081 022 Minipack System

Quick Start Guide
Installation, Operation, Commissioning and Maintenance
Minipack, PS System
DC Power Supply System
Integrated Applications
Introduction
o The Smartpack based Product Range (2 )
o Brief System Description ⎯ Minipack (2 )
Installation
o Installing Smartpack and Rectifier Modules ( 3)
o Installation and Maintenance Details
⎯ Opening or Closing the Minipack Drawer Shelf (4)
⎯ Mounting or Removing Minipack Blind Covers (4)
⎯ Removing or Mounting Load MCBs (5)
⎯ Configuring Priority and Non-Priority Load Circuits (5)
o Installation steps; mechanical, electrical (6-7)
o Location of Components, GA drawing; 6 and 4 rectifiers systems (8)
o Connections, Factory Settings, etc. (9)
Commissioning
o Pre-start check (10 )
o Commissioning steps, Startup (10-11)
Operation
o Front keys and display (12)
o Software Menus (12)
Miscellaneous
Communication
o CAN Bus Termination (13)
o Installing PowerSuite – PC software (13)
AC Mains
o External AC Fuses ~ Recommended Rating (14)
o Mains Feeds versus Rectifier ID (14)
Battery Monitoring
o Battery Symmetry – Connections (15)
o Battery Interface Card ~ Terminals & Pin-out, ( 16)
Alarms & Monitoring
o Standard Alarm Relays & Digital Inputs (17)
o Alarm Interface Card ~ Terminals & Pin-out (17)
o Alarm Interface Card, Extd. ~ Terminals & Pin-out (18)
Internal Connections
o System Interface Card ~ Terminals & Pin-out (19)
o LVD Latching Contactors (19)
Drawings
o Block Diagram Minipack 48VDC, 3.2kW (21)
o Block Diagram Minipack 48VDC, 4.8kW (22)
Check Lists pullout forms

o Installation Check List
o Circuit Distribution List
o Commissioning Procedure
356808.103 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 ⎯ Minipack

The Minipack PS system is a compact and cost-effective DC power supply system, specifically
developed for the telecom industry.
Alarm Outputs NC-C-NO PowerSuite
Digital Inputs Application
Remote
Monitoring
Minipack
USB cable
Smartpack
(Ctrl. Unit) Fuse Alarm
AC Fuses,
external
(230V) LVLD
CAN Bus
Telecom
equipment
Minipack rectifiers LVBD
Load Fuses
& MCBs
Symmetry
Alarm & DC
AC Supply Temp. Sensor Battery distribution DC Supply
(Single- or Fuses 48V
three-phase)
*
Battery string #1
Example of a typical Minipack PS system for DC power supply of telecom equipment. The
system is supplied from an external AC mains supply, and is delivered in one power shelf for
integration in existing cabinets (integrated). An external battery bank is to be connected.
Quick Start Guide Minipack PS System

2 356808.103, 1v1-2007-03
Controller & Modules Installation
Installing Smartpack and Rectifier Modules

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

Hole to release the
handle’s spring Mounting the Smartpack controller
Smartpack
controller mechanism 1. Open the handles by
inserting a screwdriver into the holes to release the spring
mechanism
2. Insert the module fully into the power shelf, after plugging the
cables to the rear panel
3. Lock the handles by
Handle in locked position pushing the handles up into their housings (locked position), so
that the module is securely locked
Removing the Smartpack controller

1. Open the handles by
inserting a screwdriver into the holes to release the spring
mechanism
2. Remove the module by
Handle in using both handles to pull the module loose gently; support from
unlocked position underneath; unplug the cables connected to the rear panel
CAUTION: The modules may be warm. Remove the locking screw before
inserting them into the power shelf (hot-pluggable).
Device
hazard Do not relocate already hot-plugged rectifiers to other positions in the power
shelf. New rectifiers must be hot-plugged in the power shelf, one at time,
starting from the left with position 1, 3, 5 and 2, 4, 6.
Mounting or Removing Minipack Rectifier Modules
Minipack
rectifier 1. Unlock the module by
using a screwdriver to loosen the locking screw
2. Insert or remove the module by
sliding it on its mounting rail fully into the power shelf, so that
the module makes proper contact (hot-pluggable)
Mounting or
Rail using the front handle to pull the module loose; support from
underneath before the unit is completely free
Front Handle
Locking Screw 3. Lock the module by
screwing home the locking screw (locked direction). Then, the
module will be securely locked in the shelf, or ready for transport
4. Mount blind covers in
unused module locations
Electric
shock
Quick Start Guide Minipack PS System 356808.103, 1v1-2007-03

3
Installation Details
Installation and Maintenance Details
Opening or Closing the Minipack Drawer Shelf

To access the Minipack distribution area, you have to open the
Fastening screws
Fastening screw for the drawer sliding drawer shelf. Do following to open or close the drawer:
for the shelf
frame
1. Unlock the drawer shelf by
using a screwdriver to loosen the upper and lower locking
screws. Do not loose the screw in the middle!
Minipack Sliding Drawer Shelf
in Operation Position 2. Open or close the drawer shelf by
holding the drawer from the side plates and sliding it
Fastening screw outwards.
for the shelf frame The drawer shelf is the in the Maintenance Position.
or
sliding it on its mounting rail fully into the shelf
3. Lock the drawer shelf by

Shelf
Frame screwing home the upper and lower locking screws.
F1, F2…Plastic The drawer is then securely locked in the shelf, in its
Cover Operation Position
Minipack Sliding Drawer Shelf
in Maintenance Position
Mounting or Removing Minipack Blind Covers
Minipack
blind cover 1. Unlock the blind cover by
using a screwdriver to loosen the locking screw
2. Insert or remove the blind cover by
sliding it on its mounting rail fully into the power shelf
or
sliding it out, by inserting your fingers in the cover’s front
handle and pulling it loose
3. Lock the blind cover by
screwing home the locking screw (locked direction).
Front handle Locking screw Then, the blind cover will be securely locked in the shelf,
to secure the blind cover
or ready for transport

4 356808.103, 1v1-2007-03
Details Installation
Removing or Mounting Load MCBs
CAUTION: Power must be OFF during this operation!

