Users Guide

Monitoring and Control Unit

Flatpack2 DC Power Supply Systems

350003.013

1 Welcome Information in this document is subject to change without notice and does not represent a commitment on the part of Eltek Energy. No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical, including photocopying and recording for any purpose without the explicit written permission of Eltek Energy. Copyright : Eltek Energy, Norway 2006

Certificate no: 900005E

Certificate no: 900005Q

Safety Precautions
The equipment described in this manual must only be operated by Eltek Energy personnel or by persons who have attended a suitable Eltek Energy training course The equipment represents an energy hazard and failure to observe this could cause terminal injury and invalidate our warranty There are hazardous voltages inside the power system. As the modules incorporate large charged capacitors, it is dangerous to work inside the system even if the mains supply is disconnected Products into which our components are incorporated have to comply with a number of requirements. Installation is to be in accordance with the recommendations herein Please read the manual carefully before using the equipment

350003.013

Issue 3, 2006 Jan

Published 2006-01-09 Mfm

Users Guide Smartpack Monitoring & Ctrl Unit,

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1 Welcome

Table of Contents 1. Welcome 4

About this Guide ............................................................................................................. 4 System Diagram Flatpack2 Power System ................................................................ 4

2.

The Smartpack Controller

Key Features................................................................................................................... 5

Block Diagram .......................................................................................................5

Typical Applications ........................................................................................................ 6

Location of Connectors & Communication Ports ..............................................6

System & Battery Signals Internal Connections ......................................................... 7 Alarm Relay & Digital Input Signals Customer Connections ...................................... 8

CAN bus addressing and termination .................................................................9

3.

Installation of Smartpack Controller

10

Safety precautions ..............................................................................................10 Mounting and Removing the Controller ............................................................10

4.

Front Panel Operation

11

Description of Keys, Display and Indicators.....................................................11

LED indicators............................................................................................................... 11 LCD Display .................................................................................................................. 11 Front Keys.....................................................................................................................11

Modes of Operation.............................................................................................12
Status Mode .................................................................................................................. 12 Menu Mode ................................................................................................................... 12

Operating Menus, Overview ...............................................................................12

User Options ................................................................................................................. 13 Service Options............................................................................................................. 14

5. 6.

Technical Specifications Functionality Description

15 16

Alarm Reset .................................................................................................................. 16 Display System Voltages (VoltageInfo)...................................................................... 16 Display Alarm Messages, (Log) (DisplayMessages).................................................. 16 Display Rectifier Information (Rectifier Info)............................................................... 17
Plug-and-Play Rectifier ...........................................................................................................17

Mains Phase Assignment versus Rectifier ID ............................................................... 18 Resetting the Number of Rectifiers ............................................................................... 18 About Battery Banks, Strings and Blocks...................................................................... 19
Battery Symmetry Measurements...........................................................................................19

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1 Welcome

1. Welcome
Congratulations on your purchase of the powerful Flatpack2 DC power supply system, which uses the new Smartpack controller a powerful and cost-effective module developed for monitoring and controlling your DC power system.

About this Guide

This booklet provides users of Flatpack2 DC power systems with the required information for operating the system using the Smartpacks front panel. The booklet also describes the Smartpack controllers building blocks, external connections and technical specifications. Read also the general and site specific documentation that was delivered with your Flatpack2 DC power system.

System Diagram Flatpack2 Power System

In the Flatpack2 PS system shown in Figure 1, the Smartpack controller monitors and controls the whole system, and serves as the local user interface between you and the system. The PowerSuite application is used for remote operation and system configuration.
Alarm Outputs NC-C-NO Digital Inputs PowerSuite Application

Flatpack2 Cabinetized

Smartpack (Ctrl. Unit)

USB cable

Fuse Alarm

CAN Bus

Flatpack2 (rectifiers) LVLD Telecom equipment

AC Fuses, external (230VAC or 400VAC

AC mains supply selector Symmetry Alarm & Temp. Sensor LVBD Load Fuses & MCBs DC distribution DC Supply (24V, 48V or 60V*)
*Available from 2006

AC Supply (Single- or three-phase)

Battery string #1

Battery Fuses

Figure 1

Example of a typical Flatpack2 PS system for DC supply of telecom equipment

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2 The Smartpack Controller

2. The Smartpack Controller

The Smartpack controller is a monitoring and control unit used as the vital nerve center of the Flatpack2 DC power plant. You operate the system from the elegant front panel, using three front keys and the LCD-display. They represent the main interface between you and the system. You can also operate the system remotely via modem, Ethernet and the Web. The module then utilizes the USB- or RS-232 ports to interface with SNMP or Web adapters. See also chapter Technical Specifications, on page 15.

