shelf, in its Operation Position

Shelf Frame

Fastening screwfor the shelf frame

Minipack Sliding Drawer Shelfin Maintenance Position

F1, F2…PlasticCover


Details Installation

Configuring Priority and Non-Priority Load Circuits CAUTION: Power must be OFF during configuration! Only one screw may be removed.

1. Remove the F1, F2… plastic cover by unscrewing the cover’s frontal screw, then inserting a small screwdriver into the cover’s gap and carefully press down and out to release the locking tabs.

2. Switch OFF and unplug the actual MCBs by switching the MCB handle to “0” (upwards), then using your fingers to pull out the MCB

3. Remove the actual Priority Load Screw by using a screwdriver to unscrew the Priority Load Screw (refer to table below). Keep the removed screw in the clip, on the cover’s inside

Plugs for MCB1

Priority Load Screws(accessible with unplugged MCBs)

F3-F10 Screw (Y6)

F5-F10 Screw (Y7)F7-F10 Screw (Y24)

F9-F10 Screw (Y25)

Screw Removed F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 None P P P P P P P P P P

Y25 NP NP NP NP NP NP NP NP P PY24 NP NP NP NP NP NP P P P P

Y7 NP NP NP NP P P P P P PY6 NP NP P P P P P P P PWARNING: Only one screw can be removed at a time. P=Priority Load Circuits NP =Non Priority Load Circuits

Configuration of Priority & Non Priority Load Circuits

Plug for MCB1

MCB1

MCB8

Minipack front

0

1

MCB8(Upper and

lower plugs)

Removing or Mounting Load MCBs CAUTION: Power must be OFF during this operation!

1. Remove the F1, F2… plastic cover by unscrewing the cover’s frontal screw, then inserting a small screwdriver into the cover’s gap and carefully press down and out to release the locking tabs.

2. Switch OFF the MCB by switching the MCB handle to “0” position (upwards)

3. Remove or insert the MCB by using your fingers to pull out and unplug the MCB or pressing the MCB into the upper and lower plugs


Installation Steps

Check off in the Installation Check List, that you find in the pulloutsection of this folder. Also, refer to the system’s specific drawings.

Installation

For external AC fuses and AC input cable ratings, refer to your site’s ACsupply specification. Read also our external AC fuse recommendationsin section “Miscellaneous”. In general, a site with better AC supplyquality (stable nominal voltage) may use smaller breakers.

Mechanical Installation Power is OFF!

Carry out the following: 4 Remove packaging and check equipment

o Check you have received all the parts and correct documentation o Inspect the equipment for physical damage (report any damages) o Leave rectifier modules in their packaging or in the selves, if

factory installed. To be installed under commissioning 5 Remove the cabinet’s top cover and dummy front panel

o Connection terminals are accesses by opening the drawer shelf o Battery shelves (if any) are placed behind the lower panels

6 Position and fasten the subassembly o Minipack is fastened in existing 19” or in ETSI cabinets, using

brackets 7 Mount the external batteries on the shelves

o Start (if applicable) placing the batteries on the lower shelf first, and continue upwards

o Do not terminate the battery cables yet! 8 Open the Minipack drawer shelf and lift the plastic cover

o Unlock the upper and lower screws and slide the drawer shelf open; read the Installation & Maintenance Details chapter

o Lift the Melenex plastic cover to access the connection terminals

Electricshock

Devicehazard

Minipack PSS, Doc. Chart, Spec. Drawings, CD-ROM

Minipack drawer shelf slid out in the maintenance position

Plastic Cover

Preparing the Installation Site

Begin preparing the following:

1 Organize the installation site o A 2U high spare location in existing 19”, 250 mm cabinet o Min. Clearances: 60 cm in front o Explosive atmospheres are to be avoided. Ensure suitable

ventilation 2 Prepare the installation tools

o Use insulated tools suitable for telecom installations 3 Prepare AC Supply: AC input cable(s) and fuses

o Correct type AC supply is available o External AC fuses have correct rating o AC input cable(s) are sized correctly

EMCregard

600 mm

2U

200 mm


Installation

Electrical Installation Power is OFF!

Carry out the following: (Refer to the system’s specific drawings)

CAUTION: The cable lengths must be long enough (service loop) to allow opening the Minipack drawer shelf.

9 Make the system completely voltage free o Switch OFF or remove all load fuses (MCB1, MCBx), battery

fuses (Fb1, Fbx) and the AC supply fuses, in external fuse boards

10 AC Connections o Check AC configuration: the external AC supply consists of 3

single phase mains feed and earth (PE) o Connect the AC Earth wires (PE) to the terminals X5:1-2 (PE) o Connect the AC input cables to the terminals X5:3-4, 5-6, 7-8.

Cable and terminal block labeling are to correspond 11 DC Connections ⎯ Load Circuits

o DC Earth (TE); check that the common DC Output Rail is connected to “Telecom Earth” (TE) at only one place (at the cabinet , cable X7A, or at a central distribution point)

o For each DC load, connect one of the cables to the common DC output terminal, and the other to terminal X6B:F1, F2, etc.

12 DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration, or

to the “Miscellaneous, Alarms & Monitoring” section, terminal blocks X1, X2A and or X2B.

o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output

terminals 13 DC Connections ⎯ Battery Cables

Careful! Use correct polarity. For 48V systems using the battery symmetry mid-point measurement, refer to the figure in this page. For other measurement methods, refer to the Battery Symmetry Connections chapters in this guide’s Miscellaneous section. For each battery shelf:

CAUTION: Mount cable lugs upside down on the (+) battery cables

a Mount 3 intercell links to connect in series 4 battery blocks b-c Connect battery cables to fuses (Fb1, Fb2, etc.) and

Common Battery (X7A) and to the battery shelf’s outer terminals; black (+); blue (-)

d-e Connect battery symmetry cables, if applicable, to the input terminals, and to the center terminal of the battery string (+) and to the -48V outer terminal. Deviation from factory settings requires Symmetry reconfiguration via PowerSuite

f-g Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the temperature sensor (at the end of the cable) to a suitable place in the middle of the installed battery bank

Electricshock

Minipack drawer shelf slid out in the maintenance position

Service LoopCable lengths

enabling to openthe drawer shelf

Devicehazard

—(-48V) Outer

Terminal+

0V Outer Terminal

Link 2 (X7A)(DC Earth)

Common Battery X7A EG Battery

Fuse, Fbx

Intercell Links

BatteryCable S

ymm

etry

1

2-1

Chassis

Card Art.200576

+ -

15 pins D-Sub (male)

Tem

p. s

enso

r Tem

p. S

enso

r cab

le 1

Block1

- + + - + - + -

Block4 Block3

Cable lugs mounted upside down

Common Battery Cables (+)


Location of Components, GA drawing Refer to the specific drawings included with your Minipack PS system, for information regarding the exact location of components in your system.

Installation

NOTE: For information about connecting Battery Symmetry, Temperature Sensor, Alarm and Monitoring circuits, refer to section “Miscellaneous”, and read the Battery Monitoring, Alarms & Monitoring chapters.