Plug for MCB1
1. Remove the F1, F2… plastic cover by
Minipack front MCB1 unscrewing the cover’s frontal screw,
then inserting a small screwdriver into the cover’s gap and
MCB8
carefully press down and out to release the locking tabs.
0 2. Switch OFF the MCB by
switching the MCB handle to “0” position (upwards)
1 3. Remove or insert the MCB by

using your fingers to pull out and unplug the MCB
or
pressing the MCB into the upper and lower plugs
MCB8
(Upper and
lower plugs)
Configuring Priority and Non-Priority Load Circuits
CAUTION: Power must be OFF during configuration! Only one

screw may be removed.
1. Remove the F1, F2… plastic cover by
unscrewing the cover’s frontal screw,
then inserting a small screwdriver into the cover’s gap and
carefully press down and out to release the locking tabs.
2. Switch OFF and unplug the actual MCBs by
switching the MCB handle to “0” (upwards),
then using your fingers to pull out the MCB
3. Remove the actual Priority Load Screw by
using a screwdriver to unscrew the Priority Load Screw
(refer to table below).
Keep the removed screw in the clip, on the cover’s inside
Priority Load Screws
(accessible with unplugged MCBs)
Configuration of Priority & Non Priority Load Circuits

Screw Removed F1 F2 F3 F4 F5 F6 F7 F8 F9 F10
None P P P P P P P P P P
Y25 NP NP NP NP NP NP NP NP P P
Y24 NP NP NP NP NP NP P P P P
Y7 NP NP NP NP P P P P P P
Y6 NP NP P P P P P P P P
Plugs for MCB1 WARNING: Only one screw can be removed at a time.
P=Priority Load Circuits NP =Non Priority Load Circuits
F3-F10 Screw (Y6)
F5-F10 Screw (Y7)
F7-F10 Screw (Y24)
F9-F10 Screw (Y25)

5
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

Begin preparing the following:
200 mm 1 Organize the installation site
o A 2U high spare location in existing 19”, 250 mm cabinet
o Min. Clearances: 60 cm in front
o Explosive atmospheres are to be avoided. Ensure suitable EMC
2U regard
ventilation
2 Prepare the installation tools
o Use insulated tools suitable for telecom installations
3 Prepare AC Supply: AC input cable(s) and fuses
o Correct type AC supply is available
o External AC fuses have correct rating
600 mm 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 “Miscellaneous”. In general, a site with better AC supply
quality (stable nominal voltage) may use smaller breakers.
Mechanical Installation Power is OFF!
Carry out the following:

4 Remove packaging and check equipment
o Check you have received all the parts and correct documentation
o Inspect the equipment for physical damage (report any damages) Device
o Leave rectifier modules in their packaging or in the selves, if hazard
Minipack PSS, Doc. Chart, Spec. factory installed. To be installed under commissioning
Drawings, CD-ROM 5 Remove the cabinet’s top cover and dummy front panel
o Connection terminals are accesses by opening the drawer shelf
o Battery shelves (if any) are placed behind the lower panels
6 Position and fasten the subassembly
o Minipack is fastened in existing 19” or in ETSI cabinets, using
brackets
7 Mount the external batteries on the shelves
o Start (if applicable) placing the batteries on the lower shelf first,
and continue upwards Electric
o Do not terminate the battery cables yet! shock
8 Open the Minipack drawer shelf and lift the plastic cover
Plastic Cover
o Unlock the upper and lower screws and slide the drawer shelf
open; read the Installation & Maintenance Details chapter
o Lift the Melenex plastic cover to access the connection terminals
Minipack drawer shelf slid out in
the maintenance position

6 356808.103, 1v1-2007-03
Installation
Service Loop
Cable lengths
enabling to open Electrical Installation Power is OFF!
the drawer shelf
Carry out the following: (Refer to the system’s specific drawings)
CAUTION: The cable lengths must be long enough (service loop) to allow Device
hazard
opening the Minipack drawer shelf.
9 Make the system completely voltage free
o Switch OFF or remove all load fuses (MCB1, MCBx), battery
fuses (Fb1, Fbx) and the AC supply fuses, in external fuse
boards
10 AC Connections
Minipack drawer shelf slid out in
the maintenance position o Check AC configuration: the external AC supply consists of 3
single phase mains feed and earth (PE)
o Connect the AC Earth wires (PE) to the terminals X5:1-2 (PE)
o Connect the AC input cables to the terminals X5:3-4, 5-6, 7-8.
Cable and terminal block labeling are to correspond
11 DC Connections ⎯ Load Circuits
o DC Earth (TE); check that the common DC Output Rail is
connected to “Telecom Earth” (TE) at only one place (at the
cabinet , cable X7A, or at a central distribution point)
Common Battery
Cables (+) o For each DC load, connect one of the cables to the common DC
output terminal, and the other to terminal X6B:F1, F2, etc.
12 DC Connections ⎯ Alarm & Signal Circuits
o Refer to your system’s connection drawings and configuration, or
to the “Miscellaneous, Alarms & Monitoring” section, terminal Electric
shock
blocks X1, X2A and or X2B.
Cable lugs mounted o Terminate Alarm Circuit cables to the relay output terminals
upside down
o Terminate Signal Circuit cables to the digital input/output
terminals
Link 2 (X7A) Chassis 13 DC Connections ⎯ Battery Cables
(DC Earth)
Common Careful! Use correct polarity.
Battery EG Battery X7A
Fuse, Fbx For 48V systems using the battery symmetry mid-point
Card Art.200576
measurement, refer to the figure in this page.
2-1 15 pins D-Sub
(male)
For other measurement methods, refer to the Battery Symmetry
Connections chapters in this guide’s Miscellaneous section.
For each battery shelf:
CAUTION: Mount cable lugs upside down on the (+) battery cables
Temp. Sensor cable 1
a Mount 3 intercell links to connect in series 4 battery blocks

b-c Connect battery cables to fuses (Fb1, Fb2, etc.) and
Common Battery (X7A) and to the battery shelf’s outer
terminals; black (+); blue (-)
d-e Connect battery symmetry cables, if applicable, to the input
Symmetry 1
terminals, and to the center terminal of the battery string

Temp. sensor
Battery
(+) and to the -48V outer terminal. Deviation from factory
Cable settings requires Symmetry reconfiguration via PowerSuite
- + f-g Connect the temperature sensor cable, if applicable, to the
D-Sub plug or input terminal, and fix the temperature
sensor (at the end of the cable) to a suitable place in the
- + - + - + - + middle of the installed battery bank
—
(-48V) Outer
Terminal Block1 Block3 Block4
+
Intercell Links 0V Outer
Terminal

7
Installation
Location of Components, GA drawing

Refer to the specific drawings included with your Minipack PS system, for
information regarding the exact location of components in your system.
Plastic Protective Cover for
CAN1
CAN bus communication with rectifiers (to Smartpack rear)
AC Terminals
CON5A, For internal connections
Cable Fastening Plate (to Smartpack rear)
LVBD latching contactor

Top view
Minipack, 6 Rectifiers (48V, 4800W)
LVLD latching contactor (optional)

X5: pin 1
AC Mains DC Earth
AC Mains & Earth (PE) Terminals X7A, Exchange Ground (EG) or system
ground. Link connected to chassis
Common DC Output (+) Common Battery (+)

Load terminal block X7A, Battery connections
Fb1, Fb2
Battery connections (−)
X6B: pin 1 Location of
DC Output (−) Smartpack controller
Load terminal block
Forward sliding
Minipack Rectifier drawer shelf
Smartpack controller
NOTE: For information about connecting
Battery Symmetry, Temperature Sensor,
Battery Fuses Alarm and Monitoring circuits, refer to
section “Miscellaneous”, and read the
Front view Load MCBs
Battery Monitoring, Alarms & Monitoring
Minipack rectifiers chapters.
CAN1
Plastic Protective Cover for CAN bus communication with rectifiers
AC Terminals (to Smartpack rear)
CON5A, For internal connections
Cable Fastening Plate (to Smartpack rear)
LVBD latching contactor