Key Features
Front panel LCD and buttons for on-site service without PC. USB- or RS-232 interface for PC connection locally or remote monitoring and control via modem, Ethernet, web or SNMP. Main program upgrade via USB port and the FWLoader application 6 user programmable relay outputs for traditional remote monitoring 6 user programmable inputs for monitoring of other equipment on site Battery monitoring and testing without site attendance Temperature compensated charging for increased battery lifetime Battery lifetime indication Password protected operator access levels Alarm/event log with time and date Windows-based PC communication software

Block Diagram
The microprocessor is the heart of the system and represents the intelligence in Smartpack controller. The main program and dynamic data are stored in Flash memory chips, easily upgraded via the USB or CAN ports DIP switches for configuring the controllers CAN bus ID number 24 / 48 / 60VDC Input supply Inputs signals (measurements) for system reference(1), battery current, battery & load fuse fail (3) Inputs signals (measurements) for battery symmetry (4), temperature sense (1) Inputs signals (measurements) for configurable digital inputs (2) Inputs signals (measurements) for battery symmetry (4), temperature sense (1), battery current (1), battery fuse fail (1) Inputs signals (measurements) for configurable digital inputs (4)

Smartpack Controller
FLASH & EEPROM Memory 256Kb

All customer-specified functions, calibration and log data are stored in EEPROM chips CAN port (2) for communication with rectifiers and other controllers on the CAN bus Power supply with regulated supply voltages for internal and external use (plug-in PCB)

Microprocessor

EEPROM
512Kb

DIP switch

CAN1
Power Bus

Power supply
Flyback rectifier

Step Down Reg. 12V Step Down Reg.+5V

Output signals (control) for LVD latching relays (2) USB 2.0 type B port (1) serial communication interface with PCs and computer devices Output signals (control) for Alarm relays (2) (Plug-in PCB)

CON5
System Connections (internal)

CON4
Battery Connections (internal)

USB
Serial Bus

Alarm I/O Connections (customer)

CON1

Battery Connections (customer)

CON3

(Plug-in PCB)

Alarm I/O Connections (customer)

CON2

Output signals (control) for Alarm relays (4)

Figure 2

Block diagram of the Smartpack controller showing the modules main functions

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2 The Smartpack Controller

Typical Applications
The Smartpack controller employs CAN bus communication with the Flatpack2 rectifiers and other bus-connected Smartpack controllers in the system thus enabling flexible expansion of system functionality and number of measuring points. System components can be set up and upgraded to meet the demand of any tailor-made power solution.

Location of Connectors & Communication Ports

DIP switches (CAN ID number) You can easily connect the Smartpack controller to a PC, plugging a standard USB A-B cable to the USB port on the front of the controller and to any available USB port on the computer. The Smartpack controller is configured from factory via DIP switches on the side with an ID number for CAN bus communication. On the controllers rear panel see Figure 4 you find two identical RJ45 CAN ports (for incoming and outgoing CAT5 twisted-pair cables) to connect the controller to the CAN bus. See also chapter CAN bus addressing and termination, on page 9.

USB 2.0 type B port (PC connection)

Figure 3

Front access USB port, and DIP switches for ID configuration on the side.

The Smartpack controllers outputs and inputs for monitoring and controlling the system, the batteries, alarm relays and status of external equipment are located on the controllers rear panel.

