Quick Start Guide

Quick Start Guide
Installation, Operation, Commissioning and Maintenance

356804.103
Flatpack2, PS System
DC Power Supply System
Integrated, Cabinetized and Outdoor Applications
Introduction
o The Smartpack based Product Range (2 )
o Brief System Description, Flatpack2 (2 )
Installation
o Installing Smartpack, Rectifier Modules and blind panels ( 3)
o Installation steps; mechanical, electrical (4-5)
Commissioning
o Pre-start check (6 )
o Commissioning steps, Startup (6-7)
Operation
o Front keys and display (8)
o Software Menus (8)
Appendix
Communication
o Installing PowerSuite – PC software (9)
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 Controller’s 48V Battery Symmetry Connections (18 )
o Controller’s 24V Battery Symmetry Connections ( 19)
o Battery Monitor’s 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 pullout forms

o Installation Check List
o Circuit Distribution List
o Commissioning Procedure
o Maintenance Procedure
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 Flatpack2 System, Integrated Minipack System, Integrated
Indoor and Outdoor Cabinets 4U and 1U Distributions
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 PowerSuite
Digital Inputs Application
Remote
Monitoring
Flatpack2
Cabinetized Smartpack USB cable
ctrl. unit Fuse Alarm
Flatpack2
CAN Bus rectifiers
LVLD
Telecom
equipment
AC mains
supply
AC Fuses, selector
external Load Fuses
(230VAC or & MCBs
400VAC Symmetry LVBD
Alarm & DC
Temp. Sensor distribution
AC Supply DC Supply
(Single- or (24V, 48V)
three-phase) 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

2 356804.103, v6-2008-11
Installation
Installing Smartpack and Rectifier Modules
CAUTION:
- The modules may be warm, but do not hand-carry them by their handles
Device - Open the handles before inserting them into the power shelves (hot-pluggable)
hazard The rectifier incorporates a Mains fuse in each line. Double Pole / Neutral Fusing
Hole to release the

handle’s spring Mounting or Removing Smartpack and Flatpack2 Modules
Smartpack
controller mechanism Note that cables are plugged to the Smartpack’s 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.
Handle in locked position

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,
RJ45 plugs and 10 pins plug)
Smartpack controller rear or
connections
using both handles to pull the module loose. Support from
underneath before the unit is completely free. Unplug the cables,
Flatpack2 when removing the Smartpack module
rectifier
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
Handle in
unlocked position 4. Mount blind panels in
Electric
unused module locations shock
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
Device number 1, 2, 3 and so on; refer to page 17.
hazard
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 panel’s upper left and right corners by
inserting a small screwdriver into the panel’s upper left gap and
Screwdriver to carefully press down and out to release the locking tabs. Repeat
release the on the upper right gap.
locking tabs 2. Remove the blind panel by
using you hand to pull the panel loose
Blind panel’s upper
locking tabs Mounting Blind Panels
1. Insert the panel’s upper edge by
pressing gently so that its upper locking tabs engage
2. Lock the panel’s lower edge by
pressing with your hand so that the blind panel’s lower tabs lock
into position.
Quick Start Guide Flatpack2 PS System 356804.103, v6-2008-11

3
Installation
Installation Steps
Check off in the Installation Check List, that you find in the pullout section of
this folder. Also, refer to the system’s specific drawings.
Preparing the Installation Site

200 mm Begin preparing the following:
1 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 EMC
ventilation regard
o 60V systems are only to be installed in Restricted Access
Locations (RAL)
2 Prepare the installation tools
o Use insulated tools suitable for telecom installations
600 mm
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
For external AC fuses and AC input cable ratings, refer to your site’s 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 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
Flatpack2 PSS, batteries, Doc. factory installed. To be installed under commissioning
Chart, Spec. Drawings, CD-ROM 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

4 356804.103, v6-2008-11
Installation
Electrical Installation Power is OFF!

Carry out the following: (Refer to the system’s specific drawings)
8 Make the system completely voltage free
General Torque o Switch OFF or remove all load fuses (MCB1, MCBx), battery
Recommended Ratings, FP2 Systems
fuses (Fb1, Fbx) and the AC supply fuses, in external fuse
Application, Torque
Type & Size (Nm)
boards
Circuit Breakers 9 AC Connections
SIEMENS 18 mm,
5SX2, 5SX5 3.5
o Check AC configuration: the AC terminals are correct configured
SIEMENS 27 mm, 5.0 to the external AC supply, otherwise reconfigure the terminals
5SX6, 5SX7, 5SP4
MG, C60 <=25A 3.5
o Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
MG, C60 >25A 3.5 o Connect the AC input cable(s) to the terminals. Cable and
CBI 13 mm, QY, QF, QA 3.0
Hex Nuts & Screws
terminal block labeling are to correspond
(Knife Fuses, general) 10 DC Connections ⎯ Load Circuits
M8.0 10.0
M10.0 16.0 o Terminate DC Earth (TE), and check that the common DC
M12.0 25.0 Output Rail is connected to “Telecom Earth” (TE) at only one
AC Terminal Blocks
WDU 1.5 0.5
place (at the cabinet or at a central distribution point). Se
WDU 2.5 0.5 chapter about AC, DC earthing systems
WDU 4 0.6
WDU 10 2.0 o For each DC load, connect one of the cables to the common DC
WDU 16 3.0 output rail, and the other directly to the MCB or load fuse
WDU 35 4.0
WDU 70 10.0 11 DC Connections ⎯ Alarm & Signal Circuits
DC Rail Terminals
AKG 16 3.0
o Refer to your system’s connection drawings and configuration, or Electric
AKG 35 3.5 to the “Appendix, Alarms & Monitoring” section (Factory shock
Note: General tolerance: ±10%. Settings)
NEC/CEC Requirements
o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output
terminals
Chassis
12 DC Connections ⎯ Battery Cables
Link 2 CAREFUL! Use correct polarity.
(DC Earth)
Battery
Common For 48V systems using the battery symmetry mid-point
EG DC Rail
Fuse measurement, refer to the figure in this page.
Card Art.200576 For other measurement methods and for 24V systems, refer to the
2-1 15 pins D-Sub Battery Symmetry Connections chapters in this guide’s “Appendix”
(male)
section.
For each battery shelf:
(In cabinetized systems, steps b, d and f are usually performed in factory)
a Mount 3 intercell links to connect in series 4 battery blocks
Temp. Sensor cable 1
b-c Connect battery cables to fuses and common DC rail, and to

the shelf’s outer terminals; (+) and (-)
d-e Connect battery symmetry cables, if applicable, to the input
terminals, and to the center terminal of the battery string
Symmetry 1
(+) and to the -48V outer terminal. Deviation from factory

settings requires Symmetry reconfiguration via PowerSuite
Temp. sensor
Battery
Cable 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
- + - + - + - +
—
(-48V) Outer
Terminal Block1 Block3 Block4
+
Intercell Links 0V Outer
Terminal

5
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)
Device o All cabling and copper bars are securely terminated and supported
hazard 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 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
Device from the power shelves
hazard o If Flatpack2 rectifier modules are not yet mounted, release their handles and insert
them partially into the correct position in the shelves
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 cabinet’s mains connection box
o Verify the AC voltage is within range

