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Quick Start Guide

Installation, Operation, Commissioning and Maintenance


356804.103

Flatpack2, PS System
DC Power Supply System

Integrated, Cabinetized and Outdoor Applications

Introduction
o
o

The Smartpack based Product Range (2 )


Brief System Description, Flatpack2 (2 )

Installation
o
o

Installing Smartpack, Rectifier Modules and blind panels


Installation steps; mechanical, electrical (4-5)

( 3)

Commissioning
o
o

Pre-start check (6 )
Commissioning steps, Startup

(6-7)

Operation
o
o

Front keys and display, Installing PowerSuite PC software


Software Menus Smartpack controller ( 9)

(8 )

Appendix
Communication
o
CAN Bus Termination and Addressing (10 )
AC Mains
o
External AC Fuses, Recommended Rating ( 11)
o
Identifying Power Shelves, 4AC, 2AC or 4AC-3kW (12 )
o
I. Mains Reconfiguration, Integrated Systems, 1U DC Distribution (12 )
o
II. Mains Reconfiguration, AC Terminal Block (13 )
o
III. Mains Reconfiguration, AC Terminal Block with OVP (14 )
o
About AC, DC Earthing Systems ( 15)
o
Mains Phases vs. Rectifier ID Phase Balancing & Monitoring (16-17)
Battery Monitoring
o
Controllers 48V Battery Symmetry Connections (18 )
o
Controllers 24V Battery Symmetry Connections ( 19)
o
Battery Monitors 48V Symmetry Connections (20-21)
o
Terminals & Pin-out Location, Battery Interface Card (22 )
Alarms & Monitoring
o
Standard Alarm Relays & Digital Inputs Connections ( 23)
o
Terminals & Pin-out Location, Alarm Interface Card ( 23)
Internal Connections
o
Terminals & Pin-out Location, System Interface Card (24 )
o
LVD Latching Contactors Connections (24 )
CAN Bus Nodes
o
Battery Monitor CAN Node (26 )
o
Load Monitor CAN Node ( 27)
o
I/O Monitor CAN Node (28 )
Flatpack2 Integrated System, 2U
o
Location of Major Components ( 31)

Check Lists
o
o
o
o

Installation Check List


Circuit Distribution List
Commissioning Procedure
Maintenance Procedure

pullout forms

Introduction
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.

Powerpack System

Flatpack2 System, Cabinetized


Indoor and Outdoor Cabinets

Flatpack2 System, Integrated


4U and 1U Distributions

Minipack System, Integrated

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 Flatpack2


The Flatpack2 PS system is a compact, powerful and cost-effective DC power supply system,
specifically developed for the telecom industry.
Alarm Outputs NC-C-NO
Digital Inputs

Flatpack2
Cabinetized

PowerSuite
Application

Remote
Monitoring
Smartpack
ctrl. unit

CAN Bus

USB cable

Fuse Alarm

Flatpack2
rectifiers
LVLD
Telecom
equipment

AC Fuses,
external
(230VAC or
400VAC

AC Supply
(Single- or
three-phase)

AC mains
supply
selector
Symmetry
Alarm &
Temp. Sensor

LVBD

Load Fuses
& MCBs
DC
distribution
DC Supply
(24V, 48V)

Battery string #1

Battery
Fuses

Example of a typical Flatpack2 PS system for DC power supply of telecom equipment. The
system is fed from an external AC mains supply, and consists of rectifiers in power shelves, a
control unit and DC distribution unit. Battery banks, LVD contactors, etc. are typically also a part
of the system.

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Installation
Installing Smartpack and Rectifier Modules
Device
hazard

CAUTION:
- The modules may be warm, but do not hand-carry them by their handles
- Open the handles before inserting them into the power shelves (hot-pluggable)
The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing

Hole to release the


handles spring
mechanism

Smartpack
controller

Mounting or Removing Smartpack and Flatpack2 Modules

Note that cables are plugged to the Smartpacks rear panel. When
mounting the controller, you must plug the cables before step 2. When
removing it, unplug the cables during step 2.
Notice:
For an overview of available rectifiers, refer to User Guide Flatpack2 Rectifier Modules,
document 350002.013.

1. Unlock the handles by


inserting a screwdriver into the holes to release the spring
mechanism
2. Insert or remove the module by
sliding it fully into the power shelf, so that the module makes
proper contact (for Smartpack, plug cables first: standard D-Sub connectors,

Handle in locked position

Smartpack controller rear


connections

Flatpack2
rectifier

Handle in
unlocked position

Device
hazard

RJ45 plugs and 10 pins plug)

or
using both handles to pull the module loose. Support from
underneath before the unit is completely free. Unplug the cables,
when removing the Smartpack module
3. Lock the handles by
pushing the handles up into their housings (locked position).
Then, the module will be securely locked in the shelf, or ready
for transport
4. Mount blind panels in
unused module locations
CAUTION: 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 ID
number 1, 2, 3 and so on; refer to page 17.
WARNING: To replace installed rectifiers with new ones, remove the installed rectifiers and
wait for the controller to notify communication error with the extracted rectifiers. Push the new
rectifiers fully into the power shelf one module at a time, allowing a 2s delay. Start with the
shelf position with lowest ID number. Lock their handles.

Removing Blind Panels

1. Release the panels upper left and right corners by


inserting a small screwdriver into the panels upper left gap and
carefully press down and out to release the locking tabs. Repeat
on the upper right gap.
2. Remove the blind panel by
using you hand to pull the panel loose

Screwdriver to
release the
locking tabs

Blind panels upper


locking tabs

Mounting Blind Panels

1. Insert the panels upper edge by


pressing gently so that its upper locking tabs engage
2. Lock the panels lower edge by
pressing with your hand so that the blind panels lower tabs lock
into position.

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Electric
shock

Installation
Installation Steps
Check off in the Installation Check List, that you find in the pullout section of
this folder. Also, refer to the systems specific drawings.
200 mm

Preparing the Installation Site

Begin preparing the following:


1

2
Location of tools
in IFC cabinets

600 mm

Organize the installation site


o Min. clearances for cabinet access: 60 cm in front, 20 cm on top
o Levelled surface able to support 600 kg (cabinetized systems)
o Explosive atmospheres are to be avoided. Ensure suitable
ventilation
o 60V systems are only to be installed in Restricted Access
Locations (RAL)
Prepare the installation tools
o Use insulated tools suitable for telecom installations
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

For external AC fuses and AC input cable ratings, refer to your sites AC
supply specification. Read also our external AC fuse recommendations
in section Appendix. In general, a site with better AC supply quality
(stable nominal voltage) may use smaller breakers.

Mechanical Installation

Flatpack2 PSS, batteries, Doc.


Chart, Spec. Drawings, CD-ROM

Fastening screw for tools


compartments cover
Cover, lifted

Location of tools
in IFC cabinets bottom

(Lifting plates, leg adjusting plates and


open-ended spanner or wrench)

Power is OFF!

Carry out the following:


4 Remove packaging and check equipment
o Check you have received all the parts, correct cabinet,
documentation, batteries (if applicable), etc.
o Inspect the equipment for physical damage (report any damages) Device
hazard
o Leave rectifier modules in their packaging or in the selves, if
factory installed. To be installed under commissioning
5 Remove top cover and dummy front panels
o Cable entry from the top. Connection terminals are located
behind the upper dummy panels
o Battery shelves (if any) are placed behind the lower panels
6 Position and fasten the cabinet or subassembly
o Cabinets are floor-mounted on levelled surface. Adjust the legs if
necessary. If the cabinet must be fastened, unscrew the legs and
use suitable bolts to fasten it to the floor
o Subassemblies are fastened in existing 19 or in ETSI cabinets,
using brackets. Mount the support & heat deflecting plate under
the lower power shelf
7 Mount the batteries on the shelves
o Start (if applicable) placing the batteries on the lower shelf first,
and continue upwards
Electric
o Do not terminate the battery cables yet!
shock

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Installation

Electrical Installation

Power is OFF!

Carry out the following: (Refer to the systems specific drawings)


8

General Torque
Recommended Ratings, FP2 Systems
Application,
Type & Size
Circuit Breakers
SIEMENS 18 mm,
5SX2, 5SX5
SIEMENS 27 mm,
5SX6, 5SX7, 5SP4
MG, C60 <=25A
MG, C60 >25A
CBI 13 mm, QY, QF, QA
Hex Nuts & Screws
(Knife Fuses, general)
M8.0
M10.0
M12.0
AC Terminal Blocks
WDU 1.5
WDU 2.5
WDU 4
WDU 10
WDU 16
WDU 35
WDU 70
DC Rail Terminals
AKG 16
AKG 35
Note: General tolerance: 10%.