Minipack, 4 Rectifiers (48V, 3200W)
X5: pin 1
AC Mains LVLD latching contactor (optional)
AC Mains & Earth (PE) Terminals
Top view DC Earth

X7A, Exchange Ground (EG) or
Common Battery (+) system ground.
X7A, Battery connections Link connected to chassis
Common DC Output (+)

Load terminal block Fb1
Fb1, Fb2, Fb3, Fb4
X6B: pin 1 Battery connections (−)
DC Output (−)
Load terminal block Location of
Minipack Rectifier Forward sliding
drawer shelf
Battery Fuses
Front view Load MCBs

Minipack rectifiers

8 356808.103, 1v1-2007-03
Installation
Connections, Factory Settings, etc

Refer to your system’s specific drawings for the exact connection points.
Minipack
PS System, Integrated
FUNCTION SIGNAL TERM. POINT
X5
PE 1 AC Earth (PE)
The figure shows the posi-
AC Mains Inputs
Smartpack PE 2
tion of the relay contacts N3 3 Mains Feed 3
(Front) when the PS system is in L3 4
alarm mode of operation; N2 5 Mains Feed 2
USB the relay coils are then L2 6
de-energized (fail-safe N1 7 Mains Feed 1
Com USB 2.0
Cable mode). The relay outputs L1 8 2
Type B serial port 2.5 mm , max.
are preprogrammed from wire section
Plug (120Ω)
End-of-Line
(Rear) factory (Factory Settings). M4 terminals

CAN bus
CAN1 port FUNCTION SIGNAL PIN-OUT

RJ45, 8 pins
X6B X6A
+ 1 Load Circuit 1
MCB1
6 mm , max. wire section

CAN1 port
RJ45, 8 pins + 2 Load Circuit 2
CAN MCB2
Load Fuses
Com
Cable (For CAN bus
termination, see section Load Circuit 8
“Miscellaneous”) MCB8 + 8
2
+ 10 Load Circuit 10
MCB10
Interface Cards Connections (Minipack systems with 6 rectifiers
have 8 DC load outputs available.
Refer to the connections for the actual terminal circuit boards Systems with 4 rectifiers have 10
installed in your system X7A DC load outputs)
Battery Cables, string 1

Battery Connections (X4)
Battery
Fb1
Fuses
Terminal Circuit Board, Art. 200576 Battery Cables, string x

Battery Symmetry 1-4 and Temp. Sense 1
Fbx
(See page 15 for pin-out information) M6 screws, cable lugs
max. 15 mm width
Battery Connections, Extended (X3) Common
Terminal Circuit Board, Art. 200576
Battery “Rail”
Batt. Symmetry 5-8, Temp. Sense 2, Batt. Current and Batt. Fuse Fail
(Not applicable for Smartpack RS232 D-Sub option, on rear panel)

(See page 15 for pin-out information)
Alarm Outputs & Digital Inputs (X1)

Digital Input 1-2 and Relay Output 1-2
Alarm Outputs & Digital Inputs Extended (X2A & X2B)

Digital Input 3-6 and Relay Output 3-6
(Not applicable for Smartpack Ethernet option)


9
Commissioning
The Minipack PSS startup consists of following stages:

I. Perform a pre-start check before the PS system is switched ON
II. Switch ON the system with disconnected load; adjust output voltage
III. Adjust the nominal output voltage with connected batteries and load
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 Minipack PS system, verify the following:
1. System installation is completed

o Ensure a correctly performed system installation, with correct polarity on all
Device connections (Installation Check List filled in)
hazard o All cabling is securely terminated and supported
o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
2. Battery and load fuses are disconnected
o Verify that all battery and load MCBs/ fuses are switched OFF
3. AC input cable(s) and AC Earth wire (PE) are terminated
o Make sure that the AC input cable(s) are correctly connected to the AC terminals
o Verify that the AC input cable(s) and external AC fuses are sized and rated as specified
o Check that AC Earth (PE) is terminated, and electrically connected to chassis
4. Site specific parameters and settings are known
o Read the site specific drawings and documentation
5. AC supply and all MCBs, fuses are switched OFF
o Make sure that all external AC fuses and internal MCBs/ fuses are switched OFF
Commissioning Steps, Startup

Check off in the Commissioning Procedure, that you find in the pullout section of this folder.
After the ”Pre-start Check” is performed, you can begin with stage II. During the stage, you
will switch ON the Minipack PSS — while the batteries and load are disconnected ⎯ then
measure the output voltage, and adjust it if required. Carry out the following:
Startup and No-Load Adjustments Power is ON!
II
1. Disconnect all rectifier modules, without removing them (keep original location)
o Verify that all Minipack rectifier modules are disconnected (unplugged) but NOT
physically removed from the power shelf.
Device Also, read about the correct rectifier position, page 14, and how to mount them, on
hazard page 3.
2. Switch ON the system
o Switch ON the AC input supply (external AC fuses) to the Minipack system
3. Measure and verify that the AC input voltage is correct
o Measure the AC terminals’ input voltage at the system’s AC Mains terminals
o Verify that the AC voltage is within range

10 356808.103, 1v1-2007-03
Commissioning
4. Mount all Minipack rectifier modules in the power shelves (keep original location)
o Plug all rectifiers firmly inwards ⎯ one module at a time, allowing a 2s delay ⎯ to plug
them in the same self location. Secure them with the locking screws. Refer to page 3.
o Mount Minipack blind covers over unused positions
5. Ensure that the Smartpack and all rectifier modules are working: LEDs are ON
o Verify correct operation, by monitoring the modules’ LED lamps and display:
No alarm are present on rectifiers. The Smartpack displays fuse alarms
6. Connect the a PC to the PS system (to facilitate operation)
o Plug a standard USB A-B cable between the PC and the Smartpack controller
o Start PowerSuite on the PC by selecting: Start > All Programs > Eltek > PowerSuite
Refer to chapter “Installing PowerSuite ⎯ PC Application”, page 13, if required
o On the toolbar, click the “Connect” button to establish connection
7. Measure and adjust DC output voltage
o Read the DC output voltage on the controller’s display
o With a multi-meter, measure the DC output voltage at the most accessible point, e.g.
between the common DC rail and the lower connection of one of the priority load MCBs
o If required, adjust the voltage using the controller’s front keys or via PowerSuite
8. Verify the alarm relays are working correctly (alarm relay test)
o Run the alarm relay test using the controller’s front keys (refer to page 12) or via
PowerSuite (select the menu Go > Output Test)
9. Make sure the System Setup is in accordance with configuration
o Verify system settings using the controller’s front keys or via PowerSuite
o Use the opportunity to enter site related information, number of used AC phases,
type of batteries, etc.
Load Adjustments Power is ON! III