6 356804.103, v6-2008-11
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 9, 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 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 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
Now, you can begin with stage III, where you will adjust again the output voltage to the
Power is ON!
III
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 controller’s front keys (refer to page 8) or via Device
PowerSuite— to equal the measured battery voltage. hazard
(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 handles and pulling them partially
out (fan housing visible). Do NOT physically remove them from the power shelves Device
hazard
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

7
Operation
Front Keys and display, menus, etc.

Graphical Alarm Warning
Display LED Lamp (red) LED Lamp (yellow)
16 char. x 2 lines Warning
LCD display LED Lamp (yellow) Power Alarm
LED Lamp (green) LED Lamp (red)
”Enter” key Power
LED Lamp (green)
”Up” arrow key
”Down” arrow key USB
0ype B port
Smartpack control unit Flatpack2 rectifier
Smartpack Controller — front keys, display Flatpack2 Rectifier Module — front panel
Display: is in Status Mode (displays the system’s Power LED is OFF (mains unavailable), Flashing
status) or in Menu Mode (displays the menu (controller accessing information) or ON (powered).
structure). Warning LED is ON (derating or similar minor
Operation: Press on the key to change from warning), Flashing (over-voltage mode) or OFF
Status Mode to Menu Mode. Press the or (OK)
keys to scroll up or down and navigate to find menu Alarm LED is ON (shutdown or similar major alarm)
options (function or parameter). Press then the or OFF (OK, no alarm)
key to select the function.
Menus: When you “enter” Menu Mode (Level 1),
you access the User Options. You may also scroll Level 2 Level 3
down to password protected Service Options. Service menu <ServiceOption>
Default password <0003> should be changed.
Change Language Æ English ↓↑ 2v0
Level 2 Level 3 NomVolt ↓↑
BoostVolt ↓↑
User menu <UserOption> LoBattMaj ↓↑
VoltAdjustment LoBattMin ↓↑
AlarmResetÆ
HiBattMaj ↓↑
NomVolt HiBattMin ↓↑
BoostVolt
The ”XvX” references, if any, on the right hand of the option, are not shown in the display. They only indicate
LVBD ↓↑
The ”XvX” references, if any, on the right hand of the option, are not shown in the display. They only indicate the
LoBattMaj LVLD 1.1 ↓↑

VoltageInfo LoBattMin VoltCalibration Æ VoltCal ↓↑
HiBattMaj ChangePassword Æ Password ↓↑
Firmware 402073.009 3v03 Smartpack, Distributed
HiBattMin SetManBoostTime Æ ↓↑
LVBD Start/StopBoost Æ
LVLD 1.1 Auto Boost Config. Æ Enable/Disable ↓↑ & Threshold ↓↑
Nxt Test DateTime Date ↓↑ Time ↓↑
the firmware version (402073.009 XvX) the option was first implemented or updated.
DisplayMessagesÆ Message ↓↑
Software Menus ~ Smartpack Controller
End Volt ↓↑
Firmware 402073.009 3v03 Smartpack, Distributed
SoftwareInfoÆ
SerialNumberÆ
Batt Test Setup MaxTestDur ↓↑
Test Int ↓↑
firmware version (402073.009 XvX) the option was first implemented or updated.
Rectifier nn Mod.Current↓↑ Guard Time ↓↑

Mod.Serial #↓↑
Mod.InputVolt↓↑
Start/Stop Test Æ
Mod.Status↓↑ 3v03 RemoveUnit(s) Æ Rem ↑ (Reset) 3v03
3v03
Mod.Temp↓↑ Rectifier ON/OFF ↓↑
3v03
Mod.OutputVolt↓↑ Rectifier Setup System ON/OFF ↓↑
Mod.SW Ver↓↑ RectWalkInTime Short/Long 3v03
SolarCharger nn 3v03
Module Info DCDC48 nn 3v03 Enable/Disable ↓↑
DCDC24 nn 3v03 Charge Curr Lim. Æ MainsFeed ↓↑ 3v03
GenFeed ↓↑ 3v03
NoOfPhases nn
Battery Setup NumOfString ↓↑
Mains Info MainsStatus
CellCap Ah nn ↓↑
MainsVoltage Output Control Æ VoltageCtrl / TempComp ↓
Temp Level InfoÆ Level ↓↑ Change Date/Time Æ Date ↓↑ Time ↓↑
NoOfString Nn Alarm Output 1 ↑
BattStringCurr ↓↑ RelayTest Alarm Output 2 ↑
BatteryInfo BattStringTemp ↓↑ Batt Contactor ↑
BattBlockVolt ↓↑ Load Contactor ↑
Alarm Output nn ↑
Battery H-D-W-U↓↑ 3v03 BlockOutputs Æ Enter OutpBlocked / Exit OutpBlocked 2v0
Load H-D-W-U↓↑ 3v03 BattLifeTime Rst Æ
Energy log Rectifier H-D-W-U↓↑ 3v03 Reboot CtrlUnit Æ Yes/No 3v03
Generator H-D-W-U↓↑ 3v03 NoOfMains Æ ↓↑ 3v03

Disable 3v03
SolarCharger H-D-W-U↓↑ 3v03 3v03
EfficiencyManagr HE Priority
LoadMonitor InfoÆ Unit&Input ↑↓ V-A-W-Total 3v03 3v03
Enable Redundancy(E/D)OffTime↓↑ShuffleTime↓↑

8 356804.103, v6-2008-11
Communication Appendix
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. Install PowerSuite
1 Insert the CD in your PC drive, start the PowerSuite installation and follow &
accept the wizard default steps
2. Switch Smartpack ON and plug USB cable (Part 202073)
2 to Smartpack and to any available USB port in the PC
3. Wait for Windows to install USB drivers
Follow & accept the wizard default steps to automatically install the USB
drivers; the wizard runs twice
3 New hardware 4. Start PowerSuite and establish connection
is ready to use
Select “Start > All Programs > Eltek Valere> PowerSuite”. On the toolbar,
click “Connect” button. On the Connection dialogue box, click the “Connect”
4 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).
PowerSuite’s newest version is always available on our FTP server. Call your Eltek Valere’s
contact person.

9
Appendix Communication
CAN Bus Termination

CAN bus
Flatpack2 systems are shipped from factory with
(twisted-pair internal the CAN bus already terminated with 120Ω
USB A-B cable CAT5 cable)
(standard) resistors.
1
120Ω
To ensure a correct bus communication and
End-of-Line End-of-Line
Resistor
avoid data reflection, you must always terminate
Resistor
120Ω the CAN bus with two 120Ω resistors, one at
01 02 n each end of the line (60Ω bus impedance). The
Flatpack2
DC Power System figure shows a Flatpack2 system communicating
via the CAN bus.
CAN Bus Addressing

All rectifiers, Smartpack controllers and other control units connected to the Eltek Valere’s CAN
bus must have a unique address or ID number. The control system’s 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 system’s controllers 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 – Smartpack controllers, Smartnode
units, Battery Monitors, Load Monitors, etc. – to the control system’s CAN bus. See table below:
Number of nodes 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Smartpack controllers 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 <-- ID #
Smartnodes 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 italics (column 15 and 16 and range 65-78) are not available due to
software constraints. For DIP switch configuration, refer 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 Alarm Outputs
NC-C-NO NC-C-NO
Digital Inputs Digital Inputs
1 Smartpack controller 2 Smartpack controller

