Eltek Minipack Quick Start Manual
Quick Start Guide
Installation, Operation, Commissioning and Maintenance
DC Power Supply System
Integrated Applications
Mini
p
ack, PS S
y
stem
356808.103
Miscellaneous
Communication
o CAN Bus Termination (13)
o Installing PowerSuite – PC software (13)
AC Mains
o Mains Feeds versus Rectifier ID (14)
o Plug-and-Play Rectifiers versus Mains Monitoring (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
Quick Start Guide Minipack PS System
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2
The Smartpack based Product Range
Eltek Energy'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
Flatpack2System, Integrated
4U and 1U Distributions
Flatpack2 System, Cabinetized
Indoor and Outdoor Cabinets
Powerpack System Minipack System, Integrated
Minipack
Battery string #1
Symmetry
Alarm &
Temp. Senso
r
LVLD
LVBD
Fuse Alarm
AC Fuses,
external
(230V)
Telecom
equipment
AC Suppl y
(Single- or
three-phase)
Batte
r
y
Fuses
Load Fuses
& MCBs
Smartpack
(Ctrl. Unit)
PowerSuite
A
pplication
USB cable
DC
distribution
DC Supply
48V
*
CAN Bus
Minipack rectifiers
A
larm Outputs NC-C-NO
Digital Inputs
Remote
Monitorin
g
Quick Start Guide Minipack PS System
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3
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
Mounting
Rail
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
Electric
shock
Controller & Modules
Installation
Quick Start Guide Minipack PS System
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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
Minipac
k
blind cove
r
Locking screw
to secure the blind cover
Front handle
Fastening screw
for the shel
f
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 screw
for the shelf frame
Minipack Sliding Drawer Shelf
in Maintenance Position
F1, F2…Plastic
Cove
r
Quick Start Guide Minipack PS System
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5
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 P
Y24
NP NP NP NP NP NP P P P P
Y7
NP NP NP NP P P P P P P
Y6
NP NP P P P P P P P P
WARNING: 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
Quick Start Guide Minipack PS System
356808.103, v1-2006-12
6
Installation Steps
Check off in the Installation Check List, that you find in the pullou
t
section 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 AC
supply specification. In general, a site with better AC supply quality
(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
Electric
shock
Device
hazard
Minipack PSS, Doc. Chart, Spec.
Drawings, CD-ROM
Minipack drawer shelf slid out in
the maintenance position
Plastic Cove
r
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
EMC
regard
600 mm
2U
200 mm
Quick Start Guide Minipack PS System
356808.103, v1-2006-12
7
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
Electric
shock
Minipack drawer shelf slid out in
the maintenance position
Service Loop
Cable lengths
enabling to open
the drawer shel
f
Device
hazard
—
(-48V) Oute
r
Terminal
+
0V Outer
Terminal
Link 2 (X7A)
(DC Earth)
Common
Battery X7A
EG
Battery
Fuse, Fbx
Intercell Links
Battery
Cable
Symmetry 1
2-1
Chassis
Card Art.200576
+
-
15 pins D-Sub
(male)
Tem
p
. senso
r
Temp. Sensor cable 1
Block1
- + + - + - + -
Block4 Block3
Cable lugs mounted
upside down
Common Battery
Cables (+)
Quick Start Guide Minipack PS System
356808.103, v1-2006-12
8
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.
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
Battery connections (−)
AC Mains
AC Mains & Earth (PE) Terminals
Plastic Protective Cover for
AC Terminals
Forward sliding
drawer shelf
Top view
Minipack Rectifier
Location of
Smart
p
ack 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
Minipack, 6 Rectifiers
(48V, 4800W)
Front view
Battery Fuses
Load MCBs
Smartpack controlle
r
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, Fb4
Battery connections (−)
AC Mains
AC Mains & Earth (PE) Terminals
Plastic Protective Cover for
AC Terminals
Forward sliding
drawer shelf
Top view
Minipack Rectifie
r
Location of
Smart
p
ack controlle
r
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 contacto
r
Minipack, 4 Rectifiers
(48V, 3200W)
Front view
Battery Fuses
Load MCBs
Smartpack controlle
r
Minipack rectifiers
Quick Start Guide Minipack PS System
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9
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 position 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).
CAN
Com
Cable
CAN bus
End-of-Line
Plug (120Ω)
(Rear)
Smartpack
(Front)
USB
Com
Cable
USB 2.0
Type B serial port
CAN1 port
RJ45, 8 pins
CAN1 port
RJ45, 8 pins
(For CAN bus
termination, see section
“Miscellaneous”)
FUNCTION SIGNA L TERM. POINT
X
5
AC Mains Inputs
6
5
4
3
2
1
7
8
PE
PE
N3
L3
N2
L2
N1
L1
2.5mm2, max.
wire section
M4 terminals
Mains Feed 1
Mains Feed 2
Mains Feed 3
A
C Earth (PE)
FUNCTION SIGNAL PIN-OUT
Load Fuses
MCB1
MCB2
X6A
2
1
10
8
+
+
+
+
6 mm
2
, max. wire section
Load Circuit 1
X
6B
Load Circuit 2
MCB8
Load 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)
Common
Battery “Rail”
Battery
Fuses
Fb1
Fbx
Battery Cables, string 1
Battery Cables, string x
M6 screws, cable lugs
max. 15 mm width
X
7A
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 16 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 16 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 17 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 18 for pin-out information)
Quick Start Guide Minipack PS System
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10
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
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