Torque
(Nm)
3.5
5.0
3.5
3.5
3.0
10.0
16.0
25.0
0.5
0.5
0.6
2.0
3.0
4.0
10.0
3.0
3.5

NEC/CEC Requirements

Chassis

Link 2
(DC Earth)
Battery
Fuse

EG

Common
DC Rail

Card Art.200576
2-1 15 pins D-Sub
(male)

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
9 AC Connections
o Check AC configuration: the AC terminals are correct configured
to the external AC supply, otherwise reconfigure the terminals
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
10 DC Connections Load Circuits
o Terminate DC Earth (TE), and check that the common DC
Output Rail is connected to Telecom Earth (TE) at only one
place (at the cabinet or at a central distribution point). Se
chapter about AC, DC earthing systems
o For each DC load, connect one of the cables to the common DC
output rail, and the other directly to the MCB or load fuse
11 DC Connections Alarm & Signal Circuits
o Refer to your systems connection drawings and configuration, or
to the Appendix, Alarms & Monitoring section (Factory
Settings)
o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output
terminals
12 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 and for 24V systems, refer to the
Battery Symmetry Connections chapters in this guides Appendix
section.
For each battery shelf:
(In cabinetized systems, steps b, d and f are usually performed in factory)

Temp. Sensor cable 1


+

f-g

Mount 3 intercell links to connect in series 4 battery blocks


Connect battery cables to fuses and common DC rail, and to
the shelfs outer terminals; (+) and (-)
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
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

- + - + - + - +

(-48V) Outer
Terminal

d-e

Temp. sensor

Symmetry 1

Battery
Cable

a
b-c

Block1

Intercell Links

Block3

Block4

0V Outer
Terminal

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Electric
shock

Commissioning
The commissioning of Flatpack2 PS System 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

I 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 Flatpack2 PS system, verify the following:
1. System installation is completed
o Ensure a correctly performed system installation, with correct polarity on all
connections, has been carried out (Installation Check List filled in)
o All cabling and copper bars are securely terminated and supported
o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled

Device
hazard

2. Battery and load fuses are disconnected


o Verify that all battery and load MCBs/ fuses are switched OFF or removed
3. AC input cable(s) and AC Earth wire (PE) are terminated
o Make sure that the AC input cable(s) are connected to correctly configured 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 (Link 1)
4. Site specific parameters and settings are known
o Read the system 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 Flatpack2 PSS while the batteries and load are disconnected then
measure the output voltage, and adjust it if required. Carry out the following:

II

Startup and No-Load Adjustments

Power is ON!

1. Disconnect all rectifier modules, without removing them (keep original location)
o Read how to install modules, on page 3 in this guide. Also, read about the correct
rectifier position on page 17, and then,
o If Flatpack2 rectifier modules are installed, unlock the handles and pull the
modules partially out (fan housing visible), but do NOT physically remove them
from the power shelves
o If Flatpack2 rectifier modules are not yet mounted, release their handles and insert
them partially into the correct position in the shelves

Device
hazard

2. Switch ON the system


o Switch ON the AC input supply (external AC fuses) to the PS cabinet
3. Measure and verify that the AC input voltage is correct
o Measure the AC input voltage at the cabinets mains connection box
o Verify the AC voltage is within range

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Commissioning
4. Mount all Flatpack2 rectifier modules in the power shelves (keep original location)
o Push all rectifiers firmly inwards one module at a time, allowing a 2s delay
to plug them in the same shelf location. Lock their handles. Refer also to page 17
o Mount blanking panels 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 alarms are present on rectifiers; The Smartpack displays fuse alarms
6. Connect 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; select: Start > All Programs > Eltek Valere> PowerSuite
Refer to chapter Installing PowerSuite , page 8, 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 controllers 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 controllers front keys or via PowerSuite
8. Verify the alarm relays are working correctly (alarm relay test)
o Run the alarm relay test using the controllers front keys (refer to page 8) 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 controllers 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 equal measured battery voltage
o Measure the battery voltage is within range (check connections have correct polarity)
o Adjust DC output voltage using the controllers front keys (refer to page 8) or via
PowerSuite to equal the measured battery voltage.
(Important adjustment to avoid arcing when connecting the batteries)

III

Device
hazard

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 handles and pulling them partially
out (fan housing visible). Do NOT physically remove them from the power shelves
o Switch ON all battery fuses or MCBs

Device
hazard

12. Adjust DC output voltage again to equal the nominal battery voltage
o Adjust DC output voltage using the controllers 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

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Operation
Front Keys and display, Installing PowerSuite
Graphical
Display

Alarm

Warning

LED Lamp (red)

16 char. x 2 lines
LCD display

LED Lamp (yellow)

Warning

LED Lamp (yellow)

Power

Enter key

Power

LED Lamp (green)

Alarm

LED Lamp (red)

LED Lamp (green)

Up arrow key
USB

Down arrow key

0ype B port
Flatpack2 rectifier

Smartpack control unit

Smartpack Controller front keys, display

Display: is in Status Mode (displays the systems


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.

Flatpack2 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)

Installing PowerSuite PC Application


The PowerSuite software application enables you to configure and operate your Smartpack based
power supply system from a personal computer running MS Windows XP or Vista.
1.

2.

3.

New hardware
is ready to use

4.

Install PowerSuite
Insert the CD in your PC drive, start the PowerSuite installation and follow &
accept the wizard default steps
Switch Smartpack ON and plug USB cable (Part 202073)
to Smartpack and to any available USB port in the PC
Wait for Windows to install USB drivers
Follow & accept the wizard default steps to automatically install the USB
drivers; the wizard runs twice
Start PowerSuite and establish connection
Select Start > All Programs > Eltek Valere> PowerSuite. On the toolbar,
click Connect button. On the Connection dialogue box, click the Connect
button

If PowerSuite fails communicating via the standard COM port, find the COMx assigned to
Smartpack (My Computer/ Properties/ Hardware/ Device Manager) and configure PowerSuite to
communicate via this COMx (read the instructions in the installation CD).
PowerSuites newest version is always available on our FTP server. Call your Eltek Valeres
contact person.

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Operation
Software Menus Smartpack Controller
The Smartpack-based DC power systems functionality is accessed via a network of software
menus and submenus 1 , enabling you to configure and control the whole power system from the
controllers front keys. Two different hierarchical menu structures are available: the User Options
menus and the Service Options menus (password protected).
Level 3

User menu <UserOption>

Service menu <ServiceOption>

AlarmReset

Change Language

SoftwareInfo
SerialNumber

NomVolt
BoostVolt
LoBattMaj
LoBattMin
HiBattMaj
HiBattMin
LVBD
LVLD 1.1

Message
nnnnnn.nnn

vv.vv

xxxxxx
Rectifier nn

Mod.Current
Mod.Serial #
Mod.InputVolt
Mod.Status 3v03
Mod.Temp
Mod.OutputVolt
Mod.SW Ver
3v03
nn

Module Info

Mains Info
Temp Level Info

BatteryInfo

Energy log

DCDC24
DCDC48 nn
SolarCharger nn

3v03
3v03

NoOfPhases nn
MainsStatus
MainsVoltage
Level
NoOfString Nn
BattMonitorCurr
SmartPackCurr
SmartPackTemp
SmartPackSymm
Battery
SolarCharger
Generator
Rectifier
Load

3v05
3v05
3v05
3v05

VoltAdjustment

Firmware 402073.009 3v05 Smartpack, Distributed

DisplayMessages

Reset
The XvX references, if any, on the right hand of the option, are not shown in the display. They only indicate the
firmware version (402073.009 XvX) the option was first implemented or updated.

VoltageInfo

Firmware 402073.009 3v05 Smartpack, Distributed

Level 2

VoltCalibration
ChangePassword
SetManBoostTime
Start/StopBoost
Auto Boost Config.

Batt Test Setup

Start/Stop Test
RemoveUnit(s)
Rectifier Setup

Charge Curr Lim.

Battery Setup

H-D-W-U 3v03
H-D-W-U 3v03

NomVolt
BoostVolt
LoBattMaj
LoBattMin
HiBattMaj
HiBattMin
LVBD
LVLD 1.1
Password

Enable/Disable & Threshold


Nxt Test DateTime Date Time
End Volt

MaxTestDur
Test Int

Guard Time
Start/Stop
Rem

(Reset)

Reboot CtrlUnit
NoOfPhases
EfficiencyManagr

3v03

Rectifier ON/OFF**
System ON/OFF**
RectWalkInTime

3v03
3v03
3v03

Short/Long

Enable/Disable
MainsFeed

GenFeed

3v03
3v03

NumOfString

CellCap Ah nn
BatteryTempSet #,Enable/Disable,Alarms,Calib
BatteryCurrentCalib
LowPoint/HighPoint
Slope mV/C

3v04
3v04
3v05

Change Date/Time Date Time

BattLifeTime Rst

Output Control

BlockOutputs

Start/Stop

H-D-W-U 3v03

RelayTest

2v0

VoltCal

H-D-W-U 3v03
H-D-W-U 3v03

LoadMonitor Info LoadMonitor V-A-W-Tota3v05

English

VoltageCtrl / TempComp
Alarm Output 1
Alarm Output 2
Batt Contactor
Load Contactor
Alarm Output nn

Enter OutpBlocked / Exit OutpBlocked


Reset
Yes/No

3v03

3v03

Disable
HE Priority
Enable Redundancy(E/D)OffTimeShuffleTime

** Only available for special regions, when enabled from factory

From a PCs web browser, via WebPower, or running the PowerSuite program you can also access the
complete functionality of the Smartpack-based DC power system.
Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

2v0

3v03
3v03
3v03

The XvX references, if any, on the right hand of the option, are not shown in the display. They only indicate
the firmware version (402073.009 XvX) the option was first implemented or updated.

Level 3

Level 2

Appendix

Communication

CAN Bus Termination


Flatpack2 systems are shipped from factory with
the CAN bus already terminated with 120
resistors.