Master Slave 1
USB A-B cable (standard) 120Ω
End-of-Line
CAN bus CAN bus Resistor
(twisted-pair CAT5 cable)
Flatpack2 Rectifiers
01 02 n n+1 n+2 m
ID Number
33 81 49 120Ω
Battery CAN bus
End-of-Line
Monitor Resistor
I/O Monitor Shunts
Current Monitoring
Load Monitor Sense Inputs
Battery string #1 Temp, Fan Speed Mon & Ctrl Fuses

Alarm Outputs NC-C-NO
Fuse Monitoring
Flatpack2 Config. Inputs Configurable Inputs
DC Power System

10 356804.103, v6-2008-11
AC Mains Appendix
External AC Fuses ⎯ Recommended Rating
The site’s AC supply quality is of great importance. In general, a site with better AC supply quality
(stable nominal voltage) may use smaller breakers.
Recommended External AC Fuses per AC Mains Feed Input
Flatpack2 Systems with 2000W Rectifiers
AC Mains No of Power Current Max. Ext. Fuse Ext. Fuse
Input Type Shelves (Type) per input (A) Type Th/Mag Type Hy/Mag
205VAC 185VAC 205VAC 185VAC 205VAC 185VAC
I 1 (4AC) 21.5 { 24.0} 25A-D {←equal} 25A-C2 {←equal}
400VAC +N
3 phase (Y) II 2 (4AC) 32.2 { 36.0} 40A-C {←equal} 40A-C2 {←equal}
III 3 (4AC or 2AC) 43.0 { 47.9} 50A-C {←equal} 50A-C2 {←equal}
IV 1 (4AC) 28.4 { 31.7} 32A-D {←equal} 32A-C2 {←equal}
230VAC
3 phase (Δ) V 2 (4AC) 55.8 { 62.3} 63A-C {←equal} 63A-C2 {←equal}
VI 3 (4AC or 2AC) 74.4 { 83.0} 80A-C {100A-C} 80A-C2 {100A-C2}
230VAC VII 1 (4AC) (equal row I) (equal row I) (equal row I)
1 phase VIII 2 (4AC) (equal row II) (equal row II) (equal row II)
Doc 2020432,2v0
Notes:
• Use the values in {} brackets in the 185VAC column, if you are unsure or know that the available
AC mains voltage may drop below 205VAC.
• Refer to chapter “Identifying Power Shelves…”, page 12). Systems with more than 3 power
shelves require more than 1 AC Mains Feed Input
• 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.
Recommended External AC Fuses per AC Mains Feed Input

Flatpack2 Systems with 3000W Rectifiers
AC Mains No of Power Current Max. Ext. Fuse Ext. Fuse
Input Type Shelves (& Rectifiers) per input (A) Type Th/Mag Type Hy/Mag
205VAC 176VAC 205VAC 176VAC 205VAC 176VAC
I 1 (4) 32.9 { 38.3} 50A-D {←equal} 60A-C2 {←equal}
400VAC +N
3 phase (Y) II 2 (8) 49.3 { 57.5} 50A-D {63A-D} (equal row I)
III 3 (12) 65.8 { 76.6} 80A-D/100A-C {←equal} --- {----}
IV 1 (4) 43.5 { 50.7} 50A-D {60A-D} (equal row I)
230VAC
3 phase (Δ) V 2 (8) 85.4 { 99.5} 100A-C {←equal} --- {----}
VI 3 (12) 113.9 {132.7} 125A-C {150A-C} --- {----}
VII 1 (1) 16.5 {19.2} **(equal row I) (equal row I)
230VAC VIII 1 (2) 32.8 {38.4} 50A-C {←equal} (equal row I)
1 phase IX 1 (3) 49.3 {57.5} (equal row II) (equal row I)
X 1 (4) (equal row III) (equal row III) --- {----}
Doc 2052045,1v0
**When no Fuse Selectivity is required, you can use a 25A-C fuse instead of the recommended 50A-D
Fuse Selectivity: Internal (the rectifier internal fuse will trip before the external AC fuse)
Fuse Selectivity: None (irrelevant whether the internal or the external fuse trips first)
Notes:
• Use the values in {} brackets in the 176VAC column, if you are unsure or know that the available
AC mains voltage may drop below 205VAC.
• The system is implemented with 4AC-3KW Power Shelves. Systems with more than 3 power
shelves require more than 1 AC Mains Feed Input
• 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.
WARNING:
Always replace a rectifier with blown internal AC fuse with a new module, and send the malfunctioning module for servicing.
For installations in External AC Input Wires Note: The external

USA and Canada only Recommended Ratings terminal blocks must
Current Wire Section be rated to accept
• For external fuses above 50A, only the high current Max. (A) (mm2) (AWG) the actual wire
backplane can be used 6 0.75 18
section above.
• External fuse rated 32A is replaced by 40A 10 1.00 16
• External fuse rated 63A is replaced by 70A 13 1.25 16
• The installation has to comply with the NEC/CEC
16 1.50 14
requirements
• Connection to AC Mains shall be in accordance with the 25 2.50 12
number of power shelves in the tables. If number of 32 4.00 10
shelves exceeds the numbers in the table, a 40 6.00 8
combination of several AC Mains must be used 63 10.00 6
instead 80 16.00 4
100 25.00 2
NEC/CEC Requirements

11
Appendix AC Mains
Identifying Power Shelves: 4AC, 2AC or 4AC-3kW

4AC-3kW Power Shelf Flatpack2 System, 1U DC Distr. Flatpack2 rectifiers are accommodated in one or
several power shelves. Following types of power
shelves are available:
Power Shelf
Power Shelf
(rear view)
• 4AC Power Shelves, or single AC feed, 1 TB
(rear view)
(4 AC inputs per shelf, each feeding 1 rectifier)
AC Mains &
PE terminals • 4AC-3kW Power Shelves, or single AC feed, 2 TB
(4 AC inputs per shelf, each feeding 1 rectifier)
4AC-3kW and 2AC Power Shelves 4AC Power Shelves

• 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 shelf’s label, or by
looking at the shape of the shelf’s AC mains terminals, at its rear; (viewable by removing the
rectifier in the shelf’s 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 shelf’s rear.
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.
Υ Mains Δ Mains Mains
Three-phase & N, 400VAC Three-phase, 230VAC One-phase, 230VAC
L1 L2 L3 N PE L1 L2 L3 PE L (L1) N (L2) PE
Single AC feed: 4 AC inputs per
shelf, each feeding 1 rectifier
4AC Power Shelves
Power Shelf Power Shelf Power Shelf

PE(CON12) PE(CON12) PE(CON12)
L1(CON11) L1(CON11) L1(CON11)
Υ Mains Δ Mains Mains

L1 L2 L3 N PE L1 L2 L3 PE L (L1) N (L2) PE
Dual AC feed: 2 AC inputs per
shelf, each feeding 2 rectifiers
2AC Power Shelves
Power Shelf 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)

12 356804.103, v6-2008-11
AC Mains Appendix
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)
Υ Mains, TN Δ Mains, IT Mains

(1 Y Mains input will feed 2 power shelves) (1 Δ Mains input will feed 2 power shelves) (3 Mains inputs will feed 2 power shelves)
3 AC Mains
Cables
AC Mains AC Mains
Cable Cable
PE L1 L2 L3
AC Mains AC Mains AC Mains

wires wires wires
1 1 2 3 4 5 6 7
Chassis
Chassis
Chassis
1 fish 3 fish 0 fish

plate plates plates
AC Mains AC Mains AC Mains
Terminal Terminal Terminal
Block Block Block
X:****** X:****** X:******

