Eltek Minipack Quick Start Manual

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Page 1

Quick Start Guide

Installation, Operation, Commissioning and Maintenance

DC Power Supply System

Integrated Applications

Mini

ack, PS S

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

Page 2

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

LVLD

LVBD

Fuse Alarm

AC Fuses,

external

(230V)

Telecom

equipment

AC Suppl y

(Single- or

three-phase)

Batte

Fuses

Load Fuses & MCBs

Smartpack

(Ctrl. Unit)

PowerSuite

pplication

USB cable

distribution

DC Supply

48V

CAN Bus

Minipack rectifiers

larm Outputs NC-C-NO

Digital Inputs

Remote Monitorin

Page 3

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

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Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

blind cove

Locking screw to secure the blind cover

Front handle

Fastening screw

for the shel

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

Page 5

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

NP NP NP NP P P P P P P

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

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

Page 6

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

Installation Steps

Check off in the Installation Check List, that you find in the pullou

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

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

200 mm

Page 7

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

Device hazard

—

(-48V) Oute

Terminal

0V Outer

Terminal

Link 2 (X7A)

(DC Earth)

Common Battery X7A

Battery

Fuse, Fbx

Intercell Links

Battery

Cable

Symmetry 1

2-1

Chassis

Card Art.200576

15 pins D-Sub (male)

Tem

. senso

Temp. Sensor cable 1

Block1

- + + - + - + -

Block4 Block3

Cable lugs mounted upside down

Common Battery Cables (+)

Page 8

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

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

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

Location of

Smart

ack controlle

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

Minipack, 4 Rectifiers

(48V, 3200W)

Front view

Battery Fuses

Load MCBs

Smartpack controlle

Minipack rectifiers

Page 9

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

AC Mains Inputs

7 8

PE PE

2.5mm2, max. wire section M4 terminals

Mains Feed 1

Mains Feed 2

Mains Feed 3

C Earth (PE)

FUNCTION SIGNAL PIN-OUT

Load Fuses

MCB1

MCB2

X6A

6 mm

, max. wire section

Load Circuit 1

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

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)

Page 10

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

Page 11

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

Device hazard

III

Page 12

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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.

Powe

LED Lamp (green)

Warning

LED Lamp (yellow)

Alarm

LED Lamp (red)

Graphical

Display

16 char. x 2 lines

LCD display

”Up” arrow key

”Down” arrow key

”Enter” key

USB

0ype B port

Smartpack control unit

Minipac

rectifie

Powe

LED Lamp (green)

Warning

LED Lamp (yellow)

larm

LED Lamp (red)

Software Menus ~ Smartpack controller

User menu <UserOption>

AlarmResetÆ NomVolt BoostVolt LoBattMaj VoltageInfo LoBattMin HiBattMaj HiBattMin LVBD LVLD 1.1 DisplayMessagesÆ

Message ↓↑

SoftwareInfoÆ SerialNumberÆ 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 InfoÆ

Level ↓↑

NoOfString Nn

BattStringCurr ↓↑

Battery Info

BattStringTemp ↓↑ BattBlockVolt ↓↑

Level 2 Level 3

…

Firmware 402073.003 1v00

Service menu <ServiceOption>

NomVolt ↓↑ BoostVolt ↓↑ LoBattMaj ↓↑

oltAdjustment

LoBattMin ↓↑ HiBattMaj ↓↑ HiBattMin ↓↑ LVBD ↓↑ LVLD 1.1 ↓↑

oltCalibration Æ

VoltCal ↓↑

ChangePassword Æ

Password ↓↑

SetManBoostTime Æ

↓

↑

Start/StopBoost Æ

uto Boost Conf. Æ

Enable/Disable ↓↑ & Th

eshold

Nxt Test DateTime Date ↓↑ Time End Volt ↓↑

Batt Test Setup

MaxTestDur ↓↑ Test Int ↓↑ Guard Time ↓↑

Start/Stop Test Æ NoOfRects. ; nn Æ Reset Charge Curr Lim. Æ

Enable/Disable ↓↑ & Max

Battery Setup

NumOfString ↓↑ CellCap Ah nn ↓↑

Output Control Æ

Volta

eCtrl / TempComp ↓

Change Date/Time Æ

Date ↓↑ Time ↓↑

Alarm Output 1 ↑

RelayTest

Alarm Output 2 ↑ Batt Contactor ↑ Load Contactor ↑ Alarm Output nn ↑

BattLifeTime Rst Æ

Level 2

Level 3

…

Firmware 402073.003 1v00

Page 13

PULLOUT

Check Lists Pullout

Pull out the pages with the gray outer band,

and use them as check lists

Page 14

Eltek Energy AS

Tel. +47 32 20 32 00

Internet: www.eltekenergy.com E-Mail: [email protected]