Now, you can begin with stage III, where you will adjust again the output voltage to the
battery voltage, and connect the batteries and the load. Carry out the following:
10. Adjust DC output voltage to measured battery voltage
o Measure the battery voltage is within range (check connections have correct polarity)
o Adjust DC output voltage — using the controller’s front keys (refer to page 12) or via
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 locking screw and pulling them Device
partially out. Do NOT physically remove them from the power shelf 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

11
Operation
Front Keys and display, menus, etc.
Graphical Alarm
Display LED Lamp (red)
Minipack
16 char. x 2 lines Warning rectifier
LCD display LED Lamp (yellow)
”Enter” key Power

LED Lamp (green) Alarm
LED Lamp (red)
”Up” arrow key
USB Power
”Down” arrow key 0ype B port LED Lamp (green)
Smartpack control unit Warning
LED Lamp (yellow)
Smartpack Control Unit — front keys, display, etc Minipack 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 structure). (controller accessing information) or ON (powered).
Operation: Press on the key to change from Warning LED is ON (derating or similar minor
Status Mode to Menu Mode. Press the or warning), Flashing (over-voltage mode) or OFF (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 down to
password protected Service Options. Default password
<0003> should be changed.
Software Menus ~ Smartpack controller

Level 2 Level 3 Level 2 Level 3
User menu <UserOption> Service menu <ServiceOption>
AlarmResetÆ Change Language Æ ↓↑
The ”XvX” references, if any, on the right hand of the option, are not shown in the display. They only indicate
English 2v0
NomVolt NomVolt ↓↑
BoostVolt BoostVolt ↓↑
LoBattMaj LoBattMaj ↓↑
VoltageInfo LoBattMin
Firmware 402073.009 2v00 Smartpack, Distributed
Firmware 402073.009 2v00 Smartpack, Distributed
VoltAdjustment LoBattMin ↓↑
HiBattMaj HiBattMaj ↓↑
HiBattMin HiBattMin ↓↑
LVBD LVBD ↓↑
LVLD 1.1 LVLD 1.1 ↓↑
DisplayMessagesÆ Message ↓↑ VoltCalibration Æ VoltCal ↓↑
SoftwareInfoÆ ChangePassword Æ Password ↓↑
the firmware version (402073.009 XvX) the option was first implemented.
SerialNumberÆ SetManBoostTime Æ ↓↑
NoOfRects. nn Start/StopBoost Æ
RectCurrent Auto Boost Config. Æ Enable/Disable ↓↑ & Threshold ↓↑
Rectifier Info RectSerialNumber Nxt Test DateTime Date ↓↑ Time ↓↑
Rect.PrimaryVolt End Volt ↓↑
Batt Test Setup MaxTestDur ↓↑
Rectifier Status Test Int ↓↑
Rectifier Temp Guard Time ↓↑
Rect. OutputVolt Start/Stop Test Æ
Rectifier SW Ver NoOfRects. ; nn Æ Reset
Charge Curr Lim. Æ Enable/Disable ↓↑ & Max C.Curr ↓↑
NoOfPhases nn
Mains Info Mains Status Battery Setup NumOfString ↓↑
Mains Voltage CellCap Ah nn ↓↑
Temp Level InfoÆ Level ↓↑ Output Control Æ VoltageCtrl / TempComp ↓
NoOfString Nn Change Date/Time Æ Date ↓↑ Time ↓↑
BattStringCurr ↓↑ Alarm Output 1 ↑
RelayTest Alarm Output 2 ↑
Battery Info BattStringTemp ↓↑ Batt Contactor ↑
…
BattBlockVolt ↓↑ Load Contactor ↑

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

12 356808.103, 1v1-2007-03
PULLOUT
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
INSTALLATION CHECK LIST
System Data Minipack PS System
Minipack Power Supply System, type: Article No.:
Site, name:
Serial No.: Software, version No.: Rectifiers, type & number of:
AC Input Voltage, measured: Battery Type: Battery Capacity: Installation carried out by, name:
Site Preparations
CARRY OUT FOLLOWING: OK
1. Organize the installation site
o Prepare a 2U high spare location in existing 19”, 250 mm cabinet; Check min. clearance: front access, 60 cm
o Ensure the installation site is suitably ventilated and in a non-explosive atmosphere.
EMC
regard 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 and correct documentation.
o Inspect the equipment for physical damage (report any damages)
Device o Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
hazard
5. Remove the cabinet’s top cover and dummy front panels
o Check that cable entry from the top is possible
o Connection terminals are accesses by opening the drawer shelf
6. Position and fasten the subassembly
o Subassemblies in existing 19” or in ETSI cabinets, using brackets.
7. Mount the external batteries on the shelves
o Start (if applicable) on the lower shelf first, and continue upwards
o Do not terminate the battery cables yet!
Electric
shock 8. Open the Minipack drawer shelf and lift the plastic cover
o Unlock the upper and lower screws and slide the drawer shelf open, then lift the Melenex plastic cover
Electrical Installation Power is OFF!
9. Make the system completely voltage free
o Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses
10. AC Connections
o Check AC configuration: Make available 3 single phase mains feed and earth (PE)
o Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
o Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
11. DC Connections ⎯ Load Circuits
Electric o Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place
shock o For each DC load, connect one of the cables to the common DC output terminal; the other to the fuse terminal
12. DC Connections ⎯ Alarm & Signal Circuits
o Refer to your system’s connection drawings and configuration, or to the Quick Start Guide
o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output terminals
13. DC Connections ⎯ Battery Cables Careful! Use correct polarity.
For each battery shelf,
o Mount 3 intercell links to connect in series 4 battery blocks
o Connect battery cables to fuses and Common Battery, and to the shelf’s outer terminals; black (+); blue (-)
o Connect battery symmetry cables, if applicable, to the input terminals
o Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the
end of the cable) to a suitable place in the middle of the installed battery bank
Approval
Responsible of installation, sign.: Date: Approved by customer, sign.:
Form 174-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss_1v1ev.doc_mfm_2006-12-29
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
Minipack PSS, type: Article No.:
Site, name:
CIRC. NO. FUSE TYPE LVLD DESCRIPTION FUSE CABLE
- MCB CONTROLLED AMPERE mm2
Fb1
Fb2
Fb3
Fb4
BATT.
F1
F2
F3
F4
F5
F6
F7
LOAD F8
F9
F10
www.eltekvalere.com
Headquarters:
COMMISSIONING PROCEDURE
Supplier’s Order No.: Minipack Power Supply System, type: Article No.:
Site, name:
AC Input Voltage, measured: Battery Type: Battery Capacity: Commissioning carried out by, name:
I Pre-Start Check Power is OFF!
CHECK FOLLOWING: OK
1. Minipack system installation is completed; The Minipack Installation Check List is filled in.
All cabling is securely terminated with correct polarity
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 Minipack rectifiers in their original locations in the power shelves

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

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

7. DC output voltage; Measure and adjust

8. Alarm relay test; Verify all alarm relays are working correctly

9. System Setup is in accordance with configuration Enter site spec. info in PowerSuite

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:
PULLOUT
MAINTENANCE PROCEDURE
Minipack 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:
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
PULLOUT
Communication Miscellaneous
CAN Bus Termination