Battery Connections Extended D-sub, 15 pins, male (Internal)

Alarm I/0 Connections Extended D-sub, 26 pins, female (Customer)

CAN port (2) RJ45, 8 pins connector (Internal and customer)

Battery Connections D-sub, 15 pins, male (Internal) System Connections D-sub, 15 pins, female (Internal) Figure 4

Alarm I/0 Connections Mini power connector, 10 pins, male (Customer)

Rear plug connections on the Smartpack controller

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2 The Smartpack Controller

System & Battery Signals Internal Connections

In standard Flatpack2 DC power systems, the controllers internal signals are cabled either directly to the corresponding monitoring or measuring points, or to internal terminals, as shown in Figure 5. See also your systems specific arrangement drawings.
Smartpack controller
FUNCTION

CON5
15 pins D-Sub (female)
SIGNAL PIN-OUT

System Specific Interface Terminals

10 14 Interface Cable 5 5 7 13 11 15-pins D-Sub male 3 15 4 6 12 9 1 2

+ + + + + +/ +/ +/

Power Input System Reference System Voltage Batt. Current 1 Batt. Fuse Fail 1 Load Fuse Fail 1 LVD1A LVD Common LVD2A Out In * To latching relays. LVD1* LVD2*

5 15

1 11

CON5 (female; orange)

System Connections

LVD1A +/ 1 LVD2A +/ 2 LVD Common +/ 3 System Voltage + 4 System Voltage 5 a *Batt Current 1 + 6 b *Batt Current 1 7 NC 8 Load Fuse Fail 1 + 9 Power Input + 10 Load Fuse Fail 1 11 c *Batt Fuse Fail 1 + 12 d *Batt Fuse Fail 1 13 System Reference 14 Power Input 15

Notice: the signals available at the interface terminals may vary. Read your systems specific documents.

(Internal Connections)

Smartpack controller

CON4
15 pins D-Sub (male) Batt Sym 1 Temp Sense 1 Batt Sym 1 Temp Sense 1 Batt Sym 2 Batt Sym 2 a * NC b * NC NC Batt Sym 3 Batt Sym 3 d * NC Batt Sym 4 c * NC Batt Sym 4 + + + 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 5 10 13 2 8 12 System Specific Interface Terminals
FUNCTION SIGNAL PIN-OUT

3 6 Interface Cable 4 11 15 4 15-pins D-Sub female 7 14

11 15 CON4 (male; blue)

+ + + + +

Batt. Symmetry 1 Batt. Symmetry 2 Batt. Symmetry 3 Batt. Symmetry 4 Temp. Sense 1 NC *, * NC *, * Internal Connections) In
c d a b

+ +

Battery Connections
Smartpack controller

CON3
15 pins D-Sub (male) System Specific Interface Terminals
FUNCTION SIGNAL PIN-OUT

3 6 Interface Cable 3 11 15 4 7 15-pins D-Sub female 14 1 5 10 13 2 8 12

11 15 CON3 (male; blue)

Ext. Battery Connections Figure 5

Batt Sym 5 Temp Sense 2 Batt Sym 5 Temp Sense 2 Batt Sym 6 Batt Sym 6 Batt Current 2 Batt Current 2 NC Batt Sym 7 Batt Sym 7 Batt Fuse Fail 2 Batt Sym 8 Batt Fuse Fail 2 Batt Sym 8

+ + + + + + +

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

+ + + + + + +

Batt. Symmetry 5 Batt. Symmetry 6 Batt. Symmetry 7 Batt. Symmetry 8 Temp. Sense 2 Batt Current 2 Batt Fuse Fail 2 (Internal Connections) In

Overview of internal system and battery connections

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2 The Smartpack Controller

Alarm Relay & Digital Input Signals Customer Connections

In standard Flatpack2 DC power systems, the controllers customer alarm relay and digital input signals are cabled to dedicated easy accessible terminals, as shown in Figure 6. See also your systems specific arrangement drawings.

Smartpack controller
FUNCTION

CON1
SIGNAL PIN-OUT

1 2

10 CON1 (male; green)

Alarm I/O Connections

Smartpack controller

Config. Input 1A 1 Config. Input 1B + 2 Config. Input 2A 3 Config. Input 2B + 4 Relay Output 1 COM 5 Relay Output 1 NO 6 Relay Output 1 NC 7 Relay Output 2 COM 8 Relay Output 2 NO 9 Relay Output 2 NC 10

Interface Cable 1

4 6 7

1 3 5 9 10

System Specific Interface T i l

10 pins Connector (male)

+ +
NO COM NC NO COM NC

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

10-pins plug female

(Customer Connections) In Out

CON2
26 pins D-Sub (female)
FUNCTION SIGNAL PIN-OUT

19 1

26 9

CON2 (female; green)

