minipack MANUAL INSTALACION

Quick Start Guide
Installation, Operation, Commissioning and Maintenance
Minipack, PS System
DC Power Supply System
Integrated Applications
Introduction
o
o
The Smartpack based Product Range (2 )
Brief System Description ⎯ Minipack (2 )
Installation
o
o
o
o
o
Installing Smartpack and Rectifier Modules ( 3)
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)
Installation steps; mechanical, electrical (6-7)
Location of Components, GA drawing; 6 and 4 rectifiers systems
Connections, Factory Settings, etc. (9)
(8)
Commissioning
o
o
Pre-start check (10 )
Commissioning steps, Startup
Operation
o
o
Front keys and display
Software Menus (12)
(10-11)
(12)
Miscellaneous
Communication
o
CAN Bus Termination (13)
o
Installing PowerSuite – PC software (13)
AC Mains
o
Mains Feeds versus Rectifier ID (14)
o
Plug-and-Play Rectifiers versus Mains Monitoring (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
356808.103
o
o
o
o
Installation Check List
Circuit Distribution List
Commissioning Procedure
Maintenance Procedure
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pullout forms
Introduction
The Smartpack based Product Range
Eltek Energy's Smartpack based product range utilizes the Smartpack controller, and Flatpack2
rectifiers, Powerpack rectifiers and Minipack rectifiers as building blocks for implementing
effective DC power systems, suitable for a wide range of applications and power ratings.
Powerpack System
Flatpack2 System, Cabinetized
Indoor and Outdoor Cabinets
Flatpack2 System, Integrated
4U and 1U Distributions
Minipack System, Integrated
Cabinetized systems are suitable for indoor or outdoor applications. In addition to the power
system and the distribution unit, the cabinet may also contain battery banks, additional
distribution and other dedicated equipment.
Integrated systems consist of the power system, which includes rectifiers and controller(s), and
the distribution unit (1U or 4U high). Integrated systems are sold primarily for mounting in
existing cabinets.
Powerpack systems are suitable for large Central Office power plants, and use three-phase
rectifier modules.
Minipack systems are suitable as small, stand-alone battery chargers and DC power supplies.
Brief System Description ⎯ 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
Digital Inputs
Minipack
PowerSuite
Application
Remote
Monitoring
Smartpack
(Ctrl. Unit)
AC Fuses,
external
(230V)
USB cable
Fuse Alarm
LVLD
CAN Bus
Telecom
equipment
Minipack rectifiers
AC Supply
(Single- or
three-phase)
Symmetry
Alarm &
Temp. Sensor
LVBD
Load Fuses
& MCBs
Battery
Fuses
DC
distribution
DC Supply
48V
*
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.
2
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Quick Start Guide Minipack PS System
356808.103, v1-2006-12
Installation
Controller & Modules
Installing Smartpack and Rectifier Modules
Device
hazard
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
inserting the controller into the power shelf.
Mounting or Removing Smartpack Controller
Hole to release the
handle’s spring
mechanism
Smartpack
controller
Handle in locked position
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
Removing the Smartpack controller
Handle in
unlocked position
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
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
Mounting
Rail
Front Handle
Locking Screw
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)
or
using the front handle to pull the module loose; support from
underneath before the unit is completely free
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
Quick Start Guide Minipack PS System
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shock
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
sliding drawer shelf. Do following to open or close the drawer:
for the drawer
Fastening screw
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
outwards.
The drawer shelf is the in the Maintenance Position.
or
sliding it on its mounting rail fully into the shelf
Fastening screw
for the shelf frame
3. Lock the drawer shelf by
screwing home the upper and lower locking screws.
The drawer is then securely locked in the shelf, in its
Operation Position
Shelf
Frame
F1, F2…Plastic
Cover
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
Front handle
Locking screw
to secure the blind cover
4
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3. Lock the blind cover by
screwing home the locking screw (locked direction).
Then, the blind cover will be securely locked in the shelf,
or ready for transport
Quick Start Guide Minipack PS System
356808.103, v1-2006-12
Installation
Details
Removing or Mounting Load MCBs
Plug for MCB1
Minipack front
MCB1
MCB8
0
CAUTION: Power must be OFF during this operation!