(To internal connections (To internal connections (To internal connections
for 2 power shelves) for 2 power shelves) for 2 power shelves)
Flatpack2 DC Power System Flatpack2 DC Power System Flatpack2 DC Power System

2009604, v9
Warning:
In Δ Mains Configuration, mount every other fish plate upside down, thus avoiding short circuits, if cut too long.
Mains reconfigura- Fixed Individual Mains Input Terminal Block

tion is NOT possible 4AC Power Shelves (single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier)
when the system is Mains
shipped with fixed One-phase, 230VAC
(8 Mains inputs will feed 2 power shelves)
individual Mains in- 8 AC Mains
put terminal blocks. Cables
Such systems have

to be configured at AC Mains wires
Chassis
the factory prior to

0 fish plates
delivery.
AC Mains
Terminal
Block
To To To To To To To To X:******
rectifier 1 rectifier 2 rectifier 3 rectifier 4 rectifier 5 rectifier 6 rectifier 7 rectifier 8
(To internal connections for 2 power shelves)
Flatpack2 DC Power System
2009604, v9

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 OVP1 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 terminal X*, pin 1 (+)
To Digital
Input 1 To terminal X*, pin 2 (-) 11 14 12
PE PE N L1 L2 L3
Terminals & Pin-out Location L1 L2 L3 PE

AC Mains
CON1A CON2A wires
1 1 2 3 4 5
X* X** Weidmuller Weidmuller Weidmuller Weidmuller

0 fish plates
AC Mains
Terminal
1 10 1 20 Block
Alarm Outputs & Digital Inputs Card,
Art. 105954 X:******
(or Art. 200916 when X** and CON2A
are not mounted) (Internal System
N N N N
Connections)
2009604, v9
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 Y Mains, NT
Three-phase & N, 400VAC Three-phase & N, 400VAC
(1 Y Mains input will (1 Y Mains input will
feed 2 power shelves) feed 2 power shelves)
To terminal X*, pin 1 (+)

To Digital
Input 1 To terminal X*, pin 2 (-)
Customer Customer
Terminals & Pin-out Location Connections Connections
(PR 1-2) (PR 3-4)
CON1A CON2A
11 14 12 11 14 12
AC Mains
wires
PE PE N L1 L2 L3 PE PE N L1 L2 L3
L1 L2 L3 PE L1 L2 L3 PE
X* X** 1 1 2 3 4 5 1 1 2 3 4 5
Weidmuller Weidmuller Weidmuller Weidmuller Weidmuller Weidmuller Weidmuller Weidmuller

0 fish plates
AC Mains
1 10 1 20
Terminal
Alarm Outputs & Digital Inputs Card, Block
Art. 105954
(or Art. 200916 when X** and CON2A X:******
(Internal System (Internal System
are not mounted) N N N N
Connections
N N N N
Connections

2009604, v9
1
Over Voltage Protection, OVP

14 356804.103, v6-2008-11
AC Mains Appendix
About AC, DC Earthing Systems

To prevent the risk of electric shock, all cabinet’s 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.
PE (Protective Earth)
TE (Telecom Earth) Earth connections are in particular important where frequent lightning might
EG (Exchange Ground)
induce high voltage levels in AC supply and in battery and load cables.
AC Mains Input
Link 2 Chassis
(L1,L2,L3,N)
(DC Earth)
Common AC Earth (PE) and DC Earth (TE) are
AC Mains EG DC Rail TE connected to chassis via “Link 1” and
“Link 2”. Remove the links (“floating
Link 1 . DC Load earth”) for compliance with other local
PE (AC Earth) Cabinet Circuit earthing systems.
Chassis
Refer to your system’s 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.
Common DC Rail + Common DC Rail —
DC Load
DC Load
— +
wires
wires
— +
— +
— +
Negative DC Positive DC
Distribution Distribution

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 shelf’s 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
Even distribution of Flatpack2 rectifiers on the Mains phases
Υ Mains
Three-phase & N, 400VAC
L3 L1
Phase 3
Phase 1
n 09 06 03 N 01 04 07 n
Δ Mains
Three-phase, 230VAC Mains
230VAC
Phase 2
400VAC, 3ph+N
L1
02 05 08 n
Phase 3
Phase 1
AC L2
Mains ID number
n 09 06 03 230VAC 01 04 07 n (Assigned
L3 L2 CAN bus
Flatpack2 rectifier address)
02
Mains
05 One-phase, 230VAC
L(L1)
08
AC
Mains
n 230VAC 01 02 03 n
N(L2)
Phase 2
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
rectifier’s 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 356804.103, v6-2008-11
PULLOUT
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
INSTALLATION CHECK LIST
System Data Flatpack2 PS System
Flatpack2 Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:
Site Preparations
CARRY OUT FOLLOWING: OK
1. Organize the installation site
o Check min. clearances for cabinet access: front access, 60cm, top access, 20cm
o Check that the levelled surface is able to support 600 kg (cabinetized systems)
EMC
regard o 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 Power is OFF!
4. Remove packaging and check equipment
o Check you have received all the parts, correct cabinet, documentation, batteries (if applicable), etc
Device o Inspect the equipment for physical damage (report any damages)
hazard
o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
5. Remove top cover and dummy front panels
o Check that cable entry from the top is possible
6. Position and fasten the cabinet or subassembly
o Cabinets on levelled surface, adjust the legs. If necessary, unscrew the legs and fasten the cabinet to floor
o Subassemblies in existing 19” or in ETSI cabinets, using brackets. Mount the support & heat deflecting plate
7. Mount the batteries on the shelves
o Start (if applicable) on the lower shelf first, and continue upwards
Electric o Do not terminate the battery cables yet!
shock
Electrical Installation Power is OFF!
8. 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
9. AC Connections
o Check AC configuration: The AC terminals are correct configured to the external AC supply
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): 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 rail, and the other directly to the MCB
Electric
shock 11. DC Connections ⎯ Alarm & Signal Circuits
o Refer to your system’s connection drawings and configuration, or to the Factory Settings in 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
12. DC Connections ⎯ Battery Cables Careful! Use correct polarity.
For each battery shelf,
o Mount 3 intercell links to connect in series 4 battery blocks, (In 24V systems: 1 link and 2 blocks)
o Connect battery cables to fuses and common DC rail, and to the shelf’s outer terminals; (+) and (-)
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.:
Form 173-gb-v4-C01_356804-103_qstart_flatpack2-pssyst_6v0.docx_mfm_2008-08-25
www.eltekvalere.com
Headquarters:
Eltek Valere Eltek Valere
1303 E. Arapaho Rd, Richardson, TX. 75081, USA Gråterudv. 8, PB 2340 Strømsø, 3003 Drammen, Norway
Phone: +1 (469) 330-9100 Fax: +1 (469) 330-9101 Phone: +47 32 20 32 00 Fax: +47 32 20 32 10
CIRCUIT DISTRIBUTION LIST
System Data
Flatpack2 PSS, type: Article No.:
Site, name:
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
Fb1
Fb2
Fb3
Fb4
BATT.
Fb5
Fb6
F1
F2
F3
F4
F5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
LOAD
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
Continue
www.eltekvalere.com
Headquarters:
CIRCUIT DISTRIBUTION LIST
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
KNIFE MCB CONTROLLED AMPERE mm2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
LOAD
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
www.eltekvalere.com
Headquarters:
MAINTENANCE PROCEDURE
Flatpack2 Power Supply System, type: Article No.:
Site, name:
AC Input Voltage, measured: Battery Type: Battery Capacity: Maintenance carried out by, name:
WARNING: Maintenance work on live equipment is only to be performed by authorized and
Electric qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.
shock
System Inspection Power is ON!
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
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.:
www.eltekvalere.com
Headquarters:
PULLOUT
COMMISSIONING PROCEDURE
Supplier’s Order No.: Flatpack2 Power Supply System, type: Article No.:
Site, name:
AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:
I Pre-Start Check Power is OFF!
CHECK FOLLOWING: OK
1. Flatpack2 system installation is completed; The Flatpack2 Installation Check List is filled in.
All cabling is securely terminated with correct polarity
Device
hazard 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!
II CARRY OUT FOLLOWING: OK
1. Disconnect all rectifier modules, without removing them (keep original location)