Ext. Alarm I/O Connections Figure 6

Config. Input 5B Config. Input 5A Config. Input 6B Config. Input 6A NC Relay Output 3 Relay Output 4 Relay Output 5 Relay Output 6 Config. Input 4A NC NC NC NC Relay Output 3 Relay Output 4 Relay Output 5 Relay Output 6 Config. Input 4B Config. Input 3A Config. Input 3B NC Relay Output 3 Relay Output 4 Relay Output 5 Relay Output 6

NC NC NC NC

1 Interface Cable 2 3 15 6 24 26-pins D-Sub male 17 8 26

10 2 4 23 16 7 25 18 9

System Specific Interface Terminals

+ +

NO NO NO NO

+ +

COM COM COM COM

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

21 20 19

NO COM NC NO COM NC NO COM NC NO COM NC

+ + + +

Input Circuit 3 Input Circuit 4 Input Circuit 5 Input Circuit 6 Alarm Circuit 3 Alarm Circuit 4 Alarm Circuit 5 Alarm Circuit 6 (Customer Connections) In Out

Overview of customer connections alarm relay & digital input signals

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2 The Smartpack Controller

CAN bus addressing and termination

The Smartpack controller is factory configured with a unique CAN bus ID number, using DIP switches on the side of controller (hardware-assignment). When Flatpack2 rectifiers are hot-plugged in the power shelves the first time, the Smartpack controller dynamically assigns the rectifiers with the next available ID number (software-assignment), and automatically increases the number of communicating rectifiers on the CAN bus. Also, the controller registers the rectifiers ID numbers, or CAN bus address (01, 02), together with their serial numbers. When a previously installed rectifier is hot-plugged in the power shelf again, it retains its previous ID and serial number. To ensure a correct bus communication and avoid data reflection, you must always terminate the CAN bus with two 120 resistors at both ends of the line, see Figure 7.
USB A-B cable (standard)
1 End-of-Line Resistor

CAN bus (twisted-pair internal CAT5 cable) 120

End-of-Line Resistor

120 Flatpack2 DC Power System

01 02 n Smartpack assigns ID numbers to the rectifiers (software-assigned). The Smartpacks ID numbers are assigned by DIP switches on the controllers side.

Figure 7

CAN bus terminated with a 120 resistor on both line ends (60 bus impedance)

The example in Figure 8 shows two networked Flatpack2 DC power systems. The CAN bus must then be terminated with only two 120 resistors, one at each end of the line.
End-of-Line Resistor

120

120 Flatpack2 DC Power System 1

01 02 n n+1 n+2 Flatpack2 DC Power System 2 m End-of-Line Resistor

Figure 8 Two Flatpack2 DC power systems CAN bus connected with CAT5 twisted-pair cables. Only two 120 resistors are to be terminated on both line ends (60 total bus impedance)

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3 Installation of Smartpack Controller

3. Installation of Smartpack Controller

Safety precautions
Get acquantied with the satety precaution on page 2, before installing or handling the equipment.

Mounting and Removing the Controller

The Smartpack controller incorporates handles that serve both to lock the module into position and to pull it out of its housing. CAUTION: Do not hand-carry the controller by its handles. Cables are plugged to the controllers rear panel. Open the handles before inserting the controller into the power shelf. Mount blind panels in unused module locations.
Electric shock

Device hazard

Smartpack controller

Hole to release the handles spring mechanism

Mounting the Smartpack controller

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

Handle in locked position

Removing the Smartpack controller

1. Open the handles by inserting a screwdriver into the holes to release the spring mechanism 2. Remove the module by using both handles to pull the module loose gently; support from underneath; unplug the cables connected to the rear panel

Handle in unlocked position

Figure 9

Smartpack controllers locking mechanism

Removing blind panels

Release the panels upper left and right corners by inserting a small screwdriver into the panels upper left gap, and carefully press down and out to release the locking tabs. Repeat on the upper right gap. Refer to the Flatpack2 systems quick start guide for more information.

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4 Front Panel Operation

4. Front Panel Operation

This chapter describes the Smartpack controllers keys and indicators, and how to operate the Flatpack2 DC power system from the controllers front panel.