Form 174-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29

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

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

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

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

Page 15

CIRCUIT DISTRIBUTION LIST

System Data

Minipack PSS, type: Article No.:

Site, name:

CIRC

FUSE

TYPE

MCB

LVLD

CONTROLLED

DESCRIPTION

FUSE

AMPERE

CABLE

Fb1

Fb2

Fb3

Fb4

F10

LOAD

BATT.

Eltek Energy AS

Tel. +47 32 20 32 00

Internet: www.eltekenergy.com E-Mail: [email protected]

Form 175-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29

Page 16

Page 17

Eltek Energy AS

Tel. +47 32 20 32 00

Internet: www.eltekenergy.com E-Mail: [email protected]

COMMISSIONING PROCEDURE

System Data

Minipack PS System

Supplier’s Order No.: 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: Commissioning carried out by, name:

Pre-Start Check

Power is OFF!

CHECK FOLLOWING

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

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

Device

hazard

III

Device

hazard

Form 176-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29

Page 18

PULLOUT

Page 19

Eltek Energy AS

Tel. +47 32 20 32 00

Internet: www.eltekenergy.com E-Mail: [email protected]

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:

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

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

System Inspection

Power is ON!

CARRY OUT FOLLOWING

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

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-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29

Page 20

PULLOUT

Check Lists Pullout

Pull out the pages with the gray outer band,

and use them as check lists

Page 21

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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 controller If required, a wizard will automatically install necessary USB drivers. Follow & accept the wizard default steps

New hardware is ready to use

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’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

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

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

120Ω

Minipack DC Power System

End-of-Line Resistor

End-of-Line

Resisto

120

Ω

CAN bus

(twisted-pair internal CAT5 cable)

USB A-B cable

(standard)

02 n01

Page 22

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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 #

Mains Feed 1

One-phase, 230VAC

(L2)

230VAC

Mains

(L1)

01 02

Mains Feed 2

One-

hase, 230VAC

(L2)

230VAC

Mains

(L1)

03 04

Mains Feed 3

One-

hase, 230VAC

(L2)

230VAC

Mains

(L1)

05 06

Distribution of Minipack rectifiers (ID #)

on the 3 AC Mains Input Circuits

Mains Feed

Mains Feed 1

Mains Feed

02 03

Minipack System

Position 6

ID number (Assigned CAN bus address)

04 05 06

Position 1

Page 23

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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) Oute

Terminal

0V Outer

Terminal

Intercell Links

2-1

X:****

Symmetry 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) Oute

Terminal

0V Outer Terminal

Intercell Links

X:****

Block1

- + + - + -+-

Block4 Block3

Card, Art. 200576

Serial Switches

Set all 4 switches

ON (down)

Symmetry 4

2-1

Symmetry 1

Symmetry 3

Symmetry 2

Battery Symmetry

Double-point Measurement

Two measurements per string, from the

middle to the outer terminals

—

(-48V) Oute

Terminal

0V Outer

Terminal

Intercell Links

X:****

Card, Art. 200576

Serial Switches

Set all 4

switches ON

(down)

Symmetry 2

2-1

Symmetry 1

Block1

- + + - +- + -

Block4 Block3

Batt. Symmetry Kit, Art. 200830

Cable Eyes

Single Cable Strand

Battery Monitoring

Miscellaneous

Page 24

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

1.5mm2, max. wire section

Battery Connections (Internal)

Configurable monitoring digital inputs

FUNCTION SIGNAL PIN-OUT

(

Internal Connections

)

Batt. Symmetry 1

−

Batt. Symmetry 2

Batt. Symmetry 3

Batt. Symmetry 4

(From internal

batteries)

(From area with

internal batteries)

Temperature

senso

−

Temperature Sense 1

(NA)

(From area with

internal batteries)