Device 2. Switch ON the system (external AC fuses ON)
hazard
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; 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

III 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:
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
PULLOUT
AC Mains Appendix
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 system’s power shelf type, by
reading the Identifying Power Shelves section, page12
2. Find out if your system’s 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
Δ Mains and Υ Mains Δ Mains and Υ Mains

Three-phase, 230VAC Three-phase & N, 400VAC Three-phase, 230VAC Three-phase & N, 400VAC
Flatpack2 Flatpack2
Smartpack rectifier Smartpack rectifier
controller controller
03 04 Position 4 02 05 Position 4
01 02 01 04
Position 1 --- --- Position 8 Position 1 --- --- Position 8
05 06 03 06
--- ---
--- ---
--- --- --- --- --- ---
--- ---
--- --- ---
Position 9 ID number Position 9 --- ID number
(Assigned CAN (Assigned CAN
bus address) bus address)
Phase 1 Phase 2 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
Δ Mains and Υ Mains Δ Mains and Υ Mains

Three-phase, 230VAC Three-phase & N, 400VAC Three-phase, 230VAC Three-phase & N, 400VAC
Flatpack2 Flatpack2
Smartpack rectifier Smartpack rectifier
controller controller
02 03 01 Position 4
02 05 Position 4
01
Position 1 04 --- Position 8 Position 1 04 --- Position 8
05 06 03 06
--- ---
--- ---
--- --- --- ---
--- --- --- ---
--- --- ---
Position 9 ID number Position 9 --- ID number
(Assigned CAN (Assigned CAN
bus address) 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.
Controller’s Battery Symmetry Connections ⎯ 48V
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 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.
Battery Symmetry Battery Symmetry
Mid-point Measurement Block Measurement
One measurement per string Four measurements per string
(Serial measurement)
Card, Art. 200576
Serial Switches
Examples of Battery Symmetry Connections on the Smartpack controller — 48V Systems
2-1 2-1 3 5 7
X:**** Card, Art. 200576 X:****
Serial Switches
Set all 4
Symmetry 1.3
Symmetry 1.4
Symmetry 1.1
Symmetry 1.2
Symmetry 1.1
switches
OFF (up) Set all 4 switches
ON (down)
- + + + + +
-
- + - + - + - + - + - + - + - +
— —
(-48V) Outer (-48V) Outer
Terminal Block1 Block3 Block4 Terminal Block1 Block3 Block4
+ +
Intercell Links 0V Outer Intercell Links 0V Outer
Terminal Terminal
Battery Symmetry
Double-point Measurement Notice that, if you open the serial switches in
card, Art. 200576 ⎯ setting all to OFF (up) ⎯
Two measurements per string, from the you have to connect the + and – wires of every
middle to the outer terminals symmetry input.
Card, Art. 200576 2-1 3
Serial Switches
X:****
Symmetry 1.1
Symmetry 1.2
Set all 4
Battery Terminology
switches ON
(down) Battery Block, Battery String and Battery Bank
Battery
Block (12V)
- + +
Battery
String #1
- + - + - + - + (48V)Batt.
—
(-48V) Outer
Battery
+ String #2
Intercell Links 0V Outer 48V Battery Bank
(48V)
Terminal

18 356804.103, v6-2008-11
Battery Monitoring Appendix
Controller’s 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 2 .
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.
Battery Symmetry
Mid-point or Block Measurement
Example of Battery Symmetry Connections on the Smartpack controller, 24V Systems
One measurement per string

Card, Art. 200576
Serial Switches 2-1
X:****
Symmetry 1.1
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)
Battery
24V Battery Bank String #2
(24V)
2
The Mid-Point and the Block Measurement Methods are identical in 24V systems.

19
Battery Monitor’s 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 Monitor Battery Monitor

Part 242100.300 Part 242100.300
ID# <33> ID# <34>
DIP 1234 DIP 1234

switches switches
for CAN for CAN
bus addr. bus addr.
Example of Battery Symmetry Connections on the Battery Monitor, 48V Systems
Symmetry 1.3
Symmetry 1.4
Symmetry 2.1
Symmetry 2.2
Symmetry 2.3
Symmetry 2.4
Symmetry 1.1
Symmetry 1.2
+ + + + + + + +
Battery Battery
String 1 String 2
- + - + - + - + - + - + - + - +
— —
+ +
Terminal Terminal
Four measurements per string Four measurements per string
Battery Monitor Battery Monitor

Part 242100.300 Part 242100.300
ID# <35> ID# <36>
DIP 1234 DIP 1234

switches switches
for CAN for CAN
bus addr. bus addr.
Symmetry 3.1
Symmetry 3.2
Symmetry 3.3
Symmetry 3.4
Symmetry 4.1
Symmetry 4.2
Symmetry 4.3
Symmetry 4.4
Notice:
+ + + + + + + + Always connect Battery
Monitor with ID#<33> to
Battery Battery battery string 1 (lowest), with
String 3 String 4 ID#<34> to string 2, and so
- + - + - + - + - + - + - + - + on. PowerSuite will then refer
— — to the correct battery string.
+ +
Terminal Terminal

20 356804.103, v6-2008-11
Battery Monitoring Appendix
Battery Monitor’s 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.
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

Example of Battery Symmetry Connections on the Battery Monitor, 48V Systems
Mid-point Measurement
One measurement per string, four strings
Battery Monitor
Part 242100.300
ID# <33>
DIP 1234
switches
for CAN
bus addr.
+ + + +
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
+
Intercell Links 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.