Description of Keys, Display and Indicators

The Smartpack controllers front panel consists of two functional areas: the presentation area (LCD display and LED lamps) and the control area (keys). For information about the handles and the USB port, read pages 6 and 10. Graphical Display 16 character x 2 lines LCD display Upper line Output voltage or menu options Lower line Battery or load current, alarms, or keys to press Down arrow key Up arrow key Figure 10 Alarm LED Lamp (red) Warning LED Lamp (yellow) Power LED Lamp (green)

Enter key

Smartpack controllers front keys and indicators

LED indicators
The Smartpack controller has the following LED indications: Power (green) indicates that the power supply is ON or OFF Alarm (red) indicates an alarm situation (major alarm) Warning (yellow) indicates an abnormal situation (minor alarm)

LCD Display
The graphic display is an important part of the power supply systems user interface. The display is in Status Mode (displays the systems status) or in Menu Mode (displays the menu structure). Depending on the displays mode, the upper line shows the output voltage or menu options, while the lower line displays battery and load current, alarms, or information about which key to press. See also chapter Modes of Operation, on page 12.

Front Keys
You can control the whole Flatpack2 DC power system via a network of software menus accessed with the controllers front keys. key to change from Status Mode to Menu Mode. o Press on the o o or keys to scroll up or down and navigate to find menu options Press the (function or parameter). Press then the key to select the function.

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4 Front Panel Operation

Modes of Operation
The controllers display is either in Status Mode or in Menu Mode.

Status Mode
When the front keys are not in operation, the display is in Status Mode. The following information is then scrolled through the display: The upper line continuously displays the battery voltage. The lower line continuously scrolls the following information: o Battery Current o Load Current o Active alarms o Other messages

Menu Mode
When the front keys are in operation, the controllers display switches to Menu Mode and the following information is scrolled through the display: The upper line shows the name of the active menu or sub-menu The lower line indicates which key to press

Notice that if no keys are pressed within 30 seconds, the display will automatically switch from Menu Mode and to back to Status Mode.

Operating Menus, Overview

The Flatpack2 DC power systems functionality is accessed via a network of software menus and submenus, enabling you to configure and control the whole power system. The functionality is divided in two different hierarchical menu structures: the User Options menus and the Service Options menus (password protected, only authorised personnel have access to them). Special, not so frequently used options such as calibration and adjustments are accessible in the Service Options sub-menus. Level 1
Display in Status Mode UserOption ServiceOption

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4 Front Panel Operation

User Options
When you enter Menu Mode, you access the User Options.

How to browse the display menus o Entering Menu Mode key to change from Press on the Status Mode to Menu Mode Browsing down to a menu option key, to scroll down within Press the the same menu level, and find menu options (functions or parameters) Selecting a menu option key to select the Press on the displayed menu option or parameter Browsing up to a menu option or level key to scroll up to the Press the previous menu option, and out to the previous menu level.

User menu <UserOption>

AlarmReset NomVolt BoostVolt LowBatt1 LowBatt2 HighBatt1 HighBatt2 LVD 1 LVD 2 Message
1v01

VoltageInfo

DisplayMessages SoftwareInfo SerialNumber Rectifier Info

NoOfRects. Nn RectCurrent RectSerialNumber Rect.PrimaryVolt Rectifier Status Rectifier Temp NoOfPhases nn Mains Status Mains Voltage Level

1v0 1v0 1v0 1v0 1v0

Mains Info Temp Level Info--

1v0

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The XvX references, if any, on the right hand of the option, are not shown in the display. They only indicate in which software vesjon (x) the option was first implemented.

Level 2

Level 3

4 Front Panel Operation

Service Options
When you enter Menu Mode, you access the User Options. You may then scroll down to the password protected Service Options. The Service Options password is factory-programmed to <0003>. We strongly recommend that this password is changed as soon as the system is installed

Level 2 How to browse the display menus o Entering Menu Mode key to change from Press on the Status Mode to Menu Mode Browsing down to a menu option key, to scroll down within Press the the same menu level, and find menu options (functions or parameters) Selecting a menu option key to select the Press on the displayed menu option or parameter Browsing up to a menu option or level key to scroll up to the Press the previous menu option, and out to the previous menu level.