CAN bus
(twisted-pair internal
CAT5 cable)

USB A-B cable


(standard)
1

120

End-of-Line
Resistor

End-of-Line
Resistor

120
01

Flatpack2
DC Power System

02

To ensure a correct bus communication and


avoid data reflection, you must always terminate
the CAN bus with two 120 resistors, one at
each end of the line (60 bus impedance). The
figure shows a Flatpack2 system communicating
via the CAN bus.

CAN Bus Addressing


All rectifiers, Compack and Smartpack controllers and other control units connected to the
Eltek Valeres CAN bus must have a unique address or ID number. The control systems master
controller assigns automatically the rectifiers addresses (software assignment). The controller
registers the rectifiers ID numbers or CAN bus address (01, 02 ...) together with their Serial
Numbers.
The control systems controllers except Compack and control units use DIP switches for
configuring their unique CAN bus ID number (hardware assignment).
You can address a maximum of 14 control units of each type max. 8 Smartpack controllers and
Smartnode units to the control systems CAN bus. See table below:
Number of nodes >>
Control Units Name

Smartpack Controllers

10

11

12

13

14

15

16
16 << ID #

10

11

12

13

14

15

Smartnode Control Units 17 18 19

20

21

22

23

24

25

26

27

28

29

30

31

32 << ID #

Battery Monitor CAN nodes 33 34 35

36

37

38

39

40

41

42

43

44

45

46

47

48 << ID #

Load Monitor CAN nodes 49 50 51

52

53

54

55

56

57

58

59

60

61

62

63

64 << ID #

** 65 66 67

68

69

70

71

72

73

74

75

76

77

78

79

80 << ID #

I/O Monitor CAN nodes 81 82 83

84

85

86

87

88

89

90

91

92

93

94

95

96 << ID #

Mains Monitor nodes 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 << ID #

ID numbers formatted in red italics are not available due to software constraints.
** Only 4 of the 8 mounted DIP switches may be used (max. 14 Load Monitors may be connected).

For DIP switch configuration, refer to actual units guide or to PowerSuite Help or to chapter
CAN Bus Nodes, page 26.
The figure shows a Flatpack2 DC power system expanded with a slave controller and 3 CAN
nodes to implement additional digital inputs, relay outputs or similar functionality.
Alarm Outputs
NC-C-NO

Alarm Outputs
NC-C-NO

Digital Inputs

Digital Inputs

1
CAN bus

Smartpack controller
Slave 1

120

End-of-Line
Resistor

CAN bus

(twisted-pair CAT5 cable)

Flatpack2 Rectifiers
01

ID Number
Battery
Monitor

Smartpack controller
Master
USB A-B cable (standard)

33

02

n+1

81

CAN bus

49

I/O Monitor

n+2

120

End-of-Line
Resistor

Shunts
Current Monitoring
Sense Inputs

Load Monitor
Battery string #1

Temp, Fan Speed Mon & Ctrl

Fuses

Alarm Outputs NC-C-NO

Flatpack2
DC Power System

10

Config. Inputs

Quick Start Guide Flatpack2 PS System

Fuse Monitoring
Configurable Inputs

356804.103, 6v1-2009-11

Appendix

AC Mains

External AC Fuses Recommended Rating


The sites AC supply quality is of great importance. In general, a site with better AC supply quality
(stable nominal voltage) may use smaller breakers.
Recommended External AC Fuses per AC Mains Feed Input
Flatpack2 Systems with 2000W Rectifiers
AC Mains
Input Type**

TN net (Y)
400VAC +N
3 phase
IT net ()
230VAC
3 phase
230VAC
1 phase

No of Power
Shelves (Type)

1 (4AC)
2 (4AC)
3 (4AC or 2AC)
1 (4AC)
2 (4AC)
3 (4AC or 2AC)
1 (4AC)
2 (4AC)

Current Max.
Ext. Fuse
per input (A)
Type Th/Mag
205VAC
185VAC 205VAC
185VAC

21.5
32.2
43.0
28.4
55.8
74.4
21.5
32.2

24.0
36.0
47.9
31.7
62.3
83.0
24.0
36.0

Ext. Fuse
Type Hy/Mag
205VAC
185VAC

1AC Feed to 1 Flatpack2 rectifier


Recommended External Fuse
Type
FS=I
FS=0

25A-D
25A-C2
40A-C
40A-C2
50A-C
50A-C2
32A-D
32A-C2
63A-C
63A-C2
80A-C
100A-C 80A-C2 100A-C2
25A-D
25A-C2
40A-C
40A-C2

Th/Mag
Hy/Mag

25A-D
25A-C2

16A-C
16A-C2

FS=I
(Fuse Selectivity: Internal)
which means that the Flatpack2 rectifiers internal fuse
will trip before the external AC
fuse.
FS=0
(Fuse
Selectivity:
none)
these fuse types may be used
when it is irrelevant whether
the internal or the external fuse
trips first.

Doc 2020432,3v0
** The external AC Mains Input is internally connected to the power shelves and rectifiers at factory.
Refer to your systems specific schematic and connection drawings for more details.

Notes:
Use the values in the 185VAC column,
if you are unsure or know that the available AC mains voltage may drop below 205VAC
The recommendations apply for use of
Thermal magnetic circuit breaker (Th/Mag), type Siemens 5SX or 5SY series, MG C60H
series or similar; and
Hydraulic magnetic breaker (Hy/Mag), type CBI QF frame or QY frame, Airpax or similar
For more information regarding External AC fuses, please read the document 2020432
Systems with more than 3 power shelves require more than 1 AC Mains Feed Input

Recommended External AC Fuses per AC Mains Feed Input


Flatpack2 Systems with 3000W Rectifiers
AC Mains
Input Type**

No of Power
Shelves (& Rectifiers)

TN net (Y)
400VAC +N
3 phase
IT net ()
230VAC
3 phase

1 (4)
2 (8)
3 (12)
1 (4)
2 (8)
3 (12)
1 (1)
1 (2)
1 (3)
1 (4)

230VAC
1 phase

Current Max.
per input (A)
205VAC
176VAC

32.9
49.3
65.8
43.5
85.4
113.9
16.5
32.8
49.3
65.8

205VAC

Ext. Fuse
Type Th/Mag

176VAC

38.3
50A-D
57.5 50A-D
63A-D
76.6
80A-D/100A-C
50.7 50A-D
60A-D
99.5
100A-C
132.7 125A-C
150A-C
19.2
*** 50A-D
38.4
50A-C
57.5 50A-D
63A-D
76.6
80A-D/100A-C

** The external AC Mains Input is internally connected to the power shelves and rectifiers at factory.
Refer to your systems specific schematic and connection drawings for more details.
***When no Fuse Selectivity is required, you can use a 25A-C fuse instead of the recommended 50A-D

Ext. Fuse
Type Hy/Mag
205VAC
176VAC

60A-C2
60A-C2
60A-C2
60A-C2
60A-C2
60A-C2

Doc 2052045,1v0

Notes:
Use the values in the 176VAC column,
if you are unsure or know that the available AC mains voltage may drop below 205VAC.
The recommendations apply for use of
Thermal magnetic circuit breaker (Th/Mag), type Siemens 5SX or 5SY series, MG C60H
series or similar; and
Hydraulic magnetic breaker (Hy/Mag), type CBI QF frame or QY frame, Airpax or similar
For more information regarding External AC fuses, please read the document 2052045
The system is implemented with 4AC-3KW Power Shelves. Systems with more than 3 power
shelves require more than 1 AC Mains Feed Input
WARNING:
Always replace a rectifier with blown internal AC fuse with a new module, and send the malfunctioning module for servicing.

For installations in
USA and Canada only

External AC Input Wires


Recommended Ratings

For external fuses above 50A, only the high current backplane can be used
External fuse rated 32A is replaced by 40A
External fuse rated 63A is replaced by 70A
The installation has to comply with the NEC/CEC requirements
Connection to AC Mains shall be in accordance with the number of power
shelves in the tables. If number of shelves exceeds the numbers in the
table, a combination of several AC Mains must be used instead

NEC/CEC Requirements

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Current
Max. (A)
6
10
13
16
25
32
40
63
80
100

Wire Section
(mm2) (AWG)
0.75
1.00
1.25
1.50
2.50
4.00
6.00
10.00
16.00
25.00

18
16
16
14
12
10
8
6
4
2

Note: The external


terminal blocks must
be rated to accept
the
actual
wire
section above.

11

Appendix

AC Mains

Identifying Power Shelves: 4AC, 2AC or 4AC-3kW


4AC-3kW Power Shelf

Flatpack2 rectifiers are accommodated in one or


several power shelves. Following types of power
shelves are available:

Flatpack2 System, 1U DC Distr.

Power Shelf
(rear view)

Power Shelf
(rear view)

AC Mains &
PE terminals

4AC-3kW and 2AC Power Shelves

4AC Power Shelves

4AC Power Shelves, or single AC feed, 1 TB


(4 AC inputs per shelf, each feeding 1 rectifier)

4AC-3kW Power Shelves, or single AC feed, 2 TB


(4 AC inputs per shelf, each feeding 1 rectifier)

2AC Power Shelves, or dual AC feed, 1 TB


(2 AC inputs per shelf, each feeding 2 rectifiers)

You can identify the type of power shelves used by your system by reading the shelfs label, or by
looking at the shape of the shelfs AC mains terminals, at its rear; (viewable by removing the
rectifier in the shelfs 1st and or 4th position). Also, 4AC-3kW power shelves are longer in depth,
and have 2 terminal blocks (TB).

I Mains Reconfiguration ~Integrated System 1U Distr.