Temperature

senso

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

11 15

Card Art.200576

To Smartpack,

CON4

CON3A or CON4A

15-pins D-Sub female

111

515

1.5mm2, max. wire section

Battery Connections (Internal)

Configurable monitoring digital inputs

FUNCTION SIGNAL PIN-OUT

(

Internal Connections

)

−

(From internal

batteries)

(From area with

internal batteries)

Temperature

senso

−

(From area with

internal batteries)

Temperature

senso

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

11 15

Card Art.200576

To Smartpack,

CON3

CON3A or CON4A

15-pins D-Sub female

111

515

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

Serial Switch

For Temp. Sense Kit

CON3A or CON4A

X3/X4

X**/X*

Terminals & Pin-out Location

CON3

CON2

CON4

CON5

CON1

PCB 200576

Smartpack

Page 25

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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.

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

Standard Relays & Digital Inputs

Correct Use of Digital Inputs (example)

Normal Mode

External Relay Y

(Energized coil)

—

Digital Input X (Normal mode)

larm Mode

External Relay Y

(De-energized coil)

—

Digital Input X (Activated)

Minipack PS System

Correct Use of Alarm Outputs (example)

Minipack PS System

—

Com

Normal Mode

Relay

(Energized coil)

—

larm Mode

Relay X

(De-energized coil)

Com

larms & Monitorin

Miscellaneous

Terminals & Pin-out Location

CON3

CAN1

Smartpack

CON2

CON4

CON5

CON1

Card neck for cable fastening

Alarm Outputs & Digital Inputs Card

Art. 218470

Card 218470

(Customer Connections)

Input Circuit 1

Input Circuit 2

larm Circuit 1

larm Circuit 2

OutIn

(To and from

external equipment)

1.5 mm2, max. wire section

Relay 1

Common Alarm

−

COM

−

Digital Input 1

Digital Input 2

larm Outputs & Digital Inputs

Voltage free relay outputs and Configurable monitoring digital inputs

FUNCTION SIGNAL PIN-OUT

To Smartpack,

CON1

Card Art.218470

To CON1

Page 26

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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.

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

Miscellaneous

Alarms & Monitoring

(Customer Connections)

Out

1.5mm2, max. wire section

Alarm Outputs & Digital Inputs, Extended

Voltage free relay outputs and Configurable monitoring digital inputs

FUNCTION SIGNAL PIN-OUT

Input Circuit 3

larm Circuit 3

Input Circuit 4

Input Circuit 5

Input Circuit 6

larm Circuit 4

larm Circuit 5

larm Circuit 6

−+−

−

Digital Input 3

Digital Input 4

Digital Input 5

Digital Input 6

(To external equipment) (From external equipment)

COM

Relay 3

Fuse Alarm

Load & Battery

Relay 5

Low Battery Alarm

Relay 6

Rectifier Alarm

Relay 4

High Battery Alarm

To Smartpack,

CON2

15 16 17 18 19 20

Card Art. 218473

To CON2

X2A

X2B

Terminals & Pin-out Location

CON3

CAN1

Smartpack

CON2

CON4

CON5

CON1

Card 218473

X2A

X2B

Card neck for cable fastening

Alarm Outputs & Digital Inputs Card, Extended

Art. 218473

(NA for Smartpack Ethernet option)

Page 27

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

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

System Connections

CON5

15 pins D-Sub (female)

LVD1A +/

−

LVD2A +/− 2

LVD Common +/− 3

System Voltage + 4 System Voltage − 5

*Batt Current 1 + 6

*Batt Current 1 − 7

NC 8

Load Fuse Fail 1 + 9

Power Input + 10

Load Fuse Fail 1 − 11

*Batt Fuse Fail 1 + 12

*Batt Fuse Fail 1 − 13

System Reference 14

Power Input − 15

FUNCTION SIGNALPIN-OUT

5 1

15 11

CON5

(female; orange)

Smartpack

controller

Latching Contactors, LVD1 & LVD2

Correct Use of Latching Contactors (example)

latching contactor changes state only when a

reversed pulse voltage is applied to its coil

+ Pulse

- Pulse

OFF

8 9

X:*****

—

LVD1A

LVD2A

LVD Common

Smartpack controller

Minipack PS System (internal)

LVD Common

Latching Contactor

LVD2

Latching Contactor

LVD1

Minipack Main PCB

Latching Contactor

Bidirectional diode

Warning! The bidirectional

diode must always be mounted to avoid damaging the controller.