21
Terminals & Pin-out Location, Battery Interface Card

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, refer to
the figures in this section.
Battery Connection Kit

Batt. Symmetry Kit, Art. 200830
Battery Connections (Internal)

Configurable monitoring digital inputs
15 pins D-Sub cable Card Art.200576 FUNCTION SIGNAL PIN-OUT
In X:****
Single Wire
1
Batt. Symmetry 1 +
− 2
3
Batt. Symmetry 2 +
(From internal
− 4
Batt. Symmetry 3 + 5
Card Art.200576
batteries)
− 6
Cable
Lugs + 7
internal batteries)
Batt. Symmetry 4 −
(From area with

8
+ 9
1 11 Temperature Sense 1 − 10
Temperature Sense Kit 11
5 15 (NA)
12
CON3A or (NA) 13 Temperature
Temp. Sensor cable sensor
CON4A 14
To Smartpack,
CON4
Temp. sensor 15-pins

D-Sub female (Internal Connections)
2
1.5 mm , max.
For temperature monitoring of the battery 1 5
X**/X* wire section
compartment, we recommend the use of the 11 15 15-pins D-Sub male
Temperature Sense Kit, instead of
internal batteries)
15-pins
(From area with

D-Sub female
Temperature Sense 1
connecting the sensor cable directly to the (Alternative use of Temp. Sense Kit,
terminals, pin 9-10. instead of connecting to X:****, 9-10) Temperature
sensor
The Temperature Sense Kit is connected to

Battery Connections (Internal)
the Battery Interface Card (Art. 200576), or Configurable monitoring digital inputs
directly to the controller’s CON3 or CON4, Card Art.200576 FUNCTION SIGNAL PIN-OUT
if unused. X:***
In
1
Batt. Symmetry 5 +− 2
3
Batt. Symmetry 6 +
(From internal
− 4
Batt. Symmetry 7 + 5
batteries)
− 6
+ 7
internal batteries)
Batt. Symmetry 8 −
(From area with
Terminals & Pin-out Location 8

+ 9
11 Temperature Sense 2 − 10
CON4A
System Connections CON4 1

Card, Art. 200625 Battery Connections
CON3 Card, Art. 200576 11
5 15 Batt Current 2
Battery Connections
12
Alarm Outputs & Digital 13 Temperature
CON3A
Inputs Card, Art. 105954 Smartpack Card, Art. 200576 CON3A or Batt Fuse Fail 2 sensor
CON4A 14
To Smartpack,
CON3
15-pins
D-Sub female (Internal Connections)
CON3A or CON4A For Temp.
Sense Kit 2
1.5 mm , max.
X**/X* 1 5
wire section
X**/X*
X***/X**** 15-pins D-Sub male
Serial Switch 11 15
internal batteries)
15-pins
(From area with
D-Sub female
1 1 Temperature Sense 2
14
(Alternative use of Temp. Sense Kit,
Battery Interface Card, Art. 200576 instead of connecting to X:***, 9-10) Temperature
The Temperature Sense Kits may also be connected directly to the sensor
Smartpack controller’s CON3 or CON4, if these connectors are unused.

22 356804.103, v6-2008-11
Alarms & Monitoring Appendix
Standard Alarm Relays & Digital Inputs Connections
Standard Relays & Digital Inputs
The alarm outputs in Flatpack2 systems use the Fail-Safe

Normal Mode NO Operation Mode (relay coils energized in the system’s
Relay X Com +
(Energized coil) NC normal operation mode). When the system is in alarm mode,
— the alarm relay coils are de-energized.
Alarm Mode NO
Com +
Relay X
(De-energized coil) NC The figure shows the position of the relay contacts when the
—
Flatpack2 PS System relay coils are de-energized (PS system in alarm mode)
Correct Use of Alarm Outputs (example)
Digital Input X + Normal Mode

(Normal mode) External Relay Y
— (Energized coil) In order to implement monitored fail-safe digital inputs
Digital Input X + Alarm Mode circuits, the external relay coil must be energized and the
(Activated) External Relay Y
— (De-energized coil) contacts closed in the system’s normal mode of operation.
Flatpack2 PS System
Correct Use of Digital Inputs (example)
Terminals & Pin-out Location, Alarm Interface Card

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) and on D-Sub
connector CON2 (4 outputs & 4 inputs).
Using the Alarm Interface Card (Art. 105954) Alarm Outputs & Digital Inputs
and two interface cables, you can make the Voltage free relay outputs and Configurable monitoring digital inputs
signals on CON1 & 2 accessible at any suitable Card Art.105954 FUNCTION SIGNAL PIN-OUT
location inside your system. In Out X:*

+ 1 Input Circuit 1
For detailed information about the card’s pin-out Digital Input 1
− 2
location and terminal block connections, refer to
external equipment)
Digital Input 2 + 3 Input Circuit 2
−
(To and from

4
the figures in this section. 5
Relay 1 NO
Common Alarm COM 6 Alarm Circuit 1
NC 7
Terminals & Pin-out Location Relay 2 NO 8
Mains Alarm COM 9 Alarm Circuit 2
System Connections
Card, Art. 200625 Battery Connections NC 10
To Smartpack,
CON1
CON2 Card, Art. 200576

X:**
CON1
(From external equipment)
Battery Connections Input Circuit 3

Alarm Outputs & Digital
CON2A
Smartpack Card, Art. 200576 Digital Input 3 1+
Inputs Card, Art. 105954 CON1A 2−
Digital Input 4 3+ Input Circuit 4
CON1A CON2A 4−
Digital Input 5 5+ Input Circuit 5
6−
X* X** Digital Input 6 7+ Input Circuit 6
8−
Relay 3 NO 9
1 10 1 20
Fuse Alarm COM 10 Alarm Circuit 3
Load & Battery NC 11
(To external equipment)
Alarm Outputs & Digital Inputs Card, Art. 105954 12

(or Art. 200916 when X** and CON2A are not mounted) Relay 4 NO
High Battery Alarm COM 13
To Smartpack,
CON2
Alarm Circuit 4
NC 14
NO 15
Relay 5
The figure shows the position of the relay Low Battery Alarm COM 16 Alarm Circuit 5
NC 17
contacts when the relay coils are de-energized Relay 6 NO 18
(PS system in alarm mode. Factory Settings in Rectifier Alarm COM 19 Alarm Circuit 6
NC 20
bold) (Customer Connections)
2
1.5 mm , max.
wire section

23
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 controller’s internal system signals are accessible on D-Sub connector
CON5, on the controller’s 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 card’s pin-out location and terminal block connections, refer to
the figures in this section.
In Out X:*****
Terminals & Pin-out Location 10 + 1 Power Input
Terminal Board, Art. 200625

−
System Connections
15 2
(To Smartpack, CON5)

CON5A
System Connections 6 + 3 Batt. Current 1

Battery Connections
Card, Art. 200625 CON5 Card, Art. 200576 7 − 4
12 + 5 Batt. Fuse Fail 1
Battery Connections 13 − 6
Alarm Outputs & Digital Card, Art. 200576 Load Fuse Fail 1
Inputs Card, Art. 105954 Smartpack 9+, Neg.D. 7
JP2
LVD1A
11−,Pos.D. 8 LVD Common LVD1
Pos. Distr. 9
1+/− LVD2A
JP1 Neg. Distr. 3+/− 10 LVD Common
JP2 3 LVD2
JP1
JP2 2+/− 11
2 (To latching contactors
1 1 LVD1 & LVD2)
2
X***** 3 (Internal Connections)
Neg. Distr.
1 11 CON5A Pos. Distr. JP1 and JP2 are used to configure the
System Connections Card, Art. 200625 system for Negative DC distribution (48 and
60V systems) or Positive DC distribution
(24V systems)
LVD Latching Contactors Connections
Flatpack2 systems’ LVBD and LVLD 3 functionality is implemented by the Smartpack controlling
magnetically latching contactors.
The coil of latching contactors is not
Latching Contactors, LVD1 & LVD2 energized in any state. They change state from
A latching contactor changes state only when a open to close, or vice versa, when a reversed
reversed pulse voltage is applied to its coil pulse is applied to the coil.
ON OFF Y
Bidirectional
+ Pulse - Pulse diode
PCB Art. Warning! The
200625 LVD1A
+ X
bidirectional
Latching diode must
Contactor always be
X:***** LVD1
X mounted to
8 Y avoid dam-
9 LVD Common
LVD2A
aging the
10 X controller.
11 Latching
Contactor Latching Contactor A
— LVD2
Smartpack
Unit
Y
X
LVD Common
Flatpack2 PS System (internal)