The AC mains terminals of Flatpack2 integrated systems with 1U DC distribution units are
located on the power shelfs rear.

4AC Power Shelves

Single AC feed: 4 AC inputs per


shelf, each feeding 1 rectifier

Switch OFF the AC supply fuses in external fuse boards. Find out if your system is
implemented with 4AC or 2AC powers shelves (read Identifying Power Shelves, page12).
Terminate the AC mains cable according to the type of AC mains to be used, as shown in the
actual example below.
Mains
Three-phase & N, 400VAC
L1 L2 L3 N
PE
Power Shelf
PE(CON12)
L1(CON11)
L2(CON10)
PE(CON15)
L1(CON14)
L2(CON13)
PE(CON18)
L1(CON17)
L2(CON16)
PE(CON21)
L1(CON20)
L2(CON19)

2AC Power Shelves

Dual AC feed: 2 AC inputs per


shelf, each feeding 2 rectifiers

Mains
Three-phase & N, 400VAC
L1 L2 L3 N
PE

12

Mains
Three-phase, 230VAC
L1 L2 L3
PE

Mains
One-phase, 230VAC
L (L1) N (L2)
PE

Power Shelf
PE(CON12)
L1(CON11)
L2(CON10)
PE(CON15)
L1(CON14)
L2(CON13)
PE(CON18)
L1(CON17)
L2(CON16)
PE(CON21)
L1(CON20)
L2(CON19)

Mains
Three-phase, 230VAC
L1 L2 L3
PE

Power Shelf

Power Shelf
PE(CON12)
L1(CON11)
L2(CON10)
PE(CON15)
L1(CON14)
L2(CON13)
PE(CON18)
L1(CON17)
L2(CON16)
PE(CON21)
L1(CON20)
L2(CON19)

Mains
One-phase, 230VAC
L (L1) N (L2)
PE

Power Shelf

Power Shelf

CON13

CON13

CON13

(PE)

(PE)

(PE)

CON9

CON9

CON9

(L1 1/2)

(L1 1/2)

(L1 1/2)

CON11

CON11

CON11

(L1 3/4)

(L1 3/4)

(L1 3/4)

CON10

CON10

CON10

(L2 1/2)

(L2 1/2)

(L2 1/2)

CON12

CON12

CON12

(L2 3/4)

(L2 3/4)

(L2 3/4)

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Appendix

AC Mains

II Mains Reconfiguration ~AC Terminal Block

To reconfigure the AC mains feed of Flatpack2 DC power systems that use the AC Mains
terminal block, you have to reconnect the AC mains wires and fish plates on the terminal block.
1. Switch OFF the AC supply fuses in external fuse boards
2. Check that your system is implemented with 4AC-3kW or 4AC powers shelves (read the
Identifying Power Shelves section, page 12). If your system utilizes 2AC power shelves,
you can NOT reconfigure it as described in this section
3. Connect the AC Mains wires to the AC terminal block, and mount the fish plates,
according to the type of AC mains to be used, as shown in the actual example in this
section
Configurable Mains Input Terminal Block
4AC-3kW or 4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)

Mains, TN
Three-phase & N, 400VAC

Mains, IT
Three-phase, 230VAC

Mains
One-phase, 230VAC

(1 Y Mains input will feed 2 power shelves)

(1 Mains input will feed 2 power shelves)

(3 Mains inputs will feed 2 power shelves)

AC Mains
Cable

3 AC Mains
Cables

AC Mains
Cable

PE

L1

L2

L3

AC Mains
wires
2

1 fish
plate
AC Mains
Terminal
Block

3 fish
plates

Chassis

Chassis

Chassis

AC Mains
wires

AC Mains
wires

0 fish
plates
AC Mains
Terminal
Block

AC Mains
Terminal
Block

X:******

X:******

X:******

(To internal connections


for 2 power shelves)

(To internal connections


for 2 power shelves)

(To internal connections


for 2 power shelves)

Flatpack2 DC Power System

Flatpack2 DC Power System

Flatpack2 DC Power System

2009604, v11

Warning:
In Mains Configuration, mount every other fish plate upside down, thus avoiding short circuits, if cut too long.

Such systems have


to be configured at
the factory prior to
delivery.

Fixed Individual Mains Input Terminal Block


4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)
Mains
One-phase, 230VAC
(8 Mains inputs will feed 2 power shelves)

8 AC Mains
Cables

AC Mains wires
Chassis

Mains reconfiguration is NOT possible


when the system is
shipped with fixed
individual Mains input terminal blocks.

To
rectifier 1

0 fish plates
AC Mains
Terminal
Block
To
To
To
rectifier 2 rectifier 3 rectifier 4

To
To
To
rectifier 5 rectifier 6 rectifier 7

(To internal connections for 2 power shelves)


Flatpack2 DC Power System

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

To
rectifier 8

X:******
2009604, v11

13

Appendix

AC Mains

III Mains Reconfiguration ~AC Terminal Block with OVP

Mains reconfiguration is NOT possible when Flatpack2 DC power systems are shipped with
AC terminal blocks with OVP2 surge arrestors. Such systems have to be configured at the
factory prior to delivery.
Refer also to page 23 for more information about connection to Digital Input 1 on card 105954.
NON Configurable Mains Input Terminal Block with OVP
4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)
Y Mains, NT
Three-phase & N, 400VAC
(1 Y Mains input will feed 2 power shelves)
Customer
connections

To Digital
Input 1

To terminal X*, pin 1 (+)


To terminal X*, pin 2 (-)

11

Terminals & Pin-out Location


CON1A
CON2A
X*

X**

10

14

12

L1

L2

Weidmuller

Weidmuller

L3

PE

PE

L1

L2

L3

PE

Weidmuller

AC Mains
wires

0 fish plates

Weidmuller

AC Mains
Terminal
Block

20

Alarm Outputs & Digital Inputs Card,


Art. 105954
(or Art. 200916 when X** and CON2A
are not mounted)

X:******
N

(Internal System
Connections)

Flatpack2 DC Power System


2009604, v11

NON Configurable Mains Input Terminal Block with OVP


4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)

To Digital
Input 1

Y Mains, NT
Three-phase & N, 400VAC

Y Mains, NT
Three-phase & N, 400VAC

(1 Y Mains input will


feed 2 power shelves)

(1 Y Mains input will


feed 2 power shelves)

To terminal X*, pin 1 (+)


To terminal X*, pin 2 (-)

Customer
Connections
(PR 1-2)

Terminals & Pin-out Location


CON1A
CON2A
11

14

12

11
PE

X*

L1

L2

L3

PE

Weidmuller

Weidmuller

Weidmuller

Weidmuller

X**

10

Customer
Connections
(PR 3-4)

PE

L1

L2

14

12

L3

L1

L2

L3

PE

Weidmuller

Weidmuller

Weidmuller

Weidmuller

PE

PE

L1

L2

L3

0 fish plates
AC Mains
Terminal
Block

20

Alarm Outputs & Digital Inputs Card,


Art. 105954
(or Art. 200916 when X** and CON2A
are not mounted)

AC Mains
wires

(Internal System
Connections

(Internal System
Connections

X:******

Flatpack2 DC Power System


2009604, v11

Over Voltage Protection, OVP

14

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Appendix

AC Mains

About AC, DC Earthing Systems


To prevent the risk of electric shock, all cabinets chassis are to be electrically
connected to AC Earth (PE). Also, it is a common practice for telecom equipment
to have its common DC output rail (+ or -) connected to a separate Telecom
Earth (TE) or DC Earth.

AC Mains Input
(L1,L2,L3,N)

PE (Protective Earth)
TE (Telecom Earth)
EG (Exchange Ground)

Earth connections are in particular important where frequent lightning might


induce high voltage levels in AC supply and in battery and load cables.
Link 2
(DC Earth)

AC Mains

Link 1
(AC Earth)

PE
Chassis

Chassis
EG

Common
DC Rail

TE

DC Load
Circuit

Cabinet

AC Earth (PE) and DC Earth (TE) are


connected to chassis via Link 1 and
Link 2. Remove the links (floating
earth) for compliance with other local
earthing systems.
Refer to your systems specific drawings to
identify how these links are implemented in
your DC power system.

Common Positive DC Output Rail is usual in 48 and 60V DC supply systems: Negative DC
Distribution. Common Negative DC Output Rail is usual in 24V systems: Positive DC
Distribution.

Negative DC
Distribution

Quick Start Guide Flatpack2 PS System

+
+

+
+

DC Load
wires

Common DC Rail
DC Load
wires

Common DC Rail +

Positive DC
Distribution

356804.103, 6v1-2009-11

15

Appendix

AC Mains

Mains Phases versus Rectifier ID

Phase Balancing & Monitoring

When Flatpack2 systems are fed with a 3-phase AC Mains input circuit, each rectifier is internally
connected to the 230VAC phases, in such a pattern that loads the 3 phases evenly.
The distribution of rectifiers among the phases is implemented both via internal wiring to the
power shelves, and how the shelfs back-wiring card routes the phases to each rectifier position.
There are 3 types of shelves: 4AC, 4AC-3kW and 2AC power shelves. Read also the Identifying
Power Shelves section, page12.
Load Balancing of Mains Phases

Mains
Three-phase & N, 400VAC

09

09

06

Flatpack2 rectifier

03

L3

01
L2

04

07

Phase 1

Phase 3

03

Mains
400VAC, 3ph+N

L1
AC
Mains
230VAC

06

01

L2

02

05

04

08

07

ID number
(Assigned
CAN bus
address)

02

Mains
One-phase, 230VAC

05
L(L1)

08

AC
Mains

230VAC
N(L2)

Phase 2

01

02

03

Plug-and-Play Rectifiers versus Phase 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. The controller registers the
rectifiers Serial Number and ID number.
When a previously installed (hot plugged) Flatpack2 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 Flatpack2
rectifiers in the indicated power shelf position, one module at a time, starting with ID number
1, 2, 3, and so on. The sequence is indifferent after ID number 6. You find more information on
page 17.
This position-versus-ID number relationship is very important for the correct monitoring of the
mains three phases, as the Smartpack controller always uses rectifier ID01, 02 and 03 to
monitor the Mains phase 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 phase 1, will cause the controller to monitor phase 1 thinking it monitors
phase 2. Then a phase 1 fault will be alarmed as a phase 2 fault.