Minipack systems are shipped from factory with the CAN bus already terminated with 120Ω
resistors.
To ensure a correct bus communication and avoid data reflection, you must always terminate
the CAN bus with two 120Ω resistors, one at each end of the line. The figure shows a
Minipack system, with its controller communicating with the rectifiers via the CAN bus.
USB A-B cable CAN bus

(standard) (twisted-pair internal CAT5 cable)
1
120Ω
End-of-Line End-of-Line
Resistor Resistor
120Ω
Minipack 01 02 n
DC Power System
Smartpack assigns ID numbers to the rectifiers (software-assigned). The Smartpack’s ID

numbers are assigned by DIP switches on the controller’s side.
Installing PowerSuite ⎯ PC Application

The PowerSuite software application enables you to configure and operate the Minipack
Power Supply System from a personal computer.
Minipack system configuration from a PC running MS Windows XP
1. Install PowerSuite
1 Insert CD in your PC drive and follow & accept the wizard default steps to install PowerSuite
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 detect the Smartpack controller

3 New hardware If required, a wizard will automatically install necessary USB drivers. Follow & accept the wizard default steps
is ready to use
4. Start PowerSuite and establish connection

4 Select “Start > All Programs > Eltek > 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, by selecting menu option “Tools >
Options” (click on the Find COMx button).
PowerSuite’s newest version is always available on our FTP server. Call your Eltek Valere’s contact person.

13
Miscellaneous AC Mains
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.
Minipack Rectifiers 48 VDC, 800W
Use the recommenda- Note:
205VAC
tions in the 205VAC ta-
Inputs
AC Mains No of Current Max. (A) Ext. Fuse The recommendations ap-
ble, if you are sure the Type Rectifiers per Input Type ply for use of Thermal mag-
available AC mains 230VAC 4 17.5 20A-C netic circuit breaker, type
voltage will not drop 26.3 Siemens 5SX or 5SY se-
below 205VAC. 1 32A-C
ries, MG C60H series or
phas 6 similar. For more informa-
OR AC Mains No of Current Max. (A) Ext. Fuse
185VAC
tion regarding External AC

Inputs
If you are unsure ⎯ or Type Rectifiers per Input Type
19.4 fuses and other types of
know that the voltage 230VAC 4 20A-C fuses, please read the arti-
may drop below 1 29.5 32A-C cle 2024398 on the CD,
205VAC ⎯ use the phas 6 356808.CD3.
185VAC table recom- Each mains input feeds 2 rectifiers
mendations.
Doc 2024398, v1
Mains Feeds versus Rectifier ID Mains Monitoring

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

Mains Feed 2
Mains Feed 1
Distribution of Minipack rectifiers (ID #)

on the 3 AC Mains Input Circuits Mains Feed 3
One-phase, 230VAC
Minipack L(L1)
System Mains Feed 2 05 06
One-phase, 230VAC AC
Mains Feed 1 Mains
L(L1)
One-phase, 230VAC 230VAC
AC 03 04
L(L1) N(L2)
Mains
AC 01 02
01 02 03 230VAC
04 05 06 Mains
Position 6 N(L2)
230VAC
Position 1 ID number
(Assigned CAN N(L2)
bus address)
Plug-and-Play Rectifiers versus Mains Monitoring

When a rectifier is hot plugged in a power shelf for the first time, the Smartpack controller
assigns the next available ID number to the rectifier, starting with “01”.
When a previously installed (hot plugged) Minipack rectifier is inserted in a power shelf, the
Smartpack controller “recognizes” the module, and assigns the same ID to the rectifier. In other
words, the controller and the rectifier “remember” the assigned ID number, even after removing
and reinserting the rectifier in the shelf.
To achieve a more controlled ID assignment, you should always insert & hot-plug new Minipack
rectifiers in the power shelf, one module at a time, in following shelf position order: 1, 3, 5 and
2, 4, 6. Position # 1 2 3 4 5 6
ID # 01 04 02 05 03 06
This position-versus-ID number relationship is very important for the correct monitoring of the
mains circuit, as the Smartpack controller always uses rectifier ID01, 02 and 03 to monitor the
Mains Feed 1, 2 and 3 respectively. If these rectifiers malfunction, rectifier ID 04, 05 and 06 will
automatically take over.
For example: accidentally inserting a rectifier with ID02 in a power shelf position internally
connected to mains feed 1, will cause the controller to monitor mains feed 1 “thinking“ it monitors
mains feed 2.

14 356808.103, 1v1-2007-03
Battery Monitoring Miscellaneous
Battery Symmetry Connections Connections

Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors
CON4 and CON3), enabling symmetry measurement of:
Batt. Symmetry Kit, Art. 200830
• 8 battery strings
Single Cable Strand
using the Mid-Point Measurement Method

using the more accurate Double Mid-Point Measurement Method
using the even more accurate Block Measurement Method
Cable
Eyes
You can implement any of these methods using one or two Battery Connection Kits (see
the illustration next page) and the appropriate number of Battery Symmetry Kits, which
contain a single cable strand with suitable cable eyes, etc.
Battery Symmetry Battery Symmetry
Mid-point Measurement Block Measurement
One measurement per string Four measurements per string
(Serial measurement)
Card, Art. 200576
Serial Switches 2-1 Card, Art. 200576 2-1 3 5 7
Serial Switches
X:**** X:****
Set all 4
Symmetry 4
Symmetry 1
Symmetry 1
Symmetry 2
Symmetry 3
switches Set all 4 switches
OFF (up) ON (down)
- + + + + +
-
− + B+ - + - + - + - + - + - +
— —
(-48V) Outer (-48V) Outer
Terminal Block1 (From − Terminal Block1 Block3 Block4
+ +
Intercell Links 0V Outer Intercell Links 0V Outer
Terminal Terminal
Battery Symmetry Notice that, if you open the serial switches in card, Art.
Double-point Measurement 200576 ⎯ setting all to OFF (up) ⎯ you have to connect the
+ and – wires of every symmetry input.
Two measurements per string, from the
middle to the outer terminals
Card, Art. 200576 2-1 3
Serial Switches
X:****
Battery Terminology
Symmetry 1
Symmetry 2
Set all 4
switches ON
(down) Battery Block, Battery String and Battery Bank
Battery
Block (12V)
- + +
Battery
String #1
- + - + - + - + (48V)Batt.
—
(-48V) Outer
Terminal Block1 Block3 Block4
Battery
+ String #2
Intercell Links 0V Outer 48V Battery Bank
(48V)
Terminal