CAN1CAN bus communication with rectifiers (to Smartpack rear)

CON5A, For internal connections (to Smartpack rear)

Common Battery (+) X7A, Battery connections

DC EarthX7A, Exchange Ground (EG) or system ground. Link connected to chassis

Fb1, Fb2 Battery connections (−)

AC MainsAC Mains & Earth (PE) Terminals

Plastic Protective Cover forAC Terminals

Forward sliding drawer shelf

Top view

Minipack Rectifier

Location ofSmartpack controller

Common DC Output (+)Load terminal block

DC Output (−)Load terminal block

Cable Fastening Plate

X5: pin 1

X6B: pin 1

LVLD latching contactor (optional)

LVBD latching contactor

Min

ipac

k, 6

Rec

tifie

rs (4

8V, 4

800W

)

Front view

Battery Fuses

Load MCBs


Minipack rectifiers

CAN1 CAN bus communication with rectifiers (to Smartpack rear)

CON5A, For internal connections (to Smartpack rear)

Common Battery (+)X7A, Battery connections

DC Earth X7A, Exchange Ground (EG) or system ground. Link connected to chassis

Fb1, Fb2, Fb3, Fb4Battery connections (−)

AC MainsAC Mains & Earth (PE) Terminals

Plastic Protective Cover forAC Terminals

Forward sliding drawer shelf

Top view

Minipack Rectifier

Location of Smartpack controller

Common DC Output (+)Load terminal block

DC Output (−)Load terminal block

Cable Fastening Plate

X5: pin 1

X6B: pin 1

LVLD latching contactor (optional)

Fb1

LVBD latching contactor

Min

ipac

k, 4

Rec

tifie

rs (4

8V, 3

200W

)

Front view

Battery Fuses

Load MCBs


Minipack rectifiers


Connections, Factory Settings, etc Refer to your system’s specific drawings for the exact connection points.

Installation

Minipack PS System, Integrated

The figure shows the posi-tion of the relay contacts when the PS system is in alarm mode of operation; the relay coils are then de-energized (fail-safe mode). The relay outputs are preprogrammed from factory (Factory Settings).

CANCom

Cable

CA

N b

us

End

-of-L

ine

Plu

g (1

20Ω

)

(Rear)

Smartpack (Front)

USBCom

Cable USB 2.0 Type B serial port

CAN1 portRJ45, 8 pins

CAN1 portRJ45, 8 pins

(For CAN bus termination, see section “Miscellaneous”)

FUNCTION SIGNAL TERM. POINT

X5

AC

Mai

ns In

puts

6 5 4 3 2 1

7 8

PEPEN3L3N2L2N1L1

2.5 mm2, max. wire section M4 terminals

Mains Feed 1

Mains Feed 2

Mains Feed 3

AC Earth (PE)

FUNCTION SIGNAL PIN-OUT

Load

Fus

es

MCB1

MCB2

X6A

2

1

10

8

+

+

+

+

6 m

m2 , m

ax. w

ire s

ectio

n Load Circuit 1X6B

Load Circuit 2

MCB8Load Circuit 8

MCB10 Load Circuit 10

(Minipack systems with 6 rectifiers have 8 DC load outputs available. Systems with 4 rectifiers have 10 DC load outputs)

CommonBattery “Rail”

Bat

tery

Fu

ses Fb1

Fbx

Battery Cables, string 1

Battery Cables, string x

M6 screws, cable lugsmax. 15 mm width

X7A

Interface Cards Connections Refer to the connections for the actual terminal circuit boards

installed in your system

Battery Connections (X4)Terminal Circuit Board, Art. 200576

Battery Symmetry 1-4 and Temp. Sense 1 (See page 15 for pin-out information)

Battery Connections, Extended (X3)Terminal Circuit Board, Art. 200576

Batt. Symmetry 5-8, Temp. Sense 2, Batt. Current and Batt. Fuse Fail

(Not applicable for Smartpack RS232 D-Sub option, on rear panel) (See page 15 for pin-out information)

Alarm Outputs & Digital Inputs (X1)Terminal Circuit Board, Art. 218470

Digital Input 1-2 and Relay Output 1-2 (See page 15 for pin-out information)

Alarm Outputs & Digital Inputs Extended (X2A & X2B)Terminal Circuit Board, Art. 218473

Digital Input 3-6 and Relay Output 3-6

(Not applicable for Smartpack Ethernet option) (See page 15 for pin-out information)


The Minipack PSS startup consists of following stages:

I. Perform a pre-start check before the PS system is switched ON II. Switch ON the system with disconnected load; adjust output voltage

III. Adjust the nominal output voltage with connected batteries and load

Pre-Start Check Power is OFF! Check off in the Commissioning Procedure, that you find in the pullout section of this folder.

If you have just finished the system installation successfully and filled in the Installation Check List, jump over the Pre-Start Check and continue with stage II.

Before you switch ON the Minipack PS system, verify the following:

1. System installation is completed o Ensure a correctly performed system installation, with correct polarity on all

connections (Installation Check List filled in) o All cabling is securely terminated and supported o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled

2. Battery and load fuses are disconnected o Verify that all battery and load MCBs/ fuses are switched OFF

3. AC input cable(s) and AC Earth wire (PE) are terminated o Make sure that the AC input cable(s) are correctly connected to the AC terminals o Verify that the AC input cable(s) and external AC fuses are sized and rated as specified o Check that AC Earth (PE) is terminated, and electrically connected to chassis

4. Site specific parameters and settings are known o Read the site specific drawings and documentation

5. AC supply and all MCBs, fuses are switched OFF o Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF

Commissioning Steps, Startup Check off in the Commissioning Procedure, that you find in the pullout section of this folder.

After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you will switch ON the Minipack PSS — while the batteries and load are disconnected ⎯ then measure the output voltage, and adjust it if required. Carry out the following:

Startup and No-Load Adjustments Power is ON!

1. Disconnect all rectifier modules, without removing them (keep original location) o Verify that all Minipack rectifier modules are disconnected (unplugged) but NOT

physically removed from the power shelf. Also, read about the correct rectifier position, page 14, and how to mount them, on page 3.

2. Switch ON the system o Switch ON the AC input supply (external AC fuses) to the Minipack system

3. Measure and verify that the AC input voltage is correct o Measure the AC terminals’ input voltage at the system’s AC Mains terminals o Verify that the AC voltage is within range

Commissioning

Device hazard

Device hazard

I

II


4. Mount all Minipack rectifier modules in the power shelves (keep original location)

o Plug all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯ to plug them in the same self location. Secure them with the locking screws. Refer to page 3.

o Mount Minipack blind covers over unused positions

5. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON o Verify correct operation, by monitoring the modules’ LED lamps and display:

No alarm are present on rectifiers. The Smartpack displays fuse alarms

6. Connect the a PC to the PS system (to facilitate operation) o Plug a standard USB A-B cable between the PC and the Smartpack controller o Start PowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite

Refer to chapter “Installing PowerSuite ⎯ PC Application”, page 13, if required o On the toolbar, click the “Connect” button to establish connection

7. Measure and adjust DC output voltage o Read the DC output voltage on the controller’s display o With a multi-meter, measure the DC output voltage at the most accessible point, e.g.

between the common DC rail and the lower connection of one of the priority load MCBs o If required, adjust the voltage using the controller’s front keys or via PowerSuite

8. Verify the alarm relays are working correctly (alarm relay test) o Run the alarm relay test using the controller’s front keys (refer to page 12) or via

PowerSuite (select the menu Go > Output Test)

9. Make sure the System Setup is in accordance with configuration o Verify system settings using the controller’s front keys or via PowerSuite o Use the opportunity to enter site related information, number of used AC phases,

type of batteries, etc.