16

Quick Start Guide Flatpack2 PS System

Phase 1

Mains
Three-phase, 230VAC

L1

230VAC

Phase 3

L3

356804.103, 6v1-2009-11

Phase 2

Even distribution of Flatpack2 rectifiers on the Mains phases

PULLOUT

Check Lists Pullout

Pull out the pages with the gray outer band,


and use them as check lists

Form 173-gb-v5-C01_356804-103_qstart_flatpack2-pssyst_6v1.docx_mfm_2007-11-01

EMC
regard

INSTALLATION CHECK LIST


System Data

Flatpack2 PS System

Flatpack2 Power Supply System, type:

Article No.:

Site, name:

Battery Type:

AC Input Voltage, measured:

Software, version No.:

Serial No.:

Battery Capacity:

Rectifiers, type & number of:


Installation carried out by, name:

Site Preparations
CARRY OUT FOLLOWING:

OK

1. Organize the installation site


o
o
o

Check min. clearances for cabinet access: front access, 60cm, top access, 20cm
Check that the levelled surface is able to support 600 kg (cabinetized systems)
Ensure the installation site is suitably ventilated and in a non-explosive atmosphere. 60V systems in RAL areas

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
o
o
o
o

o
o

OK

Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc
Inspect the equipment for physical damage (report any damages)
Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
Check that cable entry from the top is possible
Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor
Subassemblies in existing 19 or in ETSI cabinets, using brackets. Mount the support & heat deflecting plate
Start (if applicable) on the lower shelf first, and continue upwards
Do not terminate the battery cables yet!

Power is OFF!

CARRY OUT FOLLOWING:


o

o
o

Power is OFF!

CARRY OUT FOLLOWING:

4. Remove packaging and check equipment


Device
hazard

5. Remove top cover and dummy front panels


6. Position and fasten the cabinet or subassembly
o
o

7. Mount the batteries on the shelves


Electric
shock

Electrical Installation

OK

8. Make the system completely voltage free


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

9. AC Connections
o
o
o

Check AC configuration: The AC terminals are correct configured to the external AC supply
Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond

10. DC Connections Load Circuits


Electric
shock

Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place
For each DC load, connect one of the cables to the common DC output rail, and the other directly to the MCB

11. DC Connections Alarm & Signal Circuits


o
o
o

Refer to your systems connection drawings and configuration, or to the Factory Settings in the Quick Start Guide
Terminate Alarm Circuit cables to the relay output terminals
Terminate Signal Circuit cables to the digital input/output terminals

12. DC Connections Battery Cables


o
o
o
o

Careful! Use correct polarity.

For each battery shelf,


Mount 3 intercell links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks)
Connect battery cables to fuses and common DC rail, and to the shelfs outer terminals; (+) and (-)
Connect battery symmetry cables, if applicable, to the input terminals
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.:

www.eltekvalere.com
Headquarters:
Eltek Valere
Grterudv. 8, PB 2340 Strms, 3003 Drammen, Nor
Phone: +47 32 20 32 00
Fax: +47 32 20 32 10

Form 172-gb-v4-C01_356804-103_qstart_flatpack2-pssyst_6v1.docx_mfm_2009-09-17

CIRCUIT DISTRIBUTION LIST


System Data
Flatpack2 PSS, type:

Article No.:

Site, name:

CIRC.

NO.

FUSE TYPE
KNIFE

BATT.

LOAD

MCB

LVD

DESCRIPTION

CONTROLLED

FUSE
AMPERE

CABLE
mm2

Fb1
Fb2
Fb3
Fb4
Fb5
Fb6
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
F11
F12
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
F29
F30
F31
F32
F33
F34
F35
Continue

www.eltekvalere.com
Headquarters:
Eltek Valere
Grterudv. 8, PB 2340 Strms, 3003 Drammen, Nor
Phone: +47 32 20 32 00
Fax: +47 32 20 32 10

CIRC.

NO.

CIRCUIT DISTRIBUTION LIST


FUSE TYPE
KNIFE

MCB

LVD

DESCRIPTION

CONTROLLED

FUSE
AMPERE

CABLE
mm2

F36
F37
F38
F39
F40
F41
F42
F43
F44
F45
F46
F47
F48

LOAD

Form 172-gb-v4-C01_356804-103_qstart_flatpack2-pssyst_6v1.docx_mfm_2009-09-17

www.eltekvalere.com
Headquarters:
Eltek Valere
Grterudv. 8, PB 2340 Strms, 3003 Drammen, Nor
Phone: +47 32 20 32 00
Fax: +47 32 20 32 10

Electric
shock

MAINTENANCE PROCEDURE
System Data

Flatpack2 PS System

Flatpack2 Power Supply System, type:

Article No.:

Site, name:

Battery Type:

AC Input Voltage, measured:

Software, version No.:

Serial No.:

Battery Capacity:

Rectifiers, type & number of:


Maintenance carried out by, name:

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

System Inspection

Power is ON!

CARRY OUT FOLLOWING:

OK

Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.

At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration

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

1. Site specific parameters and settings are known.


2. The battery bank has been fully charged in advance.
3. The equipment is free from damage, dust or dirt; verify.

6. All rectifiers functionality & Smartpacks keys and display work OK; verify

5. The Smartpack & all rectifier modules are ON, no alarm present; verify.

4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.
Otherwise, correct and put the PS system in normal mode of operation.
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.

Using the keypad on the Smartpack controller or from the PC.

Use the PowerSuite PC application to check all rectifiers output the same amount of current (1A)

8. Rectifiers load current sharing; verify.


9. Display the stored log of Alarm Messages.
Form 171-gb-v4-C01_356804-103_qstart_flatpack2-pssyst_6v1.docx_mfm_2009-09-17

System Adjustment

Power is ON!

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 Smartpacks 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 2% from the display readings, calibrate the current from the
PC (calibration value>50% of systems 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 Smartpacks 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.:

www.eltekvalere.com
Headquarters:
Eltek Valere
Grterudv. 8, PB 2340 Strms, 3003 Drammen, Nor
Phone: +47 32 20 32 00
Fax: +47 32 20 32 10

PULLOUT

Form 170-gb-v6-C01_356804-103_qstart_flatpack2-pssyst_6v1.docx_mfm_2009-09-17

COMMISSIONING PROCEDURE
System Data
Suppliers Order No.:

Flatpack2 PS System
Flatpack2 Power Supply System, type:

Article No.:

Site, name:

Battery Type:

AC Input Voltage, measured:

Software, version No.:

Serial No.:

Battery Capacity:

Rectifiers, type & number of:


Commissioning carried out by, name:

Pre-Start Check

Power is OFF!

CHECK FOLLOWING:

OK

1. Flatpack2 system installation is completed;


Device
hazard

The Flatpack2 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

II

Start-up, No-Load & Load Adjustments

Power is ON!

CARRY OUT FOLLOWING:

OK

1. Disconnect all rectifier modules, without removing them (keep original location)
Device
hazard

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


3. AC input voltage is correct;

Measure and verify

4. Insert all Flatpack2 rectifiers in their original locations in the power shelves
5. The Smartpack and all rectifier modules are working, LEDs are ON;
6. Connect a PC to the PS system

Verify

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

III

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
Device
hazard

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.:

www.eltekvalere.com
Headquarters:
Eltek Valere
Grterudv. 8, PB 2340 Strms, 3003 Drammen, Nor
Phone: +47 32 20 32 00
Fax: +47 32 20 32 10

Check Lists Pullout


Pull out the pages with the gray outer band,
and use them as check lists

PULLOUT

Appendix

AC Mains
Correct Rectifier Positions in Power Shelves

Flatpack2 DC power systems are normally shipped from factory with empty power shelves. The
rectifier modules are shipped in separate packaging, and you have to install the modules in the
correct position in the power shelves, with respect to their ID number (or CAN bus address). Do
not relocate already pre-installed rectifiers.
For first time installations of rectifiers in Flatpack2 systems, follow the scheme below:
1. Find out your systems power shelf type, by
reading the Identifying Power Shelves section, page12
2. Find out if your systems AC mains feed is
<230VAC, 3 phase> or <400VAC, 3 phase and N>
3. Insert & hot-plug the rectifiers in the indicated power shelf positions,
one module at a time, allowing a 2s delay between them and starting with ID number 1,
2, 3, and so on. (indifferent after ID# 6)
Follow one of the four figures below:
Smartpack Located in Distribution Shelf
Correct Rectifier Position in 4AC Power Shelves