Level 3
NomVolt BoostVolt LowBatt1 LowBatt2 HighBatt1 HighBatt2 LVD 1 LVD 2 VoltCal Password

Service menu <ServiceOption>

The XvX references, if any, on the right hand of the option, are not shown in the display. They only indicate in which software vesjon (x) the option was first implemented.

VoltAdjustment

VoltCalibration ------ChangePassword --SetBoostTime--------Start/StopBoost Auto Boost Conf. --Batt Test Setup Start/Stop Test Charge Curr Lim. --Battery Setup -------Output Control ------Change Date/Time RelayTest

Enable/Disable & AutoBThrs Nxt Test DateTime End Volt MaxTestDur Test int Guard time Enable/Disable & Max C.Curr NumOfString VoltageCtrl / TempComp Alarm Output 1 Alarm Output 2 Batt Contactor Load Contactor Alarm Output nn
1v0

BattLifeTime Rst

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5 Technical Specifications

5. Technical Specifications
Remote Monitoring / Control
From a PC running Windows-based communication software (PowerSuite) With the Windows-based communication program installed on a remote computer, the system can be monitored and controlled via modem or Ethernet network. From an NMS via Ethernet (SNMP) With an SNMP agent connected to the Smartpack, the system can be monitored and controlled from a Network Management System (NMS) through Ethernet on Simple Network Management Protocol (SNMP). Using alarm relays (voltage free contacts) 6 internal failsafe alarm relays provide voltage free contacts that can be connected to equipment used for traditional alarm monitoring.

Local Monitoring / Control

From a PC running Windows-based communication software (PowerSuite) Windows-based comm. software can also communicate with the Smartpack through an USB serial or RS-232 cable. LCD and three keypads for local operations. If any alarm (major or minor) is activated, a (red or yellow) LED is lit in the front panel, the alarm text appears in the LCD and the corresponding alarm relay is activated. In normal operation, the front LCD will display the output voltage, battery current, load current and charge mode.

Available Alarms
All alarms can be set up with monitoring of minor, major, average and peak levels. System Mains Failure (individual phases) Digital Inputs (programmable names) Load Disconnect (voltage or timer) Load Fuse Load Current Battery High Battery voltage Low Battery voltage High Battery temperature Low Battery temperature Battery Capacity Battery Disconnect Battery Fuse Symmetry Failure Battery quality indication Battery discharge current Rectifier Rectifier Failure Critical Rectifier Failure (> 1, programmable) Rectifier Capacity w. programmable level Rectifier Current Limit Rectifier Over voltage Protection Rectifier Current

Features
System Output Voltage Measurement Total Load Current Measurement Load/Battery Disconnect Alarm Level Settings (major / minor) Alarm Log (up to 1000 events) Real Time Clock with Battery Backup Site Text/ID Test of Relay Outputs Voltage Level setup Battery Battery Current Measurement Battery Temperature Measurement (optional) Battery Testing (acc. to discharge table or set time limit) Battery Test Information (10 latest tests) Setup of Battery Data Battery shunt setup Battery quality indication Battery Boost Charging Battery Cable Voltage Drop Compensation Temperature Compensated Charging Protection against Temperature Probe Failure Rectifier Available information about each rectifier, e.g. serial number, version, internal temperature Individual Rectifier Current Measurement Individual Rectifier Input Voltage

Specifications
Input Voltage Firmware 24/48/60 VDC The Smartpack main program can be upgraded via the USB port, using a PC running the FWLoader application 109 x 44 (1U) x 140mm (wxhxd) (4.3 x 1.7 x 5.5)

Dimensions

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6 Functionality Description

6. Functionality Description
In this chapter you can find helpful and more detailed descriptions of expressions, technical terms, functions, etc. used in Flatpack2 DC power supply systems.

Alarm Reset
You can reset all active alarms by selecting UserOption>AlarmReset, via the Smartpack controllers front keys. The controller will immediately report alarm conditions that are still active. The Flatpack2 DC power system can be configured with automatic or manual alarm reset. When Automatic Alarm Reset is enabled (default) and the alarm condition no longer exists the Smartpack controller will deactivate the alarm lamps and relays to indicate that normal operation is established. When Manual Alarm Reset is enabled and the alarm condition no longer exists the operator must reset the alarm manually.