Load Adjustments Power is ON!

Now, you can begin with stage III, where you will adjust again the output voltage to the battery voltage, and connect the batteries and the load. Carry out the following:

10. Adjust DC output voltage to measured battery voltage o Measure the battery voltage is within range (check connections have correct polarity) o Adjust DC output voltage — using the controller’s front keys (refer to page 12) or via

PowerSuite— to equal the measured battery voltage. (Important adjustment to avoid arcing when connecting the batteries)

11. Unplug all rectifiers but one, and connect the battery fuses /MCBs (CAUTION: Have only one rectifier connected, when switching ON the battery fuses. Thus, avoiding damaging all rectifiers, due to possible incorrect polarity connections, etc.)

o Disconnect all rectifiers but one, by unlocking the locking screw and pulling them partially out. Do NOT physically remove them from the power shelf

o Switch ON all battery fuses or MCBs

12. Adjust DC output voltage again to equal the nominal battery voltage o Adjust DC output voltage — using the controller’s front keys or via PowerSuite — to

equal the nominal battery voltage (or the nominal load voltage, when not using batteries)

13. Plug in again all rectifiers, and verify the rectifiers’ current sharing o Connect all rectifiers again by pushing them firmly inwards ⎯ Repeat step 4, in stage II o Wait for about 2 min., and check — using the PowerSuite application —that each of the

rectifiers delivers the same output current. A deviation of 1A is acceptable. 14. Connect the load breakers and verify that no alarms are displayed

o Switch ON all load MCBs/ fuses o Verify correct operation: rectifiers and controller display no alarms

Commissioning

Devicehazard

Devicehazard

III


Front Keys and display, menus, etc.

Operation

Minipack Rectifier Module — front panel Power LED is OFF (mains unavailable), Flashing (controller accessing information) or ON (powered). Warning LED is ON (derating or similar minor warning), Flashing (over-voltage mode) or OFF (OK) Alarm LED is ON (shutdown or similar major alarm) or OFF (OK, no alarm)

Smartpack Control Unit — front keys, display, etc Display: is in Status Mode (displays the system’s status) or in Menu Mode (displays the menu structure). Operation: Press on the key to change from Status Mode to Menu Mode. Press the or keys to scroll up or down and navigate to find menu options (function or parameter). Press then the key to select the function. Menus: When you “enter” Menu Mode (Level 1), you access the User Options. You may also scroll down to password protected Service Options. Default password <0003> should be changed.

PowerLED Lamp (green)

Warning LED Lamp (yellow)

AlarmLED Lamp (red)

GraphicalDisplay

16 char. x 2 linesLCD display

”Up” arrow key ”Down” arrow key

”Enter” key

USB0ype B port

Smartpack control unit

Minipack rectifier

PowerLED Lamp (green)

WarningLED Lamp (yellow)

AlarmLED Lamp (red)

Software Menus ~ Smartpack controller

User menu <UserOption> AlarmReset

NomVolt

BoostVolt

LoBattMaj

VoltageInfo LoBattMin

HiBattMaj

HiBattMin

LVBD

LVLD 1.1

DisplayMessages Message ↓↑

SoftwareInfo

SerialNumber

NoOfRects. nn

RectCurrent

Rectifier Info RectSerialNumber

Rect.PrimaryVolt

Rectifier Status

Rectifier Temp

Rect. OutputVolt

Rectifier SW Ver

NoOfPhases nn

Mains Info Mains Status

Mains Voltage

Temp Level Info Level ↓↑

NoOfString Nn

BattStringCurr ↓↑

Battery Info BattStringTemp ↓↑

BattBlockVolt ↓↑

Level 2 Level 3

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Service menu <ServiceOption> Change Language English ↓↑ 2v0

NomVolt ↓↑

BoostVolt ↓↑

LoBattMaj ↓↑

VoltAdjustment LoBattMin ↓↑

HiBattMaj ↓↑

HiBattMin ↓↑

LVBD ↓↑

LVLD 1.1 ↓↑ VoltCalibration VoltCal ↓↑ ChangePassword Password ↓↑ SetManBoostTime ↓↑ Start/StopBoost Auto Boost Config. Enable/Disable ↓↑ & Threshold ↓↑

Nxt Test DateTime Date ↓↑ Time ↓↑

End Volt ↓↑ Batt Test Setup MaxTestDur ↓↑

Test Int ↓↑

Guard Time ↓↑ Start/Stop Test NoOfRects. ; nn Reset Charge Curr Lim. Enable/Disable ↓↑ & Max C.Curr ↓↑

Battery Setup NumOfString ↓↑

CellCap Ah nn ↓↑ Output Control VoltageCtrl / TempComp ↓ Change Date/Time Date ↓↑ Time ↓↑

Alarm Output 1 ↑ RelayTest Alarm Output 2 ↑

Batt Contactor ↑

Load Contactor ↑

Alarm Output nn ↑ BlockOutputs Enter OutpBlocked/Exit OutpBlocked 2v0 BattLifeTime Rst

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INSTALLATION CHECK LIST System Data Minipack PS System Minipack Power Supply System, type: Article No.:

Site, name:

Serial No.: Software, version No.: Rectifiers, type & number of:

AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:

Site Preparations CARRY OUT FOLLOWING: OK 1. Organize the installation site

o Prepare a 2U high spare location in existing 19”, 250 mm cabinet; Check min. clearance: front access, 60 cm o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere.

2. Prepare the installation tools o Check that insulated tools suitable for telecom installations are used

3. Prepare AC Supply: AC input cable(s) and fuses o Check the AC supply is the correct type, and that the external AC fuses and AC input cable(s) are suitably rated

Mechanical Installation Power is OFF! CARRY OUT FOLLOWING: OK 4. Remove packaging and check equipment

o Check you have received all the parts and correct documentation. o Inspect the equipment for physical damage (report any damages) o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)

5. Remove the cabinet’s top cover and dummy front panels o Check that cable entry from the top is possible o Connection terminals are accesses by opening the drawer shelf

6. Position and fasten the subassembly o Subassemblies in existing 19” or in ETSI cabinets, using brackets.

7. Mount the external batteries on the shelves o Start (if applicable) on the lower shelf first, and continue upwards o Do not terminate the battery cables yet!