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 the MCB by
switching the MCB handle to “0” position (upwards)
1
MCB8
(Upper and
lower plugs)
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
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
Plugs for MCB1
Screw Removed F1
F2 F3
F4
F5
F6
F7
F8
F9 F10
P
P
P
P
P
P
P
P
P
P
None
P
P
Y25 NP NP NP NP NP NP NP NP
NP NP NP NP NP NP
P
P
P
P
Y24
NP NP NP NP
P
P
P
P
P
P
Y7
NP NP
P
P
P
P
P
P
P
P
Y6
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)
Quick Start Guide Minipack PS System
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356808.103, v1-2006-12
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
2U
2
3
600 mm
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
ventilation
Prepare the installation tools
o Use insulated tools suitable for telecom installations
Prepare AC Supply: AC input cable(s) and fuses
o Correct type AC supply is available
o External AC fuses have correct rating
o AC input cable(s) are sized correctly
EMC
regard
For external AC fuses and AC input cable ratings, refer to your site’s AC
supply specification. In general, a site with better AC supply quality
(stable nominal voltage) may use smaller breakers.
Mechanical Installation
Minipack PSS, Doc. Chart, Spec.
Drawings, CD-ROM
Plastic Cover
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
hazard
o Leave rectifier modules in their packaging or in the selves, if
factory installed. To be installed under commissioning
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
shock
o Do not terminate the battery cables yet!
8 Open the Minipack drawer shelf and lift the 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
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Quick Start Guide Minipack PS System
356808.103, v1-2006-12
Installation
Service Loop
Cable lengths
enabling to open
the drawer shelf
Electrical Installation
Power is OFF!
Carry out the following: (Refer to the system’s specific drawings)
CAUTION: The cable lengths must be long enough (service loop) to allow
opening the Minipack drawer shelf.
9
Minipack drawer shelf slid out in
the maintenance position
10
11
Common Battery
Cables (+)
12
Cable lugs mounted
upside down
Chassis
Link 2 (X7A)
(DC Earth)
Battery
Fuse, Fbx
EG
Common
Battery X7A
Card Art.200576
2-1 15 pins D-Sub
(male)
13
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
AC Connections
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
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)
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.
DC Connections ⎯ Alarm & Signal Circuits
o Refer to your system’s connection drawings and configuration, or
to the “Miscellaneous, Alarms & Monitoring” section, terminal
blocks X1, X2A and or X2B.
o Terminate Alarm Circuit cables to the relay output terminals
o Terminate Signal Circuit cables to the digital input/output
terminals
DC Connections ⎯ Battery Cables
Careful! Use correct polarity.
For 48V systems using the battery symmetry mid-point
measurement, refer to the figure in this page.
For other measurement methods, 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
+
f-g
- + - + - + - +
—
(-48V) Outer
Terminal
d-e
Temp. sensor
Symmetry 1
Battery
Cable
a
b-c
Block1
Intercell Links
Block3
Mount 3 intercell links to connect in series 4 battery blocks
Connect battery cables to fuses (Fb1, Fb2, etc.) and
Common Battery (X7A) and to the battery shelf’s outer
terminals; black (+); blue (-)
Connect battery symmetry cables, if applicable, to the input
terminals, and to the center terminal of the battery string
(+) and to the -48V outer terminal. Deviation from factory
settings requires Symmetry reconfiguration via PowerSuite
Connect the temperature sensor cable, if applicable, to the
D-Sub plug or input terminal, and fix the temperature
sensor (at the end of the cable) to a suitable place in the
middle of the installed battery bank
Block4
+
0V Outer
Terminal
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7
Device
hazard
Electric
shock
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.
CAN1
Plastic Protective Cover for
AC Terminals
CAN bus communication with rectifiers (to Smartpack rear)
CON5A, For internal connections
(to Smartpack rear)
Minipack, 6 Rectifiers (48V, 4800W)
Cable Fastening Plate
LVBD latching contactor
Top view
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 Battery (+)
Common DC Output (+)
X7A, Battery connections
Load terminal block
Fb1, Fb2
Battery connections (−)
X6B: pin 1
Location of
Smartpack controller
DC Output (−)
Load terminal block
Forward sliding
drawer shelf
Minipack Rectifier
Smartpack controller
Battery Fuses
Load MCBs
Front view
Minipack rectifiers
CAN1
Plastic Protective Cover for
AC Terminals
CAN bus communication with rectifiers
(to Smartpack rear)
CON5A, For internal connections
(to Smartpack rear)
Cable Fastening Plate
Minipack, 4 Rectifiers (48V, 3200W)
NOTE: For information about connecting
Battery Symmetry, Temperature Sensor,
Alarm and Monitoring circuits, refer to
section “Miscellaneous”, and read the
Battery Monitoring, Alarms & Monitoring
chapters.