Page 28

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

Page 29

Rev.Draw. No.Page

Format

Block Diagram Minipack 48Vdc

3,2kW

Consultant

Replace for Replaced by

Eltek

2023227

Sym. Date/SignAlteration

ProjectionScale

Approved

FRNONO

Draw

ORSKNO

Design

ORSKNO

Date

22 Dec. 2006

1a1 of 1

Y X

LVBD

-FB1

-FBn

Battery Strings

Circuits -48Vdc

Customer

connections

Customer

connections

Load circuits -48Vdc

DC Earth (TE)

Customer connections

1: Optional 9 pin D-sub RS232 connection.

Can be mounted in front or on rear side of

Smartpack. Replaces ”Ext. Battery Connections”

when mounted on the rear side of Smartpack

2: Optional Web/SNMP (ENET) connection.

Replaces ”Ext. Alarm I/O Connections”

Customer

connections

CON5

System Connections

CON4

Battery connections

CON2

Ext. Alarm I/O Connections

2: Optional: Web/SNMP (ENET)

CON1

Alarm I/O Connections

USB 2.0 type B port

(PC connection)

1: Optional: RS232

Smartpack

monitoring and

control unit

CAN port

9/15

CON3

Ext. Battery connections

1: Optional: RS 232

8/26

CAN port

USB

Rear connections Front connections

See Std. Documentation

356804.10x

See Std. Documentation

356804.10x

NA for Smartpack Web/SNMP

NA for Smartpack RS232 rear

123456789

*X3

Battery Connections

Con 3A*

Battery Connections

200576

SERIAL

DIFF

Batt. Symmetry 5

Batt. Symmetry 6

Batt. Symmetry 7

Batt. Symmetry 8

Temperature Sense 2

121314

+- +

Battery Current 2

Battery Fuse Fail 2

*Con 7

Temp sense

123456789

*X4

Battery Connections

Con 4A*

Battery Connections

200576

SERIAL

DIFF

Batt. Symmetry 1

Batt. Symmetry 2

Batt. Symmetry 3

Batt. Symmetry 4

Temperature Sense 1

121314

+- +

Not Connected

*Con 6

Temp sense

COM

Alarm Outputs and

Digital Inputs

218470

2345678

+- +

Digital Input 1

Digital Input 2

Relay 1

COM

Relay 2

Con 1A*

Alarm I/O

Connections

X1*

Alarm I/O Connections

Alarm Outputs and

Digital Inputs

218473

123456789

111213141516171819

Digital Input 3

Digital Input 4

Digital Input 5

Digital Input 6

COM

Relay 3

COM

Relay 4

COM

Relay 5

COM

Relay 6

Con 2A*

Ext. Alarm I/O

Connections

X2A*

Ext. Alarm I/O Connections

X2B*

Ext. Alarm I/O Connections

Customer

connections

Mains input

terminals

* To be labeled

pin 1-8

8765432

L1NL2NL3

213333

Underwiring MPBB 6pos 3AC

X5*

Power

output + Y7

Power

output – Y8

Power module 1

PENL

Power module 2

PENL

Power module 3

PENL

Power module 4

PENL

CAN1

Smartpack

Power -/CAN bus

Interconnections

217915

Dist board 1 Minipack System MCB

10 pos load

4 pos batt

Con5A*

Smartpack Connection

213213

JP1 JP2

NEG. DIST.

POS. DIST.

NEG. DIST.

POS. DIST.

123

Batt. Fuse Fail +

Batt. Fuse Fail -

LVD 1A

LVD Common

TB1

System connections

345

X6A*

DC output +

789

SH1

Y1 Power input +

Y2 Power input -

Y7Y6Y5Y4Y3

To battery contactor

To Dist

board 2

Optional

Y X

LVLD

Y12

Y18

Y19

Y20

X7A*

To battery +

215792

Dist.Board 2 MPBB 100A

10pos G1

X6B*

DC output -

Y5 low pri loadY4Y3 Fuse

alarm

Y2 high

pri load

F10

Y24

Y25

Page 30

Rev.Draw. No.Page

Format

Block Diagram Minipack 48Vdc

4,8kW

Consultant

Replace for Replaced by

Eltek

2021886

Sym. Date/SignAlteration

ProjectionScale

Approved

HAHANO

Draw

ORSKNO

Design

ORSKNO

Date

31 oct. 2006

1a1 of 1

Mains input

connection terminals

Y X

LVBD

-FB1

-FB2

Battery Strings

Circuits -48Vdc

Customer

connections

Customer

connections

Load circuits -48Vdc

DC Earth (TE)