Correct Rectifier Position in 2AC Power Shelves

Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers

and
Mains
Three-phase, 230VAC

Mains
Three-phase & N, 400VAC
Flatpack2
rectifier

Smartpack
controller

Position 1

Position 9

01

02

03

04

05

06

---

-----

-----

-----

-------

and
Mains
Three-phase, 230VAC

Flatpack2
rectifier

Smartpack
controller

Position 4
Position 8

ID number
(Assigned CAN
bus address)

Phase 1

Mains
Three-phase & N, 400VAC

Position 1

Position 9

Phase 2

01

04

03

06

-----

-----

02

05

Position 4

---

---

Position 8

---

-----

---

ID number
(Assigned CAN
bus address)

Phase 3

Smartpack Located in Power Shelf


Correct Rectifier Position in 4AC Power Shelves

Correct Rectifier Position in 2AC Power Shelves

Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier

Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers

and
Mains
Three-phase, 230VAC

Mains
Three-phase & N, 400VAC
Flatpack2
rectifier

Smartpack
controller

Position 1

Position 9

02

03

01

05

06

04

-----

-----

-------

-----

and
Mains
Three-phase, 230VAC

Flatpack2
rectifier

Smartpack
controller

01

02

05

Position 4

03

06

04

---

Position 8

-----

-----

-----

Position 4
Position 8

ID number
(Assigned CAN
bus address)

Quick Start Guide Flatpack2 PS System

Mains
Three-phase & N, 400VAC

Position 1

Position 9

356804.103, 6v1-2009-11

----ID number
(Assigned CAN
bus address)

17

Appendix

Battery Monitoring

Battery Symmetry Connections


Smartpack based systems have many inputs on the controller and on Battery Monitors
connected to the CAN bus which are dedicated for battery symmetry measurements.
Controllers Battery Symmetry Connections 48V

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

Battery Symmetry
Mid-point Measurement

Battery Symmetry
Block Measurement

One measurement per string

Four measurements per string


(Serial measurement)
3

Symmetry 1.4

Set all 4 switches


ON (down)

Symmetry 1.3

Symmetry 1.1

Card, Art. 200576 X:****


Serial Switches

Symmetry 1.1

Set all 4
switches
OFF (up)

- + - + - + - +

(-48V) Outer
Terminal

Block1

Block3

Block4

Intercell Links

Two measurements per string, from the


middle to the outer terminals
2-1

(-48V) Outer
Terminal

Block1

Block3

Block4

0V Outer
Terminal

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.

X:****

Set all 4
switches ON
(down)

Battery Terminology

Symmetry 1.2

Card, Art. 200576


Serial Switches

- + - + - + - +

Intercell Links

0V Outer
Terminal

Battery Symmetry
Double-point Measurement

Battery Block, Battery String and Battery Bank


Battery
Block (12V)
+
Battery
String #1
(48V)Batt.

- + - + - + - +

(-48V) Outer
Terminal

Block1

Intercell Links

18

2-1

2-1
X:****

Symmetry 1.2

Card, Art. 200576


Serial Switches

Symmetry 1.1

Examples of Battery Symmetry Connections on the Smartpack controller 48V Systems

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 and the
appropriate number of Battery Symmetry Kits, which contain a single wire with suitable cable lugs,
etc. Refer to the illustration on page 22.

Block3

Block4

0V Outer
Terminal

48V Battery Bank

Quick Start Guide Flatpack2 PS System

Battery
String #2
(48V)
356804.103, 6v1-2009-11

Appendix

Battery Monitoring
Controllers Battery Symmetry Connections 24V

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 or Block
Measurement Method 3 .
You can implement any of these methods using one or two Battery Connection Kits and the
appropriate number of Battery Symmetry Kits, which contain a single wire with suitable cable lugs,
etc. Refer to the illustration on page 22.

One measurement per string


Card, Art. 200576
Serial Switches

2-1
X:****

Symmetry 1.1

Example of Battery Symmetry Connections on the Smartpack controller, 24V Systems

Battery Symmetry
Mid-point or Block Measurement

Set all 4
switches
OFF (up)

- + - +

0V Outer
Terminal

Block1

Block2

Intercell Link

24V Outer
Terminal

Battery Terminology
Battery Block, Battery String and Battery Bank
Battery
Block (12V)

Battery
String #1
(24V)

24V Battery Bank

Battery
String #2
(24V)

The Mid-Point and the Block Measurement Methods are identical in 24V systems.

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

19

Appendix

Battery Monitoring

Battery Monitors Symmetry Connections 48V (Block Measurement)

Each Battery Monitor is equipped with 4 battery symmetry inputs, enabling symmetry
measurement of 1 battery string using the Block Measurement Method.
Read the Installation Guide Battery Monitor CAN Node, document number 351507.033. Refer
also to Installation Guide Battery Monitor Symmetry Kit, document number 351497.033, which
is included with the kit. The Battery Fuse and Battery Current cables are not shipped with the
Battery Monitor ~ Symmetry Kit.
Battery Symmetry String 1 to 4
Block Measurement
Four measurements per string

Four measurements per string

+
Battery
String 2

Block3

Block4

Four measurements per string

Block1

Intercell Links

Block3

+
Battery
String 4

0V Outer
Terminal

(-48V) Outer
Terminal

- + - + - + - +

Block4

Symmetry 4.2

Symmetry 4.1

Symmetry 3.4

Symmetry 3.3

Symmetry 3.2

Battery Monitor
Part 242100.300
ID# <36>
Set DIP switch 1 2 3 4
1&2 ON (down),
the rest OFF
(up)

- + - + - + - +

(-48V) Outer
Terminal

Symmetry 2.4

0V Outer
Terminal

Four measurements per string

Set DIP switch 1 2 3 4


2 ON (down),
the rest OFF
(up)

Battery
String 3

Block4

Battery Monitor
Part 242100.300
ID# <35>

Block3

Block1

Intercell Links

0V Outer
Terminal

Symmetry 4.4

Intercell Links

- + - + - + - +

(-48V) Outer
Terminal

Symmetry 2.3

Symmetry 2.1

Symmetry 1.4
+

Symmetry 4.3

Block1

20

- + - + - + - +

(-48V) Outer
Terminal

Symmetry 1.3

Symmetry 1.2

Symmetry 1.1
Battery
String 1

Set DIP switch 1 2 3 4


1 ON (down),
the rest OFF
(up)

1234

Battery Monitor
Part 242100.300
ID# <34>

Symmetry 2.2

Set all 4
DIP
switches
OFF (up)

Symmetry 3.1

Example of Battery Symmetry Connections on the Battery Monitor, 48V Systems

Battery Monitor
Part 242100.300
ID# <33>

Block1

Intercell Links

Block3

Notice:
Always
connect
Battery
Monitor with ID#<33> to
battery string 1 (lowest), with
ID#<34> to string 2, and so
on. PowerSuite will then refer
to the correct battery string.

Block4

0V Outer
Terminal

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Appendix

Battery Monitoring

Battery Monitors Symmetry Connections 48V (Mid-Point Measurement)

Each Battery Monitor is equipped with 4 battery symmetry inputs, enabling symmetry
measurement of 4 battery strings using the Mid-Point Measurement Method.

Example of Battery Symmetry Connections on the Battery Monitor, 48V Systems

Read the Installation Guide Battery Monitor CAN Node, document number 351507.033. Refer
also to Installation Guide Battery Monitor Symmetry Kit, document number 351497.033, which
is included with the kit. The Battery Fuse and Battery Current cables are not shipped with the
Battery Monitor ~ Symmetry Kit.
Battery Symmetry String 1 to 4
Mid-point Measurement
One measurement per string, four strings
Battery Monitor
Part 242100.300
ID# <33>
Set all 4
DIP
switches
OFF (up)

1234

+
Battery String 4
Symmetry 1.4

Symmetry 1.3
Battery String 3
Symmetry 1.2
Battery String 2
Symmetry 1.1
Battery String 1
- + - + - + - +

(-48V) Outer
Terminal

Block1

Intercell Links

Block3

Block4

0V Outer
Terminal

Notice:
Always connect Battery Monitor with ID#<33> to battery strings 1 (lowest),
2, 3 and 4. Then Battery Monitor with ID#<34> to string 5, 6, 7 and 8. And
so on. PowerSuite will then refer to the correct battery string.

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

21

Appendix

Battery Monitoring

Terminals & Pin-out Location, Battery Interface Card


The Smartpack controllers battery monitoring signals are accessible on D-Sub connectors CON4
and CON3, on the controllers 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 controllers CON3.
For detailed information about the cards pin-out location and terminal block connections, refer to
the figures in this section.

The Temperature Sense Kit is connected to


the Battery Interface Card (Art. 200576), or
directly to the controllers CON3 or CON4,
if unused.

Smartpack

CON3A or CON4A

CON4A

Serial Switch
14

Battery Interface Card, Art. 200576

22

(From area with


internal batteries)

15-pins D-Sub male

Temperature Sense 1
Temperature
sensor

Configurable monitoring digital inputs


FUNCTION

Card Art.200576

SIGNAL PIN-OUT

X:***

In

Battery Connections
Card, Art. 200576

X**/X*

X***/X****

15

Battery Connections (Internal)

Battery Connections
Card, Art. 200576

For Temp.
Sense Kit

11

(Alternative use of Temp. Sense Kit,


instead of connecting to X:****, 9-10)

To Smartpack,
CON3

Alarm Outputs & Digital


Inputs Card, Art. 105954

CON3A

CON3

15-pins
D-Sub female

Terminals & Pin-out Location


CON4

(Internal Connections)
2
1.5 mm , max.
wire
section
X**/X*

1
Batt. Symmetry 5 +
2
3
Batt. Symmetry 6 +
4
Batt. Symmetry 7 + 5
6
+ 7
Batt. Symmetry 8
8
+ 9
1
11 Temperature Sense 2 10
11
Batt Current 2
5
15
12
13
CON3A or Batt Fuse Fail 2
14
CON4A
15-pins
D-Sub female
1

11

15

(From area with


internal batteries)

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.