15
Miscellaneous Battery Monitoring
Battery Interface Card ~ Terminals & Pin-out

The Smartpack controller’s battery monitoring signals are accessible on D-Sub connectors
CON4 and CON3, on the controller’s rear panel.
Battery Connection Kit Using the Battery Connection Kit ⎯ which consists of a Battery
Interface Card (Art. 200576) and a standard 15 pins D-Sub cable
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.
Card Art.200576
For detailed information about the card’s pin-out location and
terminal block connections, see the figures in this section.
Terminals & Pin-out Location Battery Connections (Internal)
Configurable monitoring digital inputs
CON3
Card Art.200576 FUNCTION SIGNAL PIN-OUT
CON2
In X4
Smartpack 1
PCB 200576 Batt. Symmetry 1 +
− 2
(From internal
3
Batt. Symmetry 2 +
batteries)
CON1
− 4
CON4 Batt. Symmetry 3 + 5
CON5 − 6
+ 7
internal batteries)
Batt. Symmetry 4 −
(From area with

PCB 200576 8
+ 9
1 11 Temperature Sense 1 − 10
CON3A or CON4A For Temp. Sense Kit
11
X**/X* 5 15 (NA)
12
X3/X4 CON3A or (NA) 13 Temperature
Serial Switch 14 sensor
CON4A
To Smartpack,
CON4
15-pins
1 D-Sub female (Internal Connections)
1
14 2
1 5
1.5 mm , max.
Battery Interface Card, Art. 200576 X**/X* wire section
11 15 15-pins D-Sub male
internal batteries)
15-pins
(From area with

D-Sub female
Temperature Sense 1
Temperature Sense Kit (Alternative use of Temp. Sense Kit,
instead of connecting to X4: 9-10) Temperature
sensor
Temp. Sensor cable
Temp. sensor Battery Connections (Internal)

Configurable monitoring digital inputs
For temperature monitoring of the battery In X3

compartment, we recommend the use of the Batt. Symmetry 5 + 1
− 2
(From internal
Temperature Sense Kit, instead of + 3

batteries)
Batt. Symmetry 6 − 4
connecting the sensor cable directly to the
Batt. Symmetry 7 + 5
terminals, pin 9-10. − 6
+ 7
internal batteries)
Batt. Symmetry 8 − 8
(From area with
The Temperature Sense Kit is connected to

the Battery Interface Card (Art. 200576), or Temperature Sense 2 + 9
1 11 − 10
directly to the controller’s CON3 or CON4, 5 15 Batt Current 2
11
if unused. 12
CON3A or Batt Fuse Fail 2 13 Temperature
sensor
CON4A 14
To Smartpack,
CON3
15-pins
D-Sub female (Internal Connections)
2
1 5
1.5 mm , max.
X**/X* wire section
11 15 15-pins D-Sub male
internal batteries)
15-pins
(From area with
D-Sub female
Temperature Sense 2
(Alternative use of Temp. Sense Kit,
instead of connecting to X3: 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.

16 356808.103, 1v1-2007-03
Alarms & Monitoring Miscellaneous
Standard Alarm Relays & Digital Inputs Connections
Standard Relays & Digital Inputs
Normal Mode NO
Relay X Com + The alarm outputs in Minipack systems use the Fail-Safe
(Energized coil) NC
— Operation Mode (relay coils energized in the system’s
Alarm Mode NO
Relay X Com + normal operation mode). When the system is in alarm
(De-energized coil) NC
—
mode, the alarm relay coils are de-energized.
Minipack PS System
Correct Use of Alarm Outputs (example)
+ Normal Mode
Digital Input X
(Normal mode) External Relay Y In order to implement monitored fail-safe digital inputs
— (Energized coil)
circuits, the external relay coil must be energized and the
Digital Input X + Alarm Mode contact closed in the system’s normal mode of operation.
(Activated) External Relay Y
— (De-energized coil)
See the figures.
Minipack PS System
Correct Use of Digital Inputs (example)
Alarm Interface Card ~ Terminals & Pin-out

The Smartpack controller’s alarm and digital input monitoring signals are accessible from the
controller’s rear panel, on mini power connector CON1 (2 outputs & 2 inputs).
Using the Alarm Interface Card (Art. 218470) plugged to Smartpack’s CON1, you can make
the signals on CON1 accessible on terminal block X1.
For detailed information about the card’s pin-out location and terminal block connections, see
the figures in this section.
Terminals & Pin-out Location

CON2
CON3
CAN1
Card neck for CON4 10

Smartpack
cable fastening CON5 X1
CON1 1 Alarm Outputs & Digital Inputs
Voltage free relay outputs and Configurable monitoring digital inputs
Card 218470
To CON1
Alarm Outputs & Digital Inputs Card In Out X1
Art. 218470 1 Input Circuit 1
1 Digital Input 1 +
2 −
external equipment)
X1 3 Input Circuit 2
Digital Input 2 +
−
(To and from
10 4
Relay 1 NO 5
Common Alarm COM 6
To Smartpack,
Alarm Circuit 1
NC 7
CON1
NO 8
COM 9 Alarm Circuit 2
NC 10
2
(Customer Connections) 1.5 mm , max.
wire section

17
Miscellaneous Alarms & Monitoring
Alarm Interface Card, Extd. ~ Terminals & Pin-out

Additional alarm and digital input monitoring signals are accessible from the Smartpack
controller’s rear panel, on D-Sub connector CON2 (4 outputs & 4 inputs).
Using the Alarm Interface Card, Extended (Art. 218473) plugged to Smartpack’s CON2, you
can make the signals on CON2 accessible on terminal blocks X2A and X2B.
For detailed information about the card’s pin-out location and terminal block connections, see the
figures in this section.
Terminals & Pin-out Location

Card 218473
X2B X2A
20 CON2
11 CON3
1
CAN1 10
Card neck for Smartpack CON4

cable fastening
CON5
CON1
Alarm Outputs & Digital Inputs Card, Extended

Art. 218473
(NA for Smartpack Ethernet option)
Alarm Outputs & Digital Inputs, Extended

Voltage free relay outputs and Configurable monitoring digital inputs
Card Art. 218473 FUNCTION SIGNAL PIN-OUT
To CON2
In Out X2A
(From external equipment)
+1 Input Circuit 3
11 10 Digital Input 3
−2
X2B X2A
Digital Input 4 +3 Input Circuit 4
20 1 −4
Digital Input 5 +5 Input Circuit 5
− 6
Digital Input 6 + 7 Input Circuit 6
−
To Smartpack,
8
NO 9
CON2
Relay 3 COM 10
Fuse Alarm
Load & Battery X2B Alarm Circuit 3
(To external equipment)
11 NC
12
Relay 4 NO
High Battery Alarm COM 13 Alarm Circuit 4
NC 14
NO 15
Relay 5
Low Battery Alarm COM 16 Alarm Circuit 5
NC 17
Relay 6 NO 18
Rectifier Alarm COM 19 Alarm Circuit 6
NC 20
2
(Customer Connections) 1.5 mm , max.
wire section

18 356808.103, 1v1-2007-03
Internal Connections Miscellaneous
System Interface Card ~ Terminals & Pin-out