Y
Correct Use of Latching Contactors (example)

Latching Contactor B
Two Types of Latching Contactors
3
LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect

24 356804.103, v6-2008-11
25
Appendix CAN Bus Nodes
CAN Bus Nodes

The CAN Bus Nodes are control units connected to the power system’s 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
Electrically identical Pin 8 Power
LED Lamp (green)
Pin 1
Battery Monitor
Battery Monitor
DIP switches
CAN ID address Monitor Inputs
Terminal Block
DIP switch #1
Battery Monitor
DIP switch configuration
ID <33>
Battery ID DIP Switch Position (All switches OFF)
Monitor # 1 ⎯2 ⎯3 ⎯4
1st Monitor 33 OFF⎯OFF⎯OFF⎯OFF
2nd Monitor 34 ON ⎯OFF⎯OFF⎯OFF
3rd Monitor
To next CAN bus
35 OFF⎯ ON⎯OFF⎯OFF
4th Monitor 36 ON ⎯ ON⎯OFF⎯OFF Note:
5th Monitor 37 OFF⎯OFF⎯ON ⎯OFF • The Battery Monitor Connections
6th Monitor 38 ON ⎯OFF⎯ ON⎯OFF monitor’s Part 242100.300
7th Monitor 39 OFF⎯ON⎯ ON ⎯OFF ID # Battery FUNCTION SIGNAL PIN-OUT
corresponds Monitor
8th Monitor 40 ON ⎯ ON⎯ ON⎯OFF to the DIP X:*
node
9th Monitor 41 OFF⎯OFF⎯OFF⎯ON switch’s Batt. Symmetry 1 + 1

10th Monitor 42 ON ⎯OFF⎯OFF⎯ON binary value Batt. Symmetry 2 + 2
11th Monitor 43 OFF⎯ON ⎯OFF⎯ON plus 33 Batt. Symmetry 3 + 3
12th Monitor 44 ON ⎯ON ⎯OFF⎯ON Batt. Symmetry 4 + 4
13th Monitor 45 OFF⎯OFF⎯ON ⎯ON Batt. Fuse + 5
batteries)
(From the
− 6
14th Monitor 46 ON ⎯OFF⎯ ON ⎯ON
Or Batt. Current + 7
RJ45 CAN bus − 8
termination plug,
if the Battery 2
1.5 mm , max.
(From the current shunt)
Monitor is the
last node in the
CAN port 1&2 wire section
(From the current shunt)
CAN bus
RJ45, 8 pins
From previous CAN
bus node
Built-in Battery
Temperature Sensor
Read also the “Installation Guide Battery Monitor CAN Node”, document 351507.033.

26 356804.103, v6-2008-11
CAN Bus Nodes Appendix
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
CAN ID address Warning
LED Lamp (yellow) Screw head DIN Rail
DIP switch #1 mounting slot (2x) mounting
Power (Head’s diameter >5 mm
and <8 mm)
clips
LED Lamp (green)
CAN port 1&2
Electrically identical
Load Monitor
Load Monitor
Current Sense Inputs

Input 1 Terminal Block X**
Fuse Monitoring Inputs
Terminal Block X* Input 1
Load Monitor Connections

CAN bus node
From previous
Voltage free relay outputs and Configurable monitoring inputs

Read also the “Installation Guide Load Monitor FUNCTION SIGNAL PIN-OUT
Load Monitor CAN Node”, X:*

document 351506.033. Config. Input 1 – Input Circuit 1
+
(From breakers and external equipment)

– Input Circuit 2
Config. Input 2
Fuse Monitoring Inputs
+
– Input Circuit 3
Config. Input 3
+
– Input Circuit 4
Config. Input 4
+
– Input Circuit 5
Config. Input 5
+
RJ45 CAN bus termination plug, if the Load
CAN – Input Circuit 6

port 1&2 Config. Input 6
Monitor is the last node in the CAN bus
RJ45, 8 pins +
To next
CAN bus node
– Input Circuit 7
Load Monitor Config. Input 7
DIP switch configuration
+
– Input Circuit 8
Config. Input 8
+
DIP
Switches X:**
Load ID DIP Switch Position ID <49> 1 – Input Circuit 1
Sense Input 1
Monitor # 1 ⎯2 ⎯3 ⎯4 (All switches OFF) 2 +
– Input Circuit 2
1st Monitor 49 OFF⎯OFF⎯OFF⎯OFF 3 Sense Input 2
+
Current Sense Inputs
2nd Monitor 50 ON ⎯OFF⎯OFF⎯OFF 4

Input Circuit 3
Or
Sense Input 3 –
(From current shunts)
3rd Monitor 51 OFF⎯ ON⎯OFF⎯OFF (5-8 always +

4th Monitor 52 ON ⎯ ON⎯OFF⎯OFF Note: OFF) – Input Circuit 4
Sense Input 4
5th Monitor 53 OFF⎯OFF⎯ON ⎯OFF • DIP switch +
6th Monitor 54 ON ⎯OFF⎯ ON⎯OFF positions 5 – Input Circuit 5
Sense Input 5
7th Monitor through 8 are +
55 OFF⎯ON⎯ ON ⎯OFF
always to be OFF – Input Circuit 6
8th Monitor 56 ON ⎯ ON⎯ ON⎯OFF Sense Input 6
+
9th Monitor 57 OFF⎯OFF⎯OFF⎯ON • The monitor’s – Input Circuit 7
10th Monitor ID # corresponds Sense Input 7
58 ON ⎯OFF⎯OFF⎯ON +
11th Monitor 59 OFF⎯ON ⎯OFF⎯ON to the DIP – Input Circuit 8
switch’s binary Sense Input 8
12th Monitor 60 ON ⎯ON ⎯OFF⎯ON +
value plus 49
13th Monitor 61 OFF⎯OFF⎯ON ⎯ON 2
1.5 mm , max.
(Customer Connections)
14th Monitor 62 ON ⎯OFF⎯ ON ⎯ON wire section

27
Appendix CAN Bus Nodes
I/O Monitor CAN Node

Alarm
DIP switches LED Lamp (red)
Screw head DIN Rail CAN ID address
mounting slot (2x) mounting Warning
(Head’s diameter >5 mm clips DIP switch #1 LED Lamp (yellow)
and <8 mm)
Power
CAN port 1&2 LED Lamp (green)
Electrically identical
I/O Monitor
I/O Monitor
Fan Control Inputs & Outputs

Terminal Block X*** Configurable Inputs Relay Outputs
Pin 1 Terminal Block X* Terminal Block X**
Input 6 Relay 1
The I/O Monitor CAN Bus Node

enables you to decentralize and
increase the number of input I/O Monitor Connections
CAN bus node
From previous
monitoring and output controlling Voltage free relay outputs and Configurable monitoring inputs
signals in your Smartpack based DC I/O Monitor FUNCTION SIGNAL PIN-OUT
power supply system. Also, it X:*