LVBD latching contactor
X5: pin 1
AC Mains
LVLD latching contactor (optional)
AC Mains & Earth (PE) Terminals
DC Earth
Top view
Common Battery (+)
X7A, Exchange Ground (EG) or
system ground.
Link connected to chassis
X7A, Battery connections
Common DC Output (+)
Load terminal block
Fb1
Fb1, Fb2, Fb3, Fb4
Battery connections (−)
X6B: pin 1
DC Output (−)
Location of
Smartpack controller
Load terminal block
Minipack Rectifier
Smartpack controller
Forward sliding
drawer shelf
Battery Fuses
Front view
Load MCBs
Minipack rectifiers
8
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Quick Start Guide Minipack PS System
356808.103, v1-2006-12
Installation
Connections, Factory Settings, etc
Refer to your system’s specific drawings for the exact connection points.
Minipack
PS System, Integrated
SIGNAL
TERM. POINT
X5
(Front)
Type B serial port
(Rear)
CAN1 port
PE
PE
N3
L3
N2
L2
N1
L1
AC Earth (PE)
1
2
3
4
5
6
7
8
Mains Feed 3
Mains Feed 2
Mains Feed 1
2
2.5 mm , max.
wire section
M4 terminals
are preprogrammed from
factory (Factory Settings).
FUNCTION
RJ45, 8 pins
SIGNAL
X6B
CAN1 port
RJ45, 8 pins
(For CAN bus
termination, see section
“Miscellaneous”)
PIN-OUT
X6A
MCB1
+ 1
Load Circuit 1
MCB2
+ 2
Load Circuit 2
MCB8
+ 8
Load Circuit 8
MCB10
+ 10
Load Circuit 10
2
CAN
Com
Cable
USB 2.0
the relay coils are then
de-energized
(fail-safe
mode). The relay outputs
Load Fuses
CAN bus
End-of-Line
Plug (120Ω)
USB
Com
Cable
The figure shows the position of the relay contacts
when the PS system is in
alarm mode of operation;
AC Mains Inputs
Smartpack
6 mm , max. wire section
FUNCTION
Interface Cards Connections
Refer to the connections for the actual terminal circuit boards
installed in your system
X7A
(Minipack systems with 6 rectifiers
have 8 DC load outputs available.
Systems with 4 rectifiers have 10
DC load outputs)
Battery Cables, string 1
Battery
Fuses
Battery Connections (X4)
Terminal Circuit Board, Art. 200576
Battery Symmetry 1-4 and Temp. Sense 1
(See page 16 for pin-out information)
Battery Connections, Extended (X3)
Terminal Circuit Board, Art. 200576
Batt. Symmetry 5-8, Temp. Sense 2, Batt. Current and Batt. Fuse Fail
Fb1
Battery Cables, string x
Fbx
M6 screws, cable lugs
max. 15 mm width
Common
Battery “Rail”
(Not applicable for Smartpack RS232 D-Sub option, on rear panel)
(See page 16 for pin-out information)
Alarm Outputs & Digital Inputs (X1)
Terminal Circuit Board, Art. 218470
Digital Input 1-2 and Relay Output 1-2
(See page 17 for pin-out information)
Alarm Outputs & Digital Inputs Extended (X2A & X2B)
Terminal Circuit Board, Art. 218473
Digital Input 3-6 and Relay Output 3-6
(Not applicable for Smartpack Ethernet option)
(See page 18 for pin-out information)
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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
connections (Installation Check List filled in)
o All cabling is securely terminated and supported
o All components, terminal blocks, MCBs/ fuses, etc. are clearly labeled
Device
hazard
2. Battery and load fuses are disconnected
o Verify that all battery and load MCBs/ fuses are switched OFF
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:
II
Device
hazard
Startup and No-Load Adjustments
Power is ON!
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.