8. Open the Minipack drawer shelf and lift the plastic cover o Unlock the upper and lower screws and slide the drawer shelf open, then lift the Melenex plastic cover

Electrical Installation Power is OFF! CARRY OUT FOLLOWING: OK 9. Make the system completely voltage free

o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses 10. AC Connections

o Check AC configuration: Make available 3 single phase mains feed and earth (PE) o Connect the AC Earth wire (PE) to the terminals AC Earth (PE) o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond

11. DC Connections ⎯ Load Circuits o Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place o For each DC load, connect one of the cables to the common DC output terminal; the other to the fuse terminal

12. DC Connections ⎯ Alarm & Signal Circuits o Refer to your system’s connection drawings and configuration, or to the Quick Start Guide o Terminate Alarm Circuit cables to the relay output terminals o Terminate Signal Circuit cables to the digital input/output terminals

13. DC Connections ⎯ Battery Cables Careful! Use correct polarity. For each battery shelf,

o Mount 3 intercell links to connect in series 4 battery blocks o Connect battery cables to fuses and Common Battery, and to the shelf’s outer terminals; black (+); blue (-) o Connect battery symmetry cables, if applicable, to the input terminals o Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the

end of the cable) to a suitable place in the middle of the installed battery bank

Approval Responsible of installation, sign.: Date: Approved by customer, sign.:

EMC regard

Electric shock

Device hazard

Electric shock

www.eltekvalere.com

Headquarters: Eltek Valere 1303 E. Arapaho Rd, Richardson, TX. 75081, USA Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101

Eltek ValereGråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway

Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

CIRCUIT DISTRIBUTION LIST System Data Minipack PSS, type: Article No.:

Site, name:

CIRC. NO. FUSE

- TYPE

MCB LVLD

CONTROLLED DESCRIPTION FUSE

AMPERECABLE

mm2

Fb1 Fb2 Fb3 Fb4 F1 F2 F3 F4 F5 F6 F7 F8 F9 F10

LOA

D

BA

TT.

Form 175-gb-v1-C



fm_2006-12-29

www.eltekvalere.com



Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

COMMISSIONING PROCEDURE System Data Minipack PS System Supplier’s Order No.: Minipack Power Supply System, type: Article No.:

Site, name:


AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:

Pre-Start Check Power is OFF! CHECK FOLLOWING: OK 1. Minipack system installation is completed; The Minipack Installation Check List is filled in.

All cabling is securely terminated with correct polarity 2. All battery and load MCBs/ fuses are disconnected

3. AC input cable(s) and AC earth wire (PE) are terminated

4. Site specific parameters and settings are known

5. AC supply and all MCBs/ fuses are switched OFF

Start-up, No-Load & Load Adjustments Power is ON! CARRY OUT FOLLOWING: OK 1. Disconnect all rectifier modules, without removing them (keep original location)

2. Switch ON the system (external AC fuses ON)

3. AC input voltage is correct; Measure and verify

4. Insert all Minipack rectifiers in their original locations in the power shelves

5. The Smartpack and all rectifier modules are working, LEDs are ON; Verify

6. Connect a PC to the PS system Install the PowerSuite software, if required

7. DC output voltage; Measure and adjust

8. Alarm relay test; Verify all alarm relays are working correctly 9. System Setup is in accordance with configuration Enter site spec. info in PowerSuite 10. Adjust DC output voltage to equal measured battery voltage Check correct polarity! 11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs 12. Adjust DC output voltage to equal nominal battery or load voltage 13. Plug in again all rectifiers, and verify the rectifiers’ current sharing 14. Connect all load MCBs/ fuses, and verify no alarms are displayed

Approval Responsible of commissioning, sign.: Date: Approved by customer, sign.:

Device hazard

I

II

Device hazard

III

Device hazard

Form 176-gb-v1-C



fm_2006-12-29

www.eltekvalere.com



Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

PU

LLOU

T

WARNING: Maintenance work on live equipment is only to be performed by authorized and qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury. Electric

shock

MAINTENANCE PROCEDURE System Data Minipack PS System Minipack Power Supply System, type: Article No.:

Site, name:


AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:

System Inspection Power is ON! CARRY OUT FOLLOWING: OK 1. Site specific parameters and settings are known.

User manuals and site specific connection & arrangement drawings are available.

2. The battery bank has been fully charged in advance. At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration

3. The equipment is free from damage, dust or dirt; verify. Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.

4. All cabling and copper bars are securely terminated and supported. Correct any loose connections, excessive cable temperature, defective insulation, etc.

5. The Smartpack & all rectifier modules are ON, no alarm present; verify. Otherwise, correct and put the PS system in normal mode of operation.

6. All rectifier’s functionality & Smartpack’s keys and display work OK; verify Correct possible abnormalities before continuing.

7. Connect the PS system to a PC (install the PowerSuite application if required) The PowerSuite program in the PC enables system configuration from the PC.

8. Rectifiers’ load current sharing; verify. Use the PowerSuite PC application to check all rectifiers output the same amount of current (±1A)

9. Display the stored log of Alarm Messages. Using the keypad on the Smartpack controller or from the PC.

System Adjustment CARRY OUT FOLLOWING: OK 1. DC Output Voltage Calibration; ensure correct display readings.

If measured DC output voltage at the load terminals deviates more than ±1% from the display reading, calibrate the output voltage from the Smartpack’s keypad or the PC.

2. Load & Battery Current Calibration; verify correct display readings. Measure with a clip-on ammeter the battery current & every load circuit current. Calculate the total load & battery current. If the calculated total values deviate more than ±1% from the display readings, calibrate the current from the PC (calibration value>50% of system’s max. capacity)

3. DC Output Voltage Adjustment; measure and adjust. Measure and, if required, adjust the output voltage to the nominal voltage recommended by the battery manufacturer. (Voltage measurements to be done at the DC rail, with little load current)

4. Alarm Relay Test; verify all alarm relays are working correctly. From the Smartpack’s keypad or PC use the Relay Test function; verify activation of external equipment

5. Battery bank control; measure and verify battery specifications. Follow the recommendations of the actual battery manufacturer.

Approval Responsible of maintenance control, sign.: Date: Approved by customer, sign.:

Form 177-gb-v1-C



fm_2006-12-29

www.eltekvalere.com



Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

PU

LLOU

T

Check Lists Pu

llout

Pull o

ut th

e pag

es with

the g

ray outer b

and,

and u

se them

as check lists


CAN Bus Termination Minipack systems are shipped from factory with the CAN bus already terminated with 120Ω resistors.

To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120Ω resistors, one at each end of the line. The figure shows a Minipack system, with its controller communicating with the rectifiers via the CAN bus.

Smartpack assigns ID numbers to the rectifiers (software-assigned). The Smartpack’s ID numbers are assigned by DIP switches on the controller’s side.

Installing PowerSuite ⎯ PC Application The PowerSuite software application enables you to configure and operate the Minipack Power Supply System from a personal computer.