Customer connections

213336

Dist.Board 2 MPBB 100A

8pos G1

X6B*

DC output -

Y5 low pri loadY4Y3 Fuse

alarm

Y2 high

pri load

Y24

213335

Dist board 1 Minipack System MCB

8 pos load

2 pos batt

Con5A*

Smartpack Connection

213213

JP1 JP2

NEG. DIST.

POS. DIST.

NEG. DIST.

POS. DIST.

123

Batt. Fuse Fail +

Batt. Fuse Fail -

LVD 1A

LVD Common

TB1

System connections

123

X6A*

DC output

567

SH1

Y1 Power input +

Y2 Power input -

Y7Y6Y5Y4Y3

X7A*

To battery + Y9

To battery contactor

To Dist

board 2

Optional

Y X

LVLD

1: Optional 9 pin D-sub RS232 connection.

Can be mounted in front or on rear side of

Smartpack. Replaces ”Ext. Battery Connections”

when mounted on the rear side of Smartpack

2: Optional Web/SNMP (ENET) connection.

Replaces ”Ext. Alarm I/O Connections”

Customer

connections

CON5

System Connections

CON4

Battery connections

CON2

Ext. Alarm I/O Connections

2: Optional: Web/SNMP (ENET)

CON1

Alarm I/O Connections

USB 2.0 type B port

(PC connection)

1: Optional: RS232

Smartpack

monitoring and

control unit

CAN port

9/15

CON3

Ext. Battery connections

1: Optional: RS 232

8/26

CAN port

USB

Rear connections Front connections

Customer

connections

See Std. Documentation

356804.10x

See Std. Documentation

356804.10x

NA for Smartpack Web/SNMP

NA for Smartpack RS232 rear

123456789

*X3

Battery Connections

Con 3A*

Battery Connections

200576

SERIAL

DIFF

Batt. Symmetry 5

Batt. Symmetry 6

Batt. Symmetry 7

Batt. Symmetry 8

Temperature Sense 2

121314

+- +

Battery Current 2

Battery Fuse Fail 2

*Con 7

Temp sense

123456789

*X4

Battery Connections

Con 4A*

Battery Connections

200576

SERIAL

DIFF

Batt. Symmetry 1

Batt. Symmetry 2

Batt. Symmetry 3

Batt. Symmetry 4

Temperature Sense 1

121314

+- +

Not Connected

*Con 6

Temp sense

COM

Alarm Outputs and

Digital Inputs

218470

2345678

+- +

Digital Input 1

Digital Input 2

Relay 1

COM

Relay 2

Con 1A*

Alarm I/O

Connections

X1*

Alarm I/O Connections

Alarm Outputs and

Digital Inputs

218473

123456789

111213141516171819

Digital Input 3

Digital Input 4

Digital Input 5

Digital Input 6

COM

Relay 3

COM

Relay 4

COM

Relay 5

COM

Relay 6

Con 2A*

Ext. Alarm I/O

Connections

X2A*

Ext. Alarm I/O Connections

X2B*

Ext. Alarm I/O Connections

pin 1-8

8765432

L1N1L2N2L3

213333

Underwiring MPBB 6pos 3AC

CAN1

Smartpack

Power -/CAN bus

Interconnections

X5*

Power

output + Y7

Power

output – Y8

Power module 1

PENL

Power module 2

PENL

Power module 3

PENL

Power module 4

PENL

Power module 5

PENL

Power module 6

PENL

Customer

connections

Mains input

terminals

* To be labeled

Page 31

Quick Start Guide Minipack PS System

356808.103, v1-2006-12

Page 32

Head Office

Eltek Energy AS

PO Box 2340 Strømsø; N-3003 Drammen; Norway

Tel:+47 32 20 32 00 — Fax:+47 32 20 32 10 E-mail: [email protected]

Internet: www.eltekenergy.com

This document may be changed without notice

Art. No. 356808.103, Issue 1, 2006 Dec

Published 2006-12-29

This product is CE marked and complies with all current requirements for relevant standards and directives.