Also, read about the correct rectifier position, page 14, and how to mount them, on
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
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Quick Start Guide Minipack PS System
356808.103, v1-2006-12
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
PowerSuite— to equal the measured battery voltage.
(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
partially out. Do NOT physically remove them from the power shelf
o Switch ON all battery fuses or MCBs
Device
hazard
Device
hazard
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
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11
Operation
Front Keys and display, menus, etc.
Graphical
Display
Alarm
LED Lamp (red)
16 char. x 2 lines
LCD display
Minipack
rectifier
Warning
LED Lamp (yellow)
Power
”Enter” key
Alarm
LED Lamp (green)
LED Lamp (red)
”Up” arrow key
Power
USB
”Down” arrow key
LED Lamp (green)
0ype B port
Warning
Smartpack control unit
LED Lamp (yellow)
Smartpack Control Unit — front keys, display, etc
Display: is in Status Mode (displays the system’s
status) or in Menu Mode (displays the menu structure).
key to change from
Operation: Press on the
or
Status Mode to Menu Mode. Press the
keys to scroll up or down and navigate to find menu
options (function or parameter). Press then the
key to select the function.
Menus: When you “enter” Menu Mode (Level 1), you
access the User Options. You may also scroll down to
password protected Service Options. Default password
<0003> should be changed.
Minipack Rectifier Module — front panel
Power LED is OFF (mains unavailable), Flashing
(controller accessing information) or ON (powered).
Warning LED is ON (derating or similar minor
warning), Flashing (over-voltage mode) or OFF (OK)
Alarm LED is ON (shutdown or similar major alarm)
or OFF (OK, no alarm)
Software Menus ~ Smartpack controller
Level 3
Level 2
User menu <UserOption>
Service menu <ServiceOption>
AlarmResetÆ
Rectifier Info
Mains Info
Temp Level InfoÆ
Battery Info
VoltAdjustment
Firmware 402073.003 1v00
DisplayMessagesÆ
SoftwareInfoÆ
SerialNumberÆ
NomVolt
BoostVolt
LoBattMaj
LoBattMin
HiBattMaj
HiBattMin
LVBD
LVLD 1.1
Message ↓↑
NoOfRects. nn
RectCurrent
RectSerialNumber
Rect.PrimaryVolt
Rectifier Status
Rectifier Temp
Rect. OutputVolt
Rectifier SW Ver
NoOfPhases nn
Mains Status
Mains Voltage
Level ↓↑
NoOfString Nn
BattStringCurr ↓↑
BattStringTemp ↓↑
BattBlockVolt ↓↑
12
Downloaded from www.Manualslib.com manuals search engine
VoltCalibration Æ
ChangePassword Æ
SetManBoostTime Æ
Start/StopBoost Æ
Auto Boost Conf. Æ
Batt Test Setup
Start/Stop Test Æ
NoOfRects. ; nn Æ
Charge Curr Lim. Æ
Battery Setup
Output Control Æ
Change Date/Time Æ
RelayTest
…
Firmware 402073.003 1v00
VoltageInfo
Level 3
BattLifeTime Rst Æ
NomVolt
BoostVolt
LoBattMaj
LoBattMin
HiBattMaj
HiBattMin
LVBD
LVLD 1.1
VoltCal
Password
↓↑
↓↑
↓↑
↓↑
↓↑
↓↑
↓↑
↓↑
↓↑
↓↑
↓↑
Enable/Disable ↓↑ & Threshold
Nxt Test DateTime Date ↓↑ Time
End Volt
↓↑
MaxTestDur ↓↑
Test Int
↓↑
Guard Time ↓↑
Reset
Enable/Disable ↓↑ & Max
NumOfString
↓↑
CellCap Ah nn ↓↑
VoltageCtrl / TempComp ↓
Date ↓↑ Time ↓↑
Alarm Output 1
↑
Alarm Output 2
↑
Batt Contactor
↑
Load Contactor
↑
Alarm Output nn
↑
Quick Start Guide Minipack PS System
356808.103, v1-2006-12
…
Level 2
PULLOUT
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
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Form 174-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29
EMC
regard
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INSTALLATION CHECK LIST
System Data
Minipack PS System
Minipack Power Supply System, type:
Article No.:
Site, name:
Battery Type:
AC Input Voltage, measured:
Software, version No.:
Serial No.:
Battery Capacity:
Rectifiers, type & number of:
Installation carried out