Communication Miscellaneous

3. Wait for Windows to detect the Smartpack controllerIf required, a wizard will automatically install necessary USB drivers. Follow & accept the wizard default steps New hardware

is ready to use 3

If PowerSuite fails communicating via the standard COM port, find the COMx assigned to Smartpack, by selecting menu option “Tools > Options” (click on the Find COMx button).

PowerSuite’s newest version is always available on our FTP server. Call your Eltek Valere’s contact person.

Minipack system configuration from a PC running MS Windows XP

2. Switch Smartpack ON and plug USB cable (Part 202073)to Smartpack and to any available USB port in the PC 2

1. Install PowerSuite Insert CD in your PC drive and follow & accept the wizard default steps to install PowerSuite 1

4. Start PowerSuite and establish connection Select “Start > All Programs > Eltek > PowerSuite”. On the toolbar, click “Connect” button. On the Connection dialogue box, click the “Connect” button

4

120Ω

Minipack DC Power System

End-of-Line Resistor

End-of-LineResistor

120Ω

CAN bus(twisted-pair internal CAT5 cable)

USB A-B cable(standard)

1

02 n01


External AC Fuses ⎯ Recommended Rating The site’s AC supply quality is of great importance. In general, a site with better AC supply quality (stable nominal voltage) may use smaller breakers.

Mains Feeds versus Rectifier ID Mains Monitoring The Minipack system is fed with 3 One-phase 230VAC Mains input circuits. Each input circuit is internally connected to feed 2 rectifiers, in such a pattern that loads the 3 circuits evenly.

Plug-and-Play Rectifiers versus Mains Monitoring

When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller assigns the next available ID number to the rectifier, starting with “01”.

When a previously installed (hot plugged) Minipack rectifier is inserted in a power shelf, the Smartpack controller “recognizes” the module, and assigns the same ID to the rectifier. In other words, the controller and the rectifier “remember” the assigned ID number, even after removing and reinserting the rectifier in the shelf.

To achieve a more controlled ID assignment, you should always insert & hot-plug new Minipack rectifiers in the power shelf, one module at a time, in following shelf position order: 1, 3, 5 and 2, 4, 6.

This position-versus-ID number relationship is very important for the correct monitoring of the mains circuit, as the Smartpack controller always uses rectifier ID01, 02 and 03 to monitor the Mains Feed 1, 2 and 3 respectively. If these rectifiers malfunction, rectifier ID 04, 05 and 06 will automatically take over.

For example: accidentally inserting a rectifier with ID02 in a power shelf position internally connected to mains feed 1, will cause the controller to monitor mains feed 1 “thinking“ it monitors mains feed 2.

Miscellaneous AC Mains

Position # 1 2 3 4 5 6 ID # 01 04 02 05 03 06

Mains Feed 1One-phase, 230VAC

N(L2) 230VAC

AC Mains

L(L1) 01 02


N(L2)

230VAC

AC Mains

L(L1)

03 04


N(L2) 230VAC

AC Mains

L(L1) 05 06

Distribution of Minipack rectifiers (ID #) on the 3 AC Mains Input Circuits

01

Mai

ns F

eed

2 M

ains

Fee

d 1

Mai

ns F

eed

3

02 03

Minipack System

Position 6

ID number (Assigned CAN bus address)

04 05 06

Position 1

205V

AC

In

puts

AC Mains No of Current Max. (A) Ext. Fuse Type Rectifiers per Input Type

230VAC1 phas

4 17.5 20A-C

626.3 32A-C

AC Mains No of Current Max. (A) Ext. Fuse Type Rectifiers per Input Type

230VAC1 phas

4 19.4 20A-C

629.5 32A-C

Minipack Rectifiers 48 VDC, 800W

Each mains input feeds 2 rectifiers

Note: The recommendations ap-ply for use of Thermal mag-netic circuit breaker, type Siemens 5SX or 5SY se-ries, MG C60H series or similar. For more informa-tion regarding External AC fuses and other types of fuses, please read the arti-cle 2024398 on the CD, 356808.CD3. 18

5VA

C

Inpu

ts

Use the recommenda-tions in the 205VAC ta-ble, if you are sure the available AC mains voltage will not drop below 205VAC.

OR If you are unsure ⎯ or know that the voltage may drop below 205VAC ⎯ use the 185VAC table recom-mendations.

Doc 2024398, v1


Battery Symmetry Connections Connections Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors CON4 and CON3), enabling symmetry measurement of:

• 8 battery strings using the Mid-Point Measurement Method

• 4 battery strings using the more accurate Double Mid-Point Measurement Method

• 2 battery strings using the even more accurate Block Measurement Method

You can implement any of these methods using one or two Battery Connection Kits (see the illustration next page) and the appropriate number of Battery Symmetry Kits, which contain a single cable strand with suitable cable eyes, etc.

Battery Terminology

Battery Block, Battery String and Battery Bank

48V Battery Bank

Battery String #1 (48V)Batt.

Battery Block (12V)

Battery String #2 (48V)

Battery Symmetry Mid-point Measurement

One measurement per string

—(-48V) Outer

Terminal+

0V Outer Terminal

Intercell Links

2-1 X:****

Sym

met

ry 1

+-

Card, Art. 200576 Serial Switches

Set all 4 switches OFF (up)

Block1

- + + - +B+−

−(From

Notice that, if you open the serial switches in card, Art.200576 ⎯ setting all to OFF (up) ⎯ you have to connect the+ and – wires of every symmetry input.

Battery Symmetry Block Measurement

Four measurements per string (Serial measurement)

—(-48V) Outer

Terminal+

0V OuterTerminal

Intercell Links

X:****

Block1

- + + - + -+-

Block4 Block3

Card, Art. 200576Serial Switches

Set all 4 switches ON (down)

7

Sym

met

ry 4

+

2-1

Sym

met

ry 1

+-

5

Sym

met

ry 3

+

3

Sym

met

ry 2

+

Battery Symmetry Double-point Measurement

Two measurements per string, from the middle to the outer terminals

—(-48V) Outer

Terminal+

0V Outer Terminal

Intercell Links

X:****Card, Art. 200576 Serial Switches

Set all 4 switches ON

(down)

3

Sym

met

ry 2

+

2-1

Sym

met

ry 1

+-

Block1

- + + - +- + -

Block4 Block3

Bat

t. S

ymm

etry

Kit,

Art.

200

830

Cable Eyes

Sin

gle

Cab

le S

trand

Battery Monitoring Miscellaneous


Battery Interface Card ~ Terminals & Pin-out The Smartpack controller’s battery monitoring signals are accessible on D-Sub connectors CON4 and CON3, on the controller’s rear panel.

Using the Battery Connection Kit ⎯ which consists of a Battery Interface Card (Art. 200576) and a standard 15 pins D-Sub cable ⎯ you can make the signals on CON4 accessible at any suitable location inside your system, e.g. near the battery blocks.

When extra battery monitoring signals are required, you can use an extra Battery Connection Kit connected to the controller’s CON3.

For detailed information about the card’s pin-out location and terminal block connections, see the figures in this section.