15-pins
D-Sub female

Temperature
sensor

Temperature
sensor

(Internal Connections)
2
1.5 mm , max.
wire section
X**/X*
15-pins D-Sub male

15-pins
D-Sub female

Temperature Sense 2

(Alternative use of Temp. Sense Kit,


instead of connecting to X:***, 9-10)
Temperature
sensor
The Temperature Sense Kits may also be connected directly to the
Smartpack controllers CON3 or CON4, if these connectors are unused.

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

(From area with


internal batteries)

Temp. sensor

To Smartpack,
CON4

Temp. Sensor cable

1
Batt. Symmetry 1 +
2
3
Batt. Symmetry 2 +
4
Batt. Symmetry 3 + 5
6
+ 7
Batt. Symmetry 4
8
+ 9
1
11 Temperature Sense 1 10
11
(NA)
5
15
12
13
(NA)
CON3A or
14
CON4A

(From area with


internal batteries)

Cable
Lugs

SIGNAL PIN-OUT

X:****

In

Temperature Sense Kit

System Connections
Card, Art. 200625

FUNCTION

(From internal
batteries)

Card Art.200576

Configurable monitoring digital inputs

Card Art.200576

(From internal
batteries)

15 pins D-Sub cable

Battery Connections (Internal)

Single Wire

Batt. Symmetry Kit, Art. 200830

Battery Connection Kit

Appendix

Alarms & Monitoring

Standard Alarm Relays & Digital Inputs

Connections

Standard Relays & Digital Inputs


NO
Com
NC

Normal Mode

Relay X
(Energized coil)

The alarm outputs in Flatpack2 systems use the Fail-Safe


Operation Mode (relay coils energized in the systems
normal operation mode). When the system is in alarm mode,
the alarm relay coils are de-energized.

NO
Com
Relay X
(De-energized coil)
NC
Flatpack2 PS System
Alarm Mode

The figure shows the position of the relay contacts when the
relay coils are de-energized (PS system in alarm mode)

Correct Use of Alarm Outputs (example)


Digital Input X
(Normal mode)
Digital Input X
(Activated)

Normal Mode

External Relay Y
(Energized coil)

Alarm Mode

In order to implement monitored fail-safe digital inputs


circuits, the external relay coil must be energized and the
contacts closed in the systems normal mode of operation.

External Relay Y
(De-energized coil)

Flatpack2 PS System

Correct Use of Digital Inputs (example)

Terminals & Pin-out Location, Alarm Interface Card


The Smartpack controllers alarm and digital input monitoring signals are accessible from the
controllers rear panel, on mini power connector CON1 (2 outputs & 2 inputs) and on D-Sub
connector CON2 (4 outputs & 4 inputs).
Alarm Outputs & Digital Inputs

Voltage free relay outputs and Configurable monitoring digital inputs

In

For detailed information about the cards pin-out


location and terminal block connections, refer to
the figures in this section.

SIGNAL PIN-OUT

Out

Digital Input 1
Digital Input 2

X:*
+

Relay 1 NO
Common Alarm COM
NC

Terminals & Pin-out Location

CON2A
CON1A

Smartpack

CON1A

Battery Connections
Card, Art. 200576

CON2A

X*

To Smartpack,
CON1

Battery Connections
Card, Art. 200576

CON2
CON1

Alarm Outputs & Digital


Inputs Card, Art. 105954

Relay 2
Mains Alarm

X**

10

20

Alarm Outputs & Digital Inputs Card, Art. 105954


(or Art. 200916 when X** and CON2A are not mounted)

The figure shows the position of the relay


contacts when the relay coils are de-energized
(PS system in alarm mode. Factory Settings in
bold)

Quick Start Guide Flatpack2 PS System

To Smartpack,
CON2

System Connections
Card, Art. 200625

356804.103, 6v1-2009-11

NO
COM
NC

1
2
3
4
5
6
7
8
9
10

Input Circuit 1
Input Circuit 2
Alarm Circuit 1
Alarm Circuit 2

X:**
1
2
3
Digital Input 4
4
5
Digital Input 5
6
7
Digital Input 6
8
Relay 3 NO 9
Fuse Alarm COM 10
Load & Battery NC 11
12
Relay 4 NO
High Battery Alarm COM 13
NC 14
NO 15
Relay 5
Low Battery Alarm COM 16
NC 17
Relay 6 NO 18
Rectifier Alarm COM 19
NC 20
(Customer Connections)
Digital Input 3

(To and from


external equipment)

FUNCTION

Input Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6
Alarm Circuit 3
Alarm Circuit 4
Alarm Circuit 5
Alarm Circuit 6
2

1.5 mm , max.
wire section

23

(From external equipment)

Card Art.105954

(To external equipment)

Using the Alarm Interface Card (Art. 105954)


and two interface cables, you can make the
signals on CON1 & 2 accessible at any suitable
location inside your system.

Appendix

Internal Connections

Terminals & Pin-out Location, System Interface Card


Flatpack2 systems are shipped from factory with the CON5 signals already connected.
Some of the Smartpack controllers internal system signals are accessible on D-Sub connector
CON5, on the controllers rear panel.
Using the System Interface Card (Art. 200625) and a standard 15 pins D-Sub cable, the signals on
CON5 may be accessible at any suitable location inside your system.
For detailed information about the cards pin-out location and terminal block connections, refer to
the figures in this section.

Alarm Outputs & Digital


Inputs Card, Art. 105954

Smartpack

JP1
3
2
1

JP2

JP1

Battery Connections
Card, Art. 200576
Pos. Distr.
Neg. Distr.
JP2
1
2
3

X*****
1

CON5A

11

Neg. Distr.
Pos. Distr.

System Connections Card, Art. 200625

X:*****

Out
10
15
6
7
12
13

9+, Neg.D.
11,Pos.D.

JP2

Battery Connections
Card, Art. 200576

CON5

System Connections

CON5A

System Connections
Card, Art. 200625

Terminal Board, Art. 200625


(To Smartpack, CON5)

In
Terminals & Pin-out Location

1+/
3+/
2+/

1
Power Input
2
3
Batt. Current 1
4
Batt. Fuse Fail 1
5
6
Load Fuse Fail 1
7
LVD1A
8 LVD Common
LVD1
9
LVD2A
10 LVD Common
LVD2
11
(To latching contactors
LVD1 & LVD2)

(Internal Connections)

JP1 and JP2 are used to configure the


system for Negative DC distribution (48 and
60V systems) or Positive DC distribution
(24V systems)

LVD Latching Contactors

Connections

Flatpack2 systems LVBD and LVLD 4 functionality is implemented by the Smartpack controlling
magnetically latching contactors.
Latching Contactors, LVD1 & LVD2
A latching contactor changes state only when a
reversed pulse voltage is applied to its coil

LVD1A
X

X:*****
8
9
10
11

Latching
Contactor

LVD1
LVD Common
LVD2A

Y
X

Latching
Contactor

Latching Contactor A

Warning! The
bidirectional
diode must
always be
mounted to
avoid damaging the
controller.

LVD2

Smartpack
Unit

Bidirectional
diode

- Pulse
PCB Art.
200625

OFF

ON
+ Pulse

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.

Y
LVD Common

Flatpack2 PS System (internal)

Correct Use of Latching Contactors (example)


Latching Contactor B
Two Types of Latching Contactors
4

LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect

24

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

25

Appendix

CAN Bus Nodes

CAN Bus Nodes


The CAN Bus Nodes are control units connected to the power systems CAN bus. They have a
rugged sealed-plastic design, with DIN-rail or Velcro tabs as standard mounting options.
When the CAN bus address is configured and the unit connected to the bus, it will automatically
communicate with the Smartpack controller (plug and play). Configure then the CAN node
functionality using PowerSuite.
Battery Monitor CAN Node

The Battery Monitor CAN Bus Node enables you to decentralize and increase the number of battery
symmetry measurements in your Smartpack based DC power supply system. Also, it monitors the
battery compartment temperature using the built-in sensor the battery fuse with a fuse
monitoring input and the battery current via a current sense input.
Warning

Alarm

LED Lamp (yellow)

LED Lamp (red)

CAN port 1&2

Power

Pin 8

Electrically identical

LED Lamp (green)

Pin 1

Battery Monitor

DIP switches

Battery Monitor

Monitor Inputs

CAN ID address

Terminal Block

DIP switch #1
Battery Monitor
DIP switch configuration

ID <33>

(All switches OFF)

Battery Monitor Connections


Battery
Monitor

Part 242100.300

FUNCTION

SIGNAL PIN-OUT

X:*

+
+
+
+
Batt. Fuse +

Batt. Current +

Batt. Symmetry 1
Batt. Symmetry 2
Batt. Symmetry 3
Batt. Symmetry 4

Or
RJ45 CAN bus
termination plug,
if the Battery
Monitor is the
last node in the
CAN bus

1
2
3
4
5
6
7
8
2

1.5 mm , max.
wire section

CAN port 1&2


RJ45, 8 pins

Built-in Battery
Temperature Sensor

Read also the Installation Guide Battery Monitor CAN Node, document 351507.033.