Display System Voltages

(VoltageInfo)

You can display important system voltages by selecting UserOption>VoltageInfo, via the Smartpack controllers front keys. Following voltages may be displayed selecting the VoltageInfo sub options (level 3): Option NomVolt BoostVolt LowBatt1 LowBatt2 HighBatt1 HighBatt2 LVD 1 Description Nominal output voltage Battery boost-charging voltage Voltage limit for Low Battery Alarm 1 Voltage limit for Low Battery Alarm 2 Voltage limit for High Battery Alarm 1 Voltage limit for High Battery Alarm 2 Voltage limit for Low Voltage Disconnect unit 1

Display Alarm Messages, (Log)

(DisplayMessages)

You can browse through the stored system alarm messages (alarm log) by selecting UserOption>DisplayMessages, via the Smartpack controllers front keys. The Smartpack controllers alarm log may store up to 1000 chronological events. Each log entry contains event text, event action, time and date. When the log is full, the oldest value is overwritten. The log is stored in EEPROM.

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6 Functionality Description

Display Rectifier Information

(Rectifier Info)

You can display information about the Flatpack2 rectifiers communicating in the system, by selecting UserOption>Rectifier Info, via the Smartpack controllers front keys. Following information may be displayed selecting the Rectifier Info sub options (level 3): Option NoOfRects. RectCurrent RectSerialNumber Rect.PrimaryVolt Rectifier Status Rectifier Temp Description Number of rectifiers installed in the system. Rectifier current Rectifier ID and serial number Rectifier input voltage Rectifier status Rectifier temperature

While the controller is accessing information from a specific rectifier, the green LED on the rectifiers front panel flashes. The Smartpack controller sends out status messages every 200ms to all the Flatpack2 rectifiers connected to the CAN bus, such as: o o o o o o The Smartpack controllers status Current Limit Reference Measured Output Voltage Reference Output Voltage Over-voltage Protection Reference Etc.

Plug-and-Play Rectifier
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. This ID number (or CAN bus address) and the rectifiers serial number are stored in both modules. When a previously installed (hot plugged) Flatpack2 rectifier is inserted in a power shelf, the Smartpack controller recognises the module, and assigns the same ID to rectifier. In other words, the controller and the rectifier remember the assigned ID and serial numbers, 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 power shelves, one module at a time, starting with shelf position 1, 2, 3 and so on. The sequence is indifferent after positions 9. Read chapter Mains Phase Assignment versus Rectifier ID, page 18. The power shelf position numbers vary with the type of AC mains and the type of power shelves installed in your system. Refer to your systems quick start guide and specific documentation for more information. Do not relocate already pre-installed rectifiers.

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6 Functionality Description

Mains Phase Assignment versus Rectifier ID

In systems with 3 phase AC feed, the Smartpack controller can be configured to report a warning if one phase fails, and to report an alarm if two phases fail, for example. The 230V phases of Flatpack2 systems mains AC feed are routed to the rectifiers inputs in a special pattern that loads the 3 phases evenly. The routing of the phases is implemented via internal wiring and the use of either 4AC Power Shelves 1 or 2AC Power Shelves 2 . Refer to your systems quick start guide and specific documentation for more information. To be able to display correct information about the phases, the Smartpack controller must know which phase is connected to which rectifier ID number. Flatpack2 DC power systems are shipped from factory with the rectifier modules already installed in the correct position in the power shelves, with respect to their ID number (or CAN bus address). This relationship is very important, as the Smartpack controller always uses rectifier ID 01, 02 and 03 to monitor mains phase L1, L2 and L3 respectively. If these rectifiers malfunction, rectifier ID 04, 05 and 06 will automatically take over. If these fail, the controller uses rectifier ID 07, 08 and 09. For example: accidentally inserting a rectifier with ID 02 in a power shelf position internally connected to mains phase L1, will cause the controller to monitor L1 thinking it monitors L2.