For temperature monitoring of the battery compartment, we recommend the use of the Temperature Sense Kit, instead of connecting the sensor cable directly to the terminals, pin 9-10.

The Temperature Sense Kit is connected to the Battery Interface Card (Art. 200576), or directly to the controller’s CON3 or CON4, if unused.

15 pins D-Sub cable

Card Art.200576

Battery Connection Kit

Temp. sensor

Temp. Sensor cable

Temperature Sense Kit

In

1.5 mm2, max.wire section

Battery Connections (Internal) Configurable monitoring digital inputs


(Internal Connections)

4 3 2 1

5

9 8 7 6

10

14 13 12 11

X4Batt. Symmetry 1 +

−+−+−+−

Batt. Symmetry 2

Batt. Symmetry 3

Batt. Symmetry 4

(Fro

m in

tern

al

batte

ries)

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperaturesensor

+−Temperature Sense 1

(NA)

(NA)

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperaturesensor

15-pins D-Sub female

(Alternative use of Temp. Sense Kit, instead of connecting to X4: 9-10)

Temperature Sense 1

X**/X*15-pins D-Sub male

1 5

11 15

Card Art.200576 To

Sm

artp

ack,

CO

N4

CON3A or CON4A 15-pins D-Sub female

1 11

5 15

In


Battery Connections (Internal) Configurable monitoring digital inputs


(Internal Connections)

4 3 2 1

5

9 8 7 6

10

14 13 12 11

X3+−+−+−+−

(Fro

m in

tern

al

batte

ries)

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperaturesensor

+−

(Fro

m a

rea

with

in

tern

al b

atte

ries)

Temperaturesensor

15-pins D-Sub female

(Alternative use of Temp. Sense Kit, instead of connecting to X3: 9-10)

Temperature Sense 2

X**/X*15-pins D-Sub male

1 5

11 15

Card Art.200576

To S

mar

tpac

k,C

ON

3

CON3A or CON4A 15-pins D-Sub female

1 11

5 15

The Temperature Sense Kits may also be connected directly to the Smartpack controller’s CON3 or CON4, if these connectors are unused.

Batt. Symmetry 5

Batt. Symmetry 6

Batt. Symmetry 7

Batt. Symmetry 8

Temperature Sense 2

Batt Current 2

Batt Fuse Fail 2

Miscellaneous Battery Monitoring

Battery Interface Card, Art. 200576 14

1

Serial Switch

For Temp. Sense Kit CON3A or CON4A

X3/X4X**/X*

1

Terminals & Pin-out Location CON3

CON2

CON4 CON5

CON1

PCB 200576

PCB 200576

Smartpack


Standard Alarm Relays & Digital Inputs Connections

The alarm outputs in Minipack systems use the Fail-Safe Operation Mode (relay coils energized in the system’s normal operation mode). When the system is in alarm mode, the alarm relay coils are de-energized.

In order to implement monitored fail-safe digital inputs circuits, the external relay coil must be energized and the contact closed in the system’s normal mode of operation. See the figures.

Alarm Interface Card ~ Terminals & Pin-out

The Smartpack controller’s alarm and digital input monitoring signals are accessible from the controller’s rear panel, on mini power connector CON1 (2 outputs & 2 inputs).

Using the Alarm Interface Card (Art. 218470) plugged to Smartpack’s CON1, you can make the signals on CON1 accessible on terminal block X1.


Standard Relays & Digital Inputs

Correct Use of Digital Inputs (example)

Normal ModeExternal Relay Y(Energized coil)

+—

Digital Input X (Normal mode)

Alarm ModeExternal Relay Y

(De-energized coil) +

—Digital Input X (Activated)

Minipack PS System

Correct Use of Alarm Outputs (example) Minipack PS System

—

+

NC

NOCom

Normal ModeRelay X

(Energized coil)

+—

Alarm Mode

Relay X(De-energized coil) NC

NOCom

Alarms & Monitoring Miscellaneous

Terminals & Pin-out Location

CON3CAN1

Smartpack

CON2

CON4CON5

CON1

10

1X1

Card neck for cable fastening

Alarm Outputs & Digital Inputs Card Art. 218470

Card 218470

4 3 2 1

5

9 8 7 6

10

X1

(Customer Connections)

Input Circuit 1

Input Circuit 2

Alarm Circuit 1

Alarm Circuit 2

OutIn

(To

and

from

ex

tern

al e

quip

men

t)


Relay 1Common Alarm

+−

NOCOM

NC

NOCOM

NC

+−

Digital Input 1

Digital Input 2

Alarm Outputs & Digital InputsVoltage free relay outputs and Configurable monitoring digital inputs


To S

mar

tpac

k,

CO

N1

Card Art.218470To CON1

1

10X1


Alarm Interface Card, Extd. ~ Terminals & Pin-out

Additional alarm and digital input monitoring signals are accessible from the Smartpack controller’s rear panel, on D-Sub connector CON2 (4 outputs & 4 inputs).

Using the Alarm Interface Card, Extended (Art. 218473) plugged to Smartpack’s CON2, you can make the signals on CON2 accessible on terminal blocks X2A and X2B.


Miscellaneous Alarms & Monitoring

(Customer Connections)

OutIn


Alarm Outputs & Digital Inputs, ExtendedVoltage free relay outputs and Configurable monitoring digital inputs


Input Circuit 3

Alarm Circuit 3

Input Circuit 4

Input Circuit 5

Input Circuit 6

Alarm Circuit 4

Alarm Circuit 5

Alarm Circuit 6

X2A

4321

5

9876

10

+−

+−

+−

+−

Digital Input 3

Digital Input 4

Digital Input 5

Digital Input 6

(To

exte

rnal

equ

ipm

ent)

(Fro

m e

xter

nal e

quip

men

t)

NOCOM

NC

NOCOM

NC

NOCOM

NC

NOCOM

NC

Relay 3Fuse Alarm

Load & Battery

Relay 5Low Battery Alarm

Relay 6Rectifier Alarm

Relay 4High Battery Alarm

To S

mar

tpac

k,

CO

N2

14131211

151617181920

X2B

Card Art. 218473To CON2

1

10

X2A

11

20X2B

Terminals & Pin-out Location

CON3CAN1

Smartpack

CON2

CON4CON5

CON1

Card 218473

1 10

X2A

1120X2B

Card neck for cable fastening

Alarm Outputs & Digital Inputs Card, ExtendedArt. 218473

(NA for Smartpack Ethernet option)


System Interface Card ~ Terminals & Pin-out Minipack systems are shipped from factory with the CON5 signals already connected.

Some of the Smartpack controller’s internal system signals are accessible on D-Sub connector CON5, on the controller’s rear panel.

Using a standard 15 pins D-Sub cable, the signals on CON5 are routed to the Minipack system’s main circuit board. See the figure in this section for an overview of the signals on CON5,

LVD Latching Contactors Connections

Minipack systems’ LVBD and LVLD functionality (Low Voltage Battery Disconnect; LV Load Disconnect) is implemented by the Smartpack controlling magnetically latching contactors.