Minipack systems are shipped from factory with the CON5 signals already connected.
Some of the Smartpack controller’s internal system signals are accessible on D-Sub connector
CON5, on the controller’s rear panel.
Using a standard 15 pins D-Sub cable, the signals on CON5 are routed to the Minipack system’s
main circuit board. See the figure in this section for an overview of the signals on CON5,
Smartpack
controller CON5
15 pins D-Sub (female)
FUNCTION SIGNAL PIN-OUT
LVD1A +/− 1
LVD2A +/− 2
LVD Common +/− 3
5 1 System Voltage + 4
System Voltage − 5
a
*Batt Current 1 + 6
*Batt Current 1 −
b
15 11 7
NC 8
CON5 Load Fuse Fail 1 + 9
(female; orange) Power Input + 10
Load Fuse Fail 1 − 11
c
*Batt Fuse Fail 1 + 12
*Batt Fuse Fail 1 − 13
d
System Reference 14
System Power Input − 15
Connections
LVD Latching Contactors Connections
Minipack systems’ LVBD and LVLD functionality (Low Voltage Battery Disconnect; LV Load
Disconnect) is implemented by the Smartpack controlling magnetically latching contactors.
The coil of latching contactors is not energized in any state. They change state from open to
close, or vice versa, when a reversed pulse is applied to the coil.
Latching Contactors, LVD1 & LVD2

A latching contactor changes state only when a Warning! The bidirectional
reversed pulse voltage is applied to its coil diode must always be
mounted to avoid dam-
aging the controller.
ON OFF Y
+ Pulse - Pulse
Bidirectional
Minipack
Main PCB LVD1A diode
+ X
Latching
Contactor
X:***** LVD1
8 Y X
9 LVD Common
10 LVD2A
X
11 Latching
Contactor Latching Contactor
— LVD2
Y
Smartpack
controller LVD Common
Minipack PS System (internal)

Correct Use of Latching Contactors (example)

19
20 356808.103, 1v1-2007-03
217915
213333 Dist board 1 Minipack System MCB
Underwiring MPBB 6pos 3AC 10 pos load
LVBD
4 pos batt X6A*
DC output + - FB1
Power module 1 1
PE 2
3
Y X
+
N 4
Customer
5
connections
NEG. DIST.
POS. DIST.
NEG. DIST.
POS. DIST.
- JP1 JP2 6
L 7
- FBn Battery Strings
Circuits -48Vdc
1 2 3 1 2 3 8
9
Power module 2 10 0V
PE
Y20
Customer
+
connections
N Y19
- X7A*
Y18
L To battery +
Y12
Y9 Alarm Outputs and
Power module 3 Digital Inputs
PE DC Earth (TE) 218470
Power
X5* + output + Y7 Y1 Power input + To battery contactor X1*
8 N Alarm I/O Connections
L1
N 7 - + 1
Digital Input 1
L2 6 L - 2
N 5 Power SH1 + 3
Digital Input 2
L3 4 - 4
output – Y8 Y2 Power input - NO 5
terminals
3
Customer
N Power module 4 Con 1A*
Mains input
connections
2 Alarm I/O Relay 1 COM 6
PE PE TB1
PE 1 Connections NC 7
+ System connections 10
NO 8
N Batt. Fuse Fail + 1 Relay 2 COM 9
- Batt. Fuse Fail - 2 NC 10
LVD 1A 3
L K1 LVD Common 4
LVLD
Alarm Outputs and
215792
Digital Inputs
Dist.Board 2 MPBB 100A
218473
Y X 10pos G1
X6B* X2A*
Y7 Y5 low pri load 2
DC output - Ext. Alarm I/O Connections
Y6 Y4 F1 10 + 1
Digital Input 3 - 2
Optional Y3 Fuse + 3
To Dist Y5 alarm Digital Input 4
- 4
F2 9
board 2 + 5
CAN1 Digital Input 5 -
Y6 6
Smartpack Y2 high
+ 7
Power -/CAN bus Y4 pri load F3 8 Digital Input 6
- 8
Interconnections Con5A* Y3 Y1 NO 9
pin 1-8
Smartpack Connection Con 2A* COM 10
F4 7 Ext. Alarm I/O
26
Connections
Y7
F5 6 X2B*
8
15
Ext. Alarm I/O Connections
F6 5 Relay 3
NC 11
Y24 NO 12
Relay 4 COM 13
F7 4
NC 14
Customer connections
NO 15
Load circuits -48Vdc

Relay 5 COM 16
F8 3 NC 17
NO 18
Y25 Relay 6 COM 19
F9 2 NC 20
F10 1
Rear connections Front connections
Smartpack
monitoring and
NA for Smartpack Web/SNMP
15 control unit
CON5
System Connections USB 2.0 type B port USB
15 (PC connection) Customer
CON4 9 connections
Battery connections
1: Optional: RS232
9/15 CON3
NA for Smartpack RS232 rear Ext. Battery connections
1: Optional: RS 232
8/26 CON2
2: Optional: Web/SNMP (ENET)
10
CON1
Alarm I/O Connections
8
CAN port
8
CAN port
1: Optional 9 pin D-sub RS232 connection.

Battery Connections Battery Connections Can be mounted in front or on rear side of
200576 200576 Smartpack. Replaces ”Ext. Battery Connections”
*X3 *X4
Battery Connections Battery Connections when mounted on the rear side of Smartpack
+ 1 + 1
Con 3A* Batt. Symmetry 5 Con 4A* Batt. Symmetry 1
15 - 2 15 - 2 2: Optional Web/SNMP (ENET) connection.
Battery Connections 3
+ +
Batt. Symmetry 6 Batt. Symmetry 2 Replaces ”Ext. Alarm I/O Connections”
- 4 - 4
+ 5 + 5
Batt. Symmetry 7 - 6 Batt. Symmetry 3 - 6
+ 7 + 7
+ 9 + 9
Temperature Sense 2 - 10 Temperature Sense 1 - 10
Battery Current 2 + 11 Not Connected + 11
SERIAL SERIAL
- 12 - 12
356804.10x
356804.10x
S1 S1
+ 13 + 13
DIFF Battery Fuse Fail 2 DIFF Not Connected
- 14 - 14
Date Design Draw Approved Scale Projection
See Std. Documentation
*Con 7 *Con 6 07 Dec. 2006 ORSKNO ORSKNO FRNONO