26

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

(From the
batteries)

Note:
The
monitors
ID #
corresponds
to the DIP
switchs
binary value
plus 33

(From the current shunt)


(From the current shunt)

DIP Switch Position


1 2 3 4
OFFOFFOFFOFF
ON OFFOFFOFF
OFF ONOFFOFF
ON ONOFFOFF
OFFOFFON OFF
ON OFF ONOFF
OFFON ON OFF
ON ON ONOFF
OFFOFFOFFON
ON OFFOFFON
OFFON OFFON
ON ON OFFON
OFFOFFON ON
ON OFF ON ON

From previous CAN


bus node

ID
#
33
34
35
36
37
38
39
40
41
42
43
44
45
46

To next CAN bus


node

Battery
Monitor
1st Monitor
2nd Monitor
3rd Monitor
4th Monitor
5th Monitor
6th Monitor
7th Monitor
8th Monitor
9th Monitor
10th Monitor
11th Monitor
12th Monitor
13th Monitor
14th Monitor

Appendix

CAN Bus Nodes


Load Monitor CAN Node

The Load Monitor CAN Bus Node enables you to decentralize and increase the number of input
fuse monitoring and current sense signals in your Smartpack based DC power supply system. The
fuse monitoring inputs are suitable for monitoring a wide range of breakers in both positive and
negative DC distributions.
Alarm

LED Lamp (red)

DIP switches

Warning

CAN ID address

Power

(Heads diameter >5 mm


and <8 mm)

LED Lamp (green)

CAN port 1&2

DIN Rail
mounting
clips

Screw head
mounting slot (2x)

LED Lamp (yellow)

DIP switch #1

Electrically identical

Load Monitor
Load Monitor

Current Sense Inputs

Input 1

Terminal Block X**

Fuse Monitoring Inputs

Input 1

DIP Switch Position


1 2 3 4
OFFOFFOFFOFF
ON OFFOFFOFF
OFF ONOFFOFF
ON ONOFFOFF
OFFOFFON OFF
ON OFF ONOFF
OFFON ON OFF
ON ON ONOFF
OFFOFFOFFON
ON OFFOFFON
OFFON OFFON
ON ON OFFON
OFFOFFON ON
ON OFF ON ON

ID <49>

(All switches OFF)

SIGNAL PIN-OUT

X:*

RJ45, 8 pins

Config. Input 3
Config. Input 4
Config. Input 5
Config. Input 6
Config. Input 7
Config. Input 8

DIP
Switches

Input Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6
Input Circuit 7
Input Circuit 8

Input Circuit 1

Input Circuit 5

(Customer Connections)

1.5 mm , max.
wire section

Sense Input 2
Sense Input 3
Sense Input 4
Sense Input 5
Sense Input 6
Sense Input 7
Sense Input 8

356804.103, 6v1-2009-11

Input Circuit 2

Sense Input 1

2
4

Input Circuit 1

X:**

(5-8 always
OFF)

The monitors
ID # corresponds
to the DIP
switchs binary
value plus 49

Config. Input 2

(From breakers and external equipment)

CAN
port 1&2

Fuse Monitoring Inputs

Config. Input 1

Note:
DIP switch
positions 5
through 8 are
always to be OFF

Quick Start Guide Flatpack2 PS System

FUNCTION

Input Circuit 2
Input Circuit 3
Input Circuit 4

Input Circuit 6
Input Circuit 7
Input Circuit 8
2

27

(From current shunts)

ID
#
49
50
51
52
53
54
55
56
57
58
59
60
61
62

Load Monitor

Current Sense Inputs

Load
Monitor
1st Monitor
2nd Monitor
3rd Monitor
4th Monitor
5th Monitor
6th Monitor
7th Monitor
8th Monitor
9th Monitor
10th Monitor
11th Monitor
12th Monitor
13th Monitor
14th Monitor

Voltage free relay outputs and Configurable monitoring inputs

To next
CAN bus node

Load Monitor
DIP switch configuration

Or
RJ45 CAN bus termination plug, if the Load
Monitor is the last node in the CAN bus

Read also the Installation Guide


Load Monitor CAN Node,
document 351506.033.

Load Monitor Connections

From previous
CAN bus node

Terminal Block X*

Appendix

CAN Bus Nodes

I/O Monitor CAN Node


DIN Rail
mounting
clips

Screw head
mounting slot (2x)

(Heads diameter >5 mm


and <8 mm)

Alarm

DIP switches

LED Lamp (red)

CAN ID address

Warning

DIP switch #1

LED Lamp (yellow)

Power

CAN port 1&2

LED Lamp (green)

Electrically identical

I/O Monitor
I/O Monitor

Fan Control Inputs & Outputs


Terminal Block X***
Pin 1

Relay Outputs

Configurable Inputs

Terminal Block X**

Terminal Block X*

Relay 1

Input 6

I/O Monitor Connections

From previous
CAN bus node

FUNCTION

SIGNAL PIN-OUT

CAN
port 1&2

Config. Input

Config. Input

Config. Input

Config. Input

Config. Input

Config. Input

RJ45, 8 pins

28

DIP Switch Position


1 2 3 4
OFFOFFOFFOFF
ON OFFOFFOFF
OFF ONOFFOFF
ON ONOFFOFF
OFFOFFON OFF
ON OFF ONOFF
OFFON ON OFF
ON ON ONOFF
OFFOFFOFFON
ON OFFOFFON
OFFON OFFON
ON ON OFFON
OFFOFFON ON
ON OFF ON ON

Input Circuit 2
Input Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6

NO
C
NC
NO
C
NC
NO
C
NC
NO
C
NC
NO
C
NC
NO
C
NC

Relay 2

1
2
3
4
(5-8 always
OFF)

Relay 3
Relay 4
Relay 5

ID <81>

(All switches OFF)


Not in use

Alarm Circuit 1
Alarm Circuit 2
Alarm Circuit 3
Alarm Circuit 4
Alarm Circuit 5
Alarm Circuit 6
(To be shorted)
Temperature
Sensor 1

X:***
Note:
DIP switch
positions 5
through 8 are
always to be OFF
The monitors
ID # corresponds
to the DIP
switchs binary
value plus 81

Temperature Sense 1 +

Temperature Sense 2 +

Tachometer Input 1
Tachometer Input 2
Speed Control Output 1
Speed Control Output 2

1
2
3
4
5
6
7
8

(Customer Connections)
Out

Temperature
Sensor 2
Fan Speed Monitor 1
Fan Speed Monitor 2
Fan Speed Control 1
Fan Speed Control 2
2

1.5 mm , max.
wire section

In

Quick Start Guide Flatpack2 PS System

(To external equipment)

DIP
Switches

Fan Control
Inputs & Outputs

ID
#
81
82
83
84
85
86
87
88
89
90
91
92
93
94

Input Circuit 1

X:**
Relay 1

Relay 6
I/O
Monitor
1st Monitor
2nd Monitor
3rd Monitor
4th Monitor
5th Monitor
6th Monitor
7th Monitor
8th Monitor
9th Monitor
10th Monitor
11th Monitor
12th Monitor
13th Monitor
14th Monitor

(From external equipment)

Programmable Inputs

X:*

356804.103, 6v1-2009-11

(To and from


external fans

I/O Monitor
DIP switch configuration

I/O Monitor

To next
CAN bus node

Or
RJ45 CAN bus termination plug, if the I/O
Monitor is the last node in the CAN bus

Read also the Installation Guide


I/O Monitor CAN Node, document
351503.033.

Voltage free relay outputs and Configurable monitoring inputs

Alarm Relay Outputs

The I/O Monitor CAN Bus Node


enables you to decentralize and
increase the number of input
monitoring and output controlling
signals in your Smartpack based DC
power supply system. Also, it
monitors
and
controls
the
compartment temperature inside fancooled outdoor cabinets.

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

29

30

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

Appendix

Flatpack2 Integrated System, 2U

Location of Major Components

Generic Overview

Refer to the specific drawings included with your Flatpack2 PS system, for information regarding
the exact location of components in your system

LVBD

Load Fuses

Battery Fuses
Smartpack
Control Unit

LVLD position
(not displayed)

CAN bus

DC Load
Terminals
(+, )

Interface I/O
Terminals

Rear view

AC Terminals
Bus Bars
Supply Battery
Connections

Common Battery
Connections

Front view
Battery Fuses

Load Fuses

USB 2.0 type B port


PC connection, etc

1U

1U

DC Distribution (1U high) with built-in Smartpack


controller, load fuses and MCBs

Power shelf (1U high) with 4 Flatpack2 rectifiers

Quick Start Guide Flatpack2 PS System

356804.103, 6v1-2009-11

31

This product is CE marked and


complies with all current requirements
for relevant standards and directives.

www.eltekvalere.com
Copyright Eltek Valere, 2009
This document may be changed without notice
Art. No. 356804.103, Issue 6.1, 2009 Nov
Published 2009-11-10

Headquarters:
Eltek Valere
Grterudv. 8, Pb 2340 Strms, 3003 Drammen, Norway
Phone: +47 32 20 32 00
Fax: +47 32 20 32 10