The coil of latching contactors is not energized in any state. They change state from open to close, or vice versa, when a reversed pulse is applied to the coil.

Internal Connections Miscellaneous

SystemConnections

CON515 pins D-Sub (female)

LVD1A +/− 1LVD2A +/− 2

LVD Common +/− 3System Voltage + 4System Voltage − 5a*Batt Current 1 + 6b*Batt Current 1 − 7

NC 8Load Fuse Fail 1 + 9

Power Input + 10Load Fuse Fail 1 − 11

c*Batt Fuse Fail 1 + 12d*Batt Fuse Fail 1 − 13

System Reference 14Power Input − 15

FUNCTION SIGNALPIN-OUT

5 1

15 11CON5

(female; orange)

Smartpackcontroller

Latching Contactors, LVD1 & LVD2

Correct Use of Latching Contactors (example)

A latching contactor changes state only when a reversed pulse voltage is applied to its coil

+ Pulse

ON

- Pulse

OFF

10

89

X:*****

+

—

LVD1A

LVD2A LVD Common


Minipack PS System (internal)

11

LVD Common

Latching Contactor LVD2

Y

X

Latching Contactor LVD1

Y

X

Minipack Main PCB

Latching Contactor

Y

X

Bidirectional diode

Warning! The bidirectionaldiode must always bemounted to avoid dam-aging the controller.

Rev

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raw

. N

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Battery Strings

Circuits -48Vdc

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Customer

connections

Customer

connections

Load circuits -48Vdc

DC

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rth (

TE

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Customer connections

1:

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See Std.Documentation

356804.10x


356804.10x

NA for Smartpack Web/SNMP

NA

for

Sm

art

pack R

S232

re

ar

1 2 3 4 5 6 7 8 9

10

*X3

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try

5

+ -B

att.

Sym

me

try

6

+ -B

att.

Sym

me

try

7

+ -B

att.

Sym

me

try

8

+ -T

em

pe

ratu

re S

ense

2

12

13

14

+ - + -

11

Batt

ery

Curr

en

t2

Ba

tte

ry F

use

Fail

2

15

*Co

n 7

Te

mp

se

ns

e

1 2 3 4 5 6 7 8 9

10

*X4

Ba

ttery

Co

nn

ec

tio

ns

Co

n 4

A*

Batt

ery

Co

nn

ecti

on

s

Ba

ttery

Con

nections

20057

6

15

SE

RIA

L

DIF

F

S1

+ -B

att. S

ym

me

try

1

+ -B

att. S

ym

me

try

2

+ -B

att. S

ym

me

try

3

+ -B

att. S

ym

me

try

4

+ -T

em

pera

ture

Se

nse 1

12

13

14

+ - + -

11

No

t C

onn

ecte

d

No

t C

onn

ecte

d

15

*Co

n 6

Tem

p s

en

se

CO

M

NO

NC

1

Ala

rm O

utp

uts

an

d

Dig

ital In

puts

218470

10

2 3 4 5 6 7 8 9 10

+ - + -

Dig

ita

l In

pu

t1

Dig

ita

l In

pu

t2

Rela

y 1

CO

M

NO

NC

Re

lay 2

Co

n 1

A*

Ala

rm I

/O

Co

nn

ec

tio

ns

X1*

Ala

rm I

/O C

on

ne

cti

on

s

Ala

rm O

utp

uts

and

Dig

ital In

puts

218473

26

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

+ -D

igita

l In

pu

t3

+ -D

igita

l In

pu

t4

+ -D

igita

l In

pu

t5

+ -D

igita

l In

pu

t6

CO

M

NO

NC

Rela

y 3

CO

M

NO

NC

Rela

y 4

CO

M

NO

NC

Rela

y 5

CO

M

NO

NC

Rela

y 6

Co

n 2

A*

Ext.

Ala

rm I/O

Co

nn

ec

tio

ns

X2A

*

Ext.

Ala

rm I/O

Co

nn

ecti

on

s

X2B

*

Ext.

Ala

rm I/O

Co

nn

ecti

on

s

Customer

connections

Mains input

terminals

*T

o b

e la

bele

d

8

pin

1-8

8 7 6 5 4 3 2 1

L1 N L2 N L3 N

PE

PE

2133

33

Un

derw

irin

gM

PB

B 6

pos 3

AC

X5*

Pow

er

outp

ut

+ Y

7

Pow

er

outp

ut – Y

8

Pow

er

mo

dule

1P

E

N L

+ -

Pow

er

mo

dule

2P

E

N L

+ -

Pow

er

mo

dule

3P

E

N L

+ -

Pow

er

mo

dule

4P

E

N L

+ -

CA

N1

Sm

art

pa

ck

Po

wer

-/C

AN

bu

s

Inte

rco

nn

ecti

on

s

217

915

Dis

t board

1 M

inip

ack S

yste

mM

CB

10 p

os loa

d

4 p

os b

att

Co

n5A

*S

mart

pa

ck C

on

nec

tio

n

21

32

13

JP

1JP

2

NEG. DIST.

POS. DIST.

NEG. DIST.

POS. DIST.

15

1 2 3 4

Batt. F

use F

ail

+B

att. F

use F

ail

-LV

D 1

ALV

D C

om

mon

TB

1S

yste

m c

on

ne

cti

on

s

3 4 5 6

X6A

*D

C o

utp

ut

+

7 8 910

SH

1

Y1 P

ow

er

input

+

Y2 P

ow

er

input

-

Y7

Y6

Y5

Y4

Y3Y9

To b

attery

con

tacto

r

To

Dis

t

bo

ard

2

Op

tio

na

l

YX

LV

LD

K1

Y1

2

Y1

8

Y1

9

Y2

0

X7A

*

To b

attery

+

1 2

215792

Dis

t.B

oa

rd2 M

PB

B 1

00A

10pos G

1X

6B

*D

C o

utp

ut

-Y

5 low

pri

load

Y4

Y3 F

use

ala

rm

Y2 h

igh

pri loa

d

Y1

F1

F2

F3

F4

F5

F6

F7

F8

F9

F10

Y6

Y7

Y24

Y25

10 9 8 7 6 5 4 3 2 1

2

Rev

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raw

. N

o.

Pag

eF

orm

at

Blo

ck D

iag

ram

Min

ipa

ck 4

8V

dc

4,8

kW

Consu

ltan

t

Rep

lace

for

Rep

lace

d b

y

Co

py

rig

ht

A/S

Elt

ek.

All

rig

hts

res

erved

Eltek

2021886

2007

-01-0

3

SH

WIN

OC

R 0

7010

3N

A2

Sy

m.

Dat

e/S

ign

Alt

erat

ion

A3

Pro

ject

ion

Sca

leA

pp

roved

HA

HA

NO

Dra

w

OR

SK

NO

Des

ign

OR

SK

NO

Dat

e

31

oct

.2

00

6

21 o

f 1

--

-

Mains input

connection terminals

YX

LV

BD

-F

B1

-F

B2

Battery Strings

Circuits -48Vdc

0V

Customer

connections

Customer

connections

Load circuits -48Vdc

DC

Ea

rth (

TE

)

Customer connections

213

335

Dis

t board

1 M

inip

ack S

yste

mM

CB

8 p

os load

2 p

os b

att

Co

n5A

*

Sm

art

pa

ck C

on

nec

tio

n

21

32

13

JP

1JP

2

NEG. DIST.

