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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
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
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1 Welcome
About this Guide ............................................................................................................. 4 System Diagram Flatpack2 Power System ................................................................ 4
2.
Key Features................................................................................................................... 5
3.
10
4.
11
Modes of Operation.............................................................................................12
Status Mode .................................................................................................................. 12 Menu Mode ................................................................................................................... 12
5. 6.
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.
Flatpack2 Cabinetized
USB cable
Fuse Alarm
CAN Bus
AC mains supply selector Symmetry Alarm & Temp. Sensor LVBD Load Fuses & MCBs DC distribution DC Supply (24V, 48V or 60V*)
*Available from 2006
Battery string #1
Battery Fuses
Figure 1
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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
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
CON1
CON3
(Plug-in PCB)
CON2
Figure 2
Block diagram of the Smartpack controller showing the modules main functions
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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.
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 D-sub, 15 pins, male (Internal) System Connections D-sub, 15 pins, female (Internal) Figure 4
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CON5
15 pins D-Sub (female)
SIGNAL PIN-OUT
+ + + + + +/ +/ +/
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
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
+ + + + +
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
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
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Smartpack controller
FUNCTION
CON1
SIGNAL PIN-OUT
1 2
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
+ +
NO COM NC NO COM NC
CON2
26 pins D-Sub (female)
FUNCTION SIGNAL PIN-OUT
19 1
26 9
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
10 2 4 23 16 7 25 18 9
+ +
NO NO NO NO
+ +
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
+ + + +
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
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End-of-Line Resistor
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
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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Device hazard
Smartpack controller
Figure 9
10
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Enter key
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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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.
12
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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.
VoltageInfo
NoOfRects. Nn RectCurrent RectSerialNumber Rect.PrimaryVolt Rectifier Status Rectifier Temp NoOfPhases nn Mains Status Mains Voltage Level
1v0
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13
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
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
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
14
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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.
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.
(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
(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.
16
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6 Functionality Description
(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
01 05 09 ---
02 06 10 ---
03 07
04 08
--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,
18
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6 Functionality Description
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
Set all 4 switches OFF (up) Four measurement points per string (Diff. measurement)
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)
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
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ELTEK Energy
P-O- BOX 2340 Stms N-3003 DRAMMEN NORWAY Phone: Telefax: Internet: +47 32203200 +47 32203210 http://www.eltekenergy.com eltek@eltekenergy.com
e-mail:
Company Eltek Energy AS Eltek Energy, LLC Eltek Energy Pte Ltd. Eltek Energy Ltd. Eltek Energy UK Ltd. Eltek Middle East
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