15 15
Temp sense Temp sense
Block Diagram Minipack 48Vdc

Eltek
Copyright A/S Eltek. All rights reserved
2007-01-03 3,2kW Replace for Replaced by
2 CR 070103NA
SHWINO - -
* To be labeled Consultant Format Page Draw. No. Rev.
Sym. Alteration Date/Sign
- A3 1 of 1 2023227 2
213335
213333 Dist board 1 Minipack System MCB
Underwiring MPBB 6pos 3AC 8 pos load
LVBD
2 pos batt
Power module 1 X6A* - FB1
PE
DC output
+1 Y X
+
N 2
Customer
3
connections
NEG. DIST.
POS. DIST.
NEG. DIST.
POS. DIST.
- JP1 JP2 4
L 5 0V
- FB2 Battery Strings
Circuits -48Vdc
1 2 3 1 2 3 6
Customer
7
connections
Power module 2 8
PE
+ Customer
N connections
-
L
X7A*
To battery + Y9 Alarm Outputs and
Power module 3 Digital Inputs
PE DC Earth (TE) 218470
X5* + Power To battery contactor X1*
8 N output + Y7 Y1 Power input + Alarm I/O Connections
L1
N1 7 - + 1
Power Digital Input 1
L2 6 L - 2
N2 5 output – Y8 Y2 Power input - SH1 + 3
Digital Input 2
L3 4 - 4
NO 5
terminals
3
Customer
N3 Power module 4 Con 1A*
Mains input
connections
2 Alarm I/O Relay 1 COM 6
PE PE TB1
PE 1 Connections NC 7
System connections 10
Mains input
+ NO 8
N Batt. Fuse Fail + 1 Relay 2 COM 9
- Batt. Fuse Fail - 2 NC 10
LVD 1A 3
L
connection terminals
K1 LVD Common 4
LVLD
Power module 5 Alarm Outputs and
PE
213336
Digital Inputs
+ Dist.Board 2 MPBB 100A
218473
Y X Y8 8pos G1
N X6B* X2A*
- Y7 Y5 low pri load 2 DC output -
L Y6 Y4 F1 8 + 1
Digital Input 3 - 2
Optional Y3 Fuse + 3
Power module 6 To Dist Y5 alarm Digital Input 4
- 4
F2 7
PE board 2 + 5
CAN1 Y2 high Digital Input 5 -
+ Y6 6
Smartpack Y4 pri load + 7
N F3 6 Digital Input 6
Power -/CAN bus
Y1 - 8
- Con5A* Y3
Interconnections
pin 1-8 NO 9
L Smartpack Connection Con 2A* COM 10
F4 5 Ext. Alarm I/O
26
Connections
Y7
F5 4 X2B*
8
15
F6 3 Relay 3
Customer connections
NC 11
Load circuits -48Vdc

Y24 NO 12
Relay 4 COM 13
F7 2
NC 14
NO 15
Relay 5 COM 16
F8 1 NC 17
NO 18
Relay 6 COM 19
NC 20
Rear connections Front connections

Smartpack
monitoring and
NA for Smartpack Web/SNMP
15 control unit
CON5
System Connections USB 2.0 type B port USB
15 (PC connection) Customer
CON4 9 connections
Battery connections
1: Optional: RS232
9/15 CON3
NA for Smartpack RS232 rear Ext. Battery connections
1: Optional: RS 232
8/26 CON2
2: Optional: Web/SNMP (ENET)
10
CON1
Alarm I/O Connections
8
CAN port
8
CAN port
1: Optional 9 pin D-sub RS232 connection.

Battery Connections Battery Connections Can be mounted in front or on rear side of
200576 200576 Smartpack. Replaces ”Ext. Battery Connections”
*X3 *X4
Battery Connections Battery Connections when mounted on the rear side of Smartpack
+ 1 + 1
Con 3A* Batt. Symmetry 5 Con 4A* Batt. Symmetry 1
15 - 2 15 - 2 2: Optional Web/SNMP (ENET) connection.
+ +
Batt. Symmetry 6 Batt. Symmetry 2 Replaces ”Ext. Alarm I/O Connections”
- 4 - 4
+ 5 + 5
+ 7 + 7
+ 9 + 9
Temperature Sense 2 - 10 Temperature Sense 1 - 10
Battery Current 2 + 11 Not Connected + 11
SERIAL SERIAL
- 12 - 12
356804.10x
356804.10x
S1 S1
+ 13 + 13
DIFF Battery Fuse Fail 2 DIFF Not Connected
- 14 - 14
Date Design Draw Approved Scale Projection
*Con 7 *Con 6 31 oct. 2006 ORSKNO ORSKNO HAHANO

15 15
Temp sense Temp sense
Block Diagram Minipack 48Vdc

Eltek
Copyright A/S Eltek. All rights reserved
2007-01-03 4,8kW Replace for Replaced by
2 CR 070103NA
SHWINO - -
* To be labeled Consultant Format Page Draw. No. Rev.
Sym. Alteration Date/Sign
- A3 1 of 1 2021886 2
23
This product is CE marked and Copyright © Eltek Valere, 2007
complies with all current requirements This document may be changed without notice
for relevant standards and directives.
Art. No. 356808.103, Issue 1.1ev, 2007 Mar
Published 2007-03-19
www.eltekvalere.com
Headquarters:
1303 E. Arapaho Rd, Richardson, TX. 75081, USA Gråterudv. 8, Pb 2340 Strømsø, 3003 Drammen, Norway

081 022 Minipack System

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081 022 Minipack System

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Quick Start Guide

Installation, Operation, Commissioning and Maintenance

Check Lists pullout forms

The Smartpack based Product Range

Brief System Description ⎯ Minipack

Minipack rectifiers LVBD

Quick Start Guide Minipack PS System

Installing Smartpack and Rectifier Modules

Mounting or Removing Smartpack Controller

Removing the Smartpack controller

Mounting or Removing Minipack Rectifier Modules

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

Installation and Maintenance Details

Opening or Closing the Minipack Drawer Shelf

3. Lock the drawer shelf by

Mounting or Removing Minipack Blind Covers

Quick Start Guide Minipack PS System

Removing or Mounting Load MCBs

CAUTION: Power must be OFF during this operation!

1 3. Remove or insert the MCB by

Configuring Priority and Non-Priority Load Circuits

CAUTION: Power must be OFF during configuration! Only one

Configuration of Priority & Non Priority Load Circuits

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

Preparing the Installation Site

Mechanical Installation Power is OFF!

Carry out the following:

Quick Start Guide Minipack PS System

a Mount 3 intercell links to connect in series 4 battery blocks

terminals, and to the center terminal of the battery string

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

Location of Components, GA drawing

LVBD latching contactor

LVLD latching contactor (optional)

Common DC Output (+) Common Battery (+)

LVBD latching contactor

Top view DC Earth

Common DC Output (+)

Front view Load MCBs

Quick Start Guide Minipack PS System

Connections, Factory Settings, etc

(Rear) factory (Factory Settings). M4 terminals

CAN1 port FUNCTION SIGNAL PIN-OUT

6 mm , max. wire section

Battery Cables, string 1

Terminal Circuit Board, Art. 200576 Battery Cables, string x

(Not applicable for Smartpack RS232 D-Sub option, on rear panel)

Alarm Outputs & Digital Inputs (X1)

Alarm Outputs & Digital Inputs Extended (X2A & X2B)

(Not applicable for Smartpack Ethernet option)

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

The Minipack PSS startup consists of following stages:

I Pre-Start Check Power is OFF!

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

1. System installation is completed

Commissioning Steps, Startup

Quick Start Guide Minipack PS System

Load Adjustments Power is ON! III

o Switch ON all battery fuses or MCBs

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

Front Keys and display, menus, etc.

”Enter” key Power

Software Menus ~ Smartpack controller

Con 7 Con 6 07 Dec. 2006 ORSKNO ORSKNO FRNONO

Con 7 Con 6 31 oct. 2006 ORSKNO ORSKNO HAHANO