POS. DIST.

NEG. DIST.

POS. DIST.

15

1 2 3 4

Batt. F

use F

ail

+B

att. F

use F

ail

-LV

D 1

ALV

D C

om

mon

TB

1S

yste

m c

on

ne

cti

on

s

1 2 3 4

X6A

*

DC

ou

tpu

t +

5 6 7 8

SH

1

Y1 P

ow

er

input

+

Y2 P

ow

er

input

-

Y7

Y6

Y5

Y4

Y3

X7

A*

To b

att

ery

+ Y

9

To b

attery

con

tacto

r

To

Dis

t

bo

ard

2

Op

tio

na

l

YX

LV

LD

K1

Y8

1:

Op

tio

nal9 p

inD

-su

b R

S23

2 c

onn

ectio

n.

Can b

e m

ounte

d in fro

nt

or

on r

ear

sid

e o

f

Sm

art

pack. R

ep

laces ”

Ext.

Batt

ery

Co

nn

ecti

on

s”

when

mounte

d o

n th

ere

ar

sid

e o

fS

mart

pa

ck

2:

Op

tio

nal W

eb/S

NM

P (

EN

ET

) conne

ction

.

Repla

ces

”E

xt.

Ala

rm I/O

Co

nn

ecti

on

s”

Custo

mer

connections

CO

N5

Syste

m C

on

nec

tio

ns

CO

N4

Ba

ttery

co

nn

ecti

on

s

CO

N2

Ext.

Ala

rm I/O

Co

nn

ec

tio

ns

2: O

ptio

nal: W

eb/S

NM

P (

EN

ET

)

CO

N1

Ala

rm I/O

Co

nn

ecti

on

s

US

B 2

.0 t

yp

e B

po

rt

(PC

con

nection)

9

1:

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l:R

S2

32

Sm

art

pa

ck

monitorin

g a

nd

contr

ol u

nit

10

CA

N p

ort

15

15

9/1

5C

ON

3

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ery

co

nn

ec

tio

ns

1: O

ptio

nal: R

S 2

32

8/2

6

CA

N p

ort

US

B

Re

ar

conne

ctio

ns

Fro

nt con

nection

s

88

Custo

mer

conne

ction

s


356804.10x


356804.10x

NA for Smartpack Web/SNMP

NA

for

Sm

art

pack R

S232

re

ar

1 2 3 4 5 6 7 8 9

10

*X3

Batt

ery

Co

nn

ecti

on

s

Co

n 3

A*

Ba

ttery

Co

nn

ec

tio

ns

Batt

ery

Co

nnections

2005

76

15

SE

RIA

L

DIF

F

S1

+ -B

att.

Sym

me

try

5

+ -B

att.

Sym

me

try

6

+ -B

att.

Sym

me

try

7

+ -B

att.

Sym

me

try

8

+ -T

em

pe

ratu

re S

ense

2

12

13

14

+ - + -

11

Batt

ery

Curr

en

t2

Ba

tte

ry F

use

Fail

2

15

*Co

n 7

Te

mp

se

ns

e

1 2 3 4 5 6 7 8 9

10

*X4

Ba

ttery

Co

nn

ec

tio

ns

Co

n 4

A*

Batt

ery

Co

nn

ecti

on

s

Ba

ttery

Con

nections

20057

6

15

SE

RIA

L

DIF

F

S1

+ -B

att. S

ym

me

try

1

+ -B

att. S

ym

me

try

2

+ -B

att. S

ym

me

try

3

+ -B

att. S

ym

me

try

4

+ -T

em

pera

ture

Se

nse 1

12

13

14

+ - + -

11

No

t C

onn

ecte

d

No

t C

onn

ecte

d

15

*Co

n 6

Tem

p s

en

se

CO

M

NO

NC

1

Ala

rm O

utp

uts

an

d

Dig

ital In

puts

218470

10

2 3 4 5 6 7 8 9 10

+ - + -

Dig

ita

l In

pu

t1

Dig

ita

l In

pu

t2

Rela

y 1

CO

M

NO

NC

Re

lay 2

Co

n 1

A*

Ala

rm I

/O

Co

nn

ec

tio

ns

X1*

Ala

rm I

/O C

on

ne

cti

on

s

Ala

rm O

utp

uts

and

Dig

ital In

puts

218473

26

1 2 3 4 5 6 7 8 9 10

11

12

13

14

15

16

17

18

19

20

+ -D

igita

l In

pu

t3

+ -D

igita

l In

pu

t4

+ -D

igita

l In

pu

t5

+ -D

igita

l In

pu

t6

CO

M

NO

NC

Rela

y 3

CO

M

NO

NC

Rela

y 4

CO

M

NO

NC

Rela

y 5

CO

M

NO

NC

Rela

y 6

Co

n 2

A*

Ext.

Ala

rm I/O

Co

nn

ec

tio

ns

X2A

*

Ext.

Ala

rm I/O

Co

nn

ecti

on

s

X2B

*

Ext.

Ala

rm I/O

Co

nn

ecti

on

s

8

pin

1-8

8 7 6 5 4 3 2 1

L1

N1

L2

N2

L3

N3

PE

PE

2133

33

Un

derw

irin

gM

PB

B 6

pos 3

AC

CA

N1

Sm

art

pa

ck

Po

wer

-/C

AN

bu

s

Inte

rco

nn

ecti

on

s

X5*

Pow

er

outp

ut

+ Y

7

Pow

er

outp

ut – Y

8

Pow

er

mo

dule

1P

E

N L

+ -

Pow

er

mo

dule

2P

E

N L

+ -

Pow

er

mo

dule

3P

E

N L

+ -

Pow

er

mo

dule

4P

E

N L

+ -

Pow

er

mo

dule

5P

E

N L

+ -

Pow

er

mo

dule

6P

E

N L

+ -

Customer

connections

Mains input

terminals

*T

o b

e la

bele

d

213

336

Dis

t.B

oard

2 M

PB

B 1

00

A

8pos G

1X

6B

*D

C o

utp

ut

-Y

5lo

w p

ri load

Y4

Y3 F

use

ala

rm

Y2 h

igh

pri

lo

ad

Y1

F1

F2

F3

F4

F5

F6

F7

F8

Y6

Y7

Y24

8 7 6 5 4 3 2 1

2

www.eltekvalere.com


Eltek ValereGråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway

Phone: +47 32 20 32 00 Fax: +47 32 20 32 10

This product is CE marked andcomplies with all current requirementsfor relevant standards and directives.

Copyright © Eltek Valere, 2007This document may be changed without notice

Art. No. 356808.103, Issue 1.1ev, 2007 MarPublished 2007-03-19

081 022 Minipack System

Documents

Transcript of 081 022 Minipack System