– Input Circuit 1
monitors and controls the Programmable Inputs Config. Input 1
+
compartment temperature inside fan- – Input Circuit 2
(From external equipment)

Config. Input 2
cooled outdoor cabinets. +
– Input Circuit 3
Config. Input 3
+
– Input Circuit 4
Config. Input 4
+
– Input Circuit 5
Config. Input 5
+
Read also the “Installation Guide CAN – Input Circuit 6
RJ45 CAN bus termination plug, if the I/O
port 1&2 Config. Input 6

Monitor is the last node in the CAN bus
I/O Monitor CAN Node”, document RJ45, 8 pins +

To next
CAN bus node
351503.033. X:**
Relay 1 NO
C Alarm Circuit 1
DIP NC
Switches Relay 2 NO
C Alarm Circuit 2
Alarm Relay Outputs
1
NC
(To external equipment)
2
Relay 3 NO
3
C Alarm Circuit 3
4 NC
Or
Relay 4 NO
(5-8 always
OFF) C Alarm Circuit 4
I/O Monitor
DIP switch configuration NC
Relay 5 NO
C Alarm Circuit 5
NC
Relay 6 NO
I/O ID DIP Switch Position C Alarm Circuit 6
ID <81>
NC
Monitor # 1 ⎯2 ⎯3 ⎯4 (All switches OFF)
– (To be shorted)
1st Monitor 81 OFF⎯OFF⎯OFF⎯OFF Not in use
+
2nd Monitor 82 ON ⎯OFF⎯OFF⎯OFF Temperature
3rd Monitor 83 OFF⎯ ON⎯OFF⎯OFF X:*** Sensor 1
4th Monitor 84 ON ⎯ ON⎯OFF⎯OFF Temperature Sense 1 + 1
Inputs & Outputs
Note: − 2
5th Monitor 85 OFF⎯OFF⎯ON ⎯OFF • DIP switch
Fan Control
3 Temperature
6th Monitor 86 ON ⎯OFF⎯ ON⎯OFF positions 5 Temperature Sense 2 + Sensor 2
− 4
7th Monitor 87 OFF⎯ON⎯ ON ⎯OFF through 8 are
always to be OFF Tachometer Input 1 5
(To and from
external fans
Fan Speed Monitor 1

8th Monitor 88 ON ⎯ ON⎯ ON⎯OFF Tachometer Input 2 6 Fan Speed Monitor 2
9th Monitor 89 OFF⎯OFF⎯OFF⎯ON • The monitor’s Speed Control Output 1 7
Fan Speed Control 1
10th Monitor 90 ON ⎯OFF⎯OFF⎯ON ID # corresponds Speed Control Output 2 8 Fan Speed Control 2
11th Monitor 91 OFF⎯ON ⎯OFF⎯ON to the DIP
12th Monitor switch’s binary
92 ON ⎯ON ⎯OFF⎯ON value plus 81 (Customer Connections)
2
1.5 mm , max.
13th Monitor 93 OFF⎯OFF⎯ON ⎯ON wire section
14th Monitor 94 ON ⎯OFF⎯ ON ⎯ON Out In

28 356804.103, v6-2008-11
29
30 356804.103, v6-2008-11
Flatpack2 Integrated System, 2U Appendix
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
Load Fuses LVBD Battery Fuses
Smartpack
Control Unit
LVLD position
(not displayed) CAN bus
DC Load
Terminals
(+, −)
Interface I/O
Terminals
Rear view
AC Terminals
Bus Bars
Common Battery Supply Battery
Connections Connections
Front view
Battery Fuses Load Fuses
USB 2.0 type B port DC Distribution (1U high) with built-in Smartpack
PC connection, etc controller, load fuses and MCBs
1U
1U
Power shelf (1U high) with 4 Flatpack2 rectifiers

31
This product is CE marked and Copyright © Eltek Valere, 2008
complies with all current requirements This document may be changed without notice
for relevant standards and directives.
Art. No. 356804.103, Issue 6, 2008 Nov
Published 2008-11-13
www.eltekvalere.com
Headquarters:
1303 E. Arapaho Rd, Richardson, TX. 75081, USA Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway

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Installation, Operation, Commissioning and Maintenance

Check Lists pullout forms

The Smartpack based Product Range

Brief System Description — Flatpack2

Quick Start Guide Flatpack2 PS System

Hole to release the

Handle in locked position

Removing Blind Panels

Quick Start Guide Flatpack2 PS System 356804.103, v6-2008-11

Preparing the Installation Site

Mechanical Installation Power is OFF!

Quick Start Guide Flatpack2 PS System

Electrical Installation Power is OFF!

b-c Connect battery cables to fuses and common DC rail, and to

(+) and to the -48V outer terminal. Deviation from factory

Quick Start Guide Flatpack2 PS System 356804.103, v6-2008-11

Before you switch ON the Flatpack2 PS system, verify the following:

Commissioning Steps, Startup

II Startup and No-Load Adjustments Power is ON!

Quick Start Guide Flatpack2 PS System

(Important adjustment to avoid arcing when connecting the batteries)

Quick Start Guide Flatpack2 PS System 356804.103, v6-2008-11

Front Keys and display, menus, etc.

LoBattMaj LVLD 1.1 ↓↑

Rectifier nn Mod.Current↓↑ Guard Time ↓↑

Generator H-D-W-U↓↑ 3v03 NoOfMains Æ ↓↑ 3v03

Quick Start Guide Flatpack2 PS System

Quick Start Guide Flatpack2 PS System 356804.103, v6-2008-11

CAN Bus Termination

CAN Bus Addressing

Digital Inputs Digital Inputs

1 Smartpack controller 2 Smartpack controller

Battery string #1 Temp, Fan Speed Mon & Ctrl Fuses

Quick Start Guide Flatpack2 PS System

Recommended External AC Fuses per AC Mains Feed Input

For installations in External AC Input Wires Note: The external

Quick Start Guide Flatpack2 PS System 356804.103, v6-2008-11

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

4AC-3kW and 2AC Power Shelves 4AC Power Shelves

I Mains Reconfiguration ~Integrated System 1U Distr.

Power Shelf Power Shelf Power Shelf

Υ Mains Δ Mains Mains

Power Shelf Power Shelf Power Shelf

CON9 CON9 CON9

CON11 CON11 CON11

CON10 CON10 CON10

CON12 CON12 CON12

Quick Start Guide Flatpack2 PS System

II Mains Reconfiguration ~AC Terminal Block

1. Switch OFF the AC supply fuses in external fuse boards

Configurable Mains Input Terminal Block

Υ Mains, TN Δ Mains, IT Mains

AC Mains AC Mains AC Mains

1 fish 3 fish 0 fish

X:****** X:****** X:******

Flatpack2 DC Power System Flatpack2 DC Power System Flatpack2 DC Power System

Mains reconfigura- Fixed Individual Mains Input Terminal Block

Such systems have

the factory prior to

Quick Start Guide Flatpack2 PS System 356804.103, v6-2008-11

III Mains Reconfiguration ~AC Terminal Block with OVP

NON Configurable Mains Input Terminal Block with OVP

X: X: X:**