Resetting the Number of Rectifiers

When a rectifier reset is activated, the number of rectifiers is recalculated, and only the number of communicating modules at the moment will be counted. For instance: in a DC power system equipped with 10 rectifiers, rectifier with ID number 04 malfunctions. If you insert rectifier ID#10 in the position of the failing ID#04, and then activate a rectifier reset, the Smartpack controller recalculates the number of communicating rectifiers to only 9. At the same time the controller reassigns rectifier with ID#10 to ID#04, thus filling the gap. Example: DC power system with malfunctioning rectifier; 3 power shelves with 10 rectifiers (rectifier ID #04 malfunctions)
Rectifier ID Serial No. Rectifier ID Serial No. Rectifier ID Serial No. 01 01 05 05 09 09 Rectifier ID Serial No. Rectifier ID Serial No. Rectifier ID Serial No. 02 02 06 06 10 10 Rectifier ID Serial No. Rectifier ID Serial No. 03 03 07 07 Rectifier ID Serial No. Rectifier ID Serial No. 04 04 08 08

01 05 09 ---

02 06 10 ---

03 07

04 08

ID 04 SNo.: 04 Flatpack2 rectifier

--ID --- 10

SNo.: 10

After rectifier reset: 3 power shelves with 9 rectifiers (rectifier ID #10 reassigned to #04)
Rectifier ID Serial No. Rectifier ID Serial No. Rectifier ID Serial No. 01 01 05 05 09 09 Rectifier ID Serial No. Rectifier ID Serial No. 02 02 06 06 Rectifier ID Serial No. Rectifier ID Serial No. 03 03 07 07 Rectifier ID Serial No. Rectifier ID Serial No. 04 10 08 08

ID 04 SNo.: 10

01 05 09 ---

02 06 ---

03 07 ---

04 08 --Flatpack2 rectifier

1 2

4AC Power Shelves (Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier). 2AC Power Shelves (Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers). Users Guide Smartpack Monitoring & Ctrl Unit,

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6 Functionality Description

About Battery Banks, Strings and Blocks

Battery Block (12V)

Normally, battery banks are implemented by connecting in parallel several battery strings; each string is formed by battery blocks connected in series. Figure 11 Example of a 48V battery bank implemented with two 48V battery strings; each string consists of four 12V battery blocks

Battery String #1 (48V) Battery String #2 (48V)

48V Battery Bank

Battery Symmetry Measurements

Symmetry measurement is a battery monitoring method for automatically detecting unbalanced battery blocks. Symmetry monitoring of a battery string may be performed after three different methods: o Block measurement method Measuring each battery block o Mid-point measurement method Measuring from the mid-point of the battery string to one end Double mid-point measurement method Measuring from the mid-point of the string to both ends

Card, Art. 200576 Diff. Switches

Battery Symmetry Block Measurement

(-48V) + (0V) Symmetry 1 2 3 4 + - + - + - + -

Set all 4 switches OFF (up) Four measurement points per string (Diff. measurement)

Card, Art. 200576 Diff. Switches

Battery Symmetry Mid-point Measurement

(-48V) Symmetry 1 + + (0V)

Set all 4 switches OFF (up)

The mid-point measurement method requires 2 symmetry wires per battery string; the double midpoint measurement method requires 4 symmetry wires per battery string, while the block measurement method requires 8 symmetry wires per battery string. Refer to the systems quick start guide for connections using fewer wires, setting the switches to ON. Flatpack2 cabinetized systems are normally delivered with the symmetry measurement method and the number of measurement points already preprogrammed in the Smartpack controller. Any deviation from factory settings requires Symmetry reconfiguration via the PowerSuite PC program. Each Smartpack controller is equipped with 8 battery symmetry inputs (on CON4 and CON3), enabling symmetry measurement of: o 2 battery strings (block meas. method) o 4 battery strings (double mid-point meas. method) o 8 battery strings (mid-point meas. method)

One measurement point per string

Battery Symmetry Double Mid-point Measurement

(-48V) Card, Art. 200576 Diff. Switches Symmetry Symmetry 1 2 + + + (0V)

Set all 4 switches OFF (up)

Two measurement points per string, from the middle to the outer terminals

Figure 12 Example of terminal connection points for Symmetry Block, Mid-point and Double Mid-point measurement methods

Users Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v3-2006-01

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e-mail:

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Telephone +47 32 20 32 00 +1 815 459 9100 +65 6 7732326 +769 22651108 +44 1442 219355 +971 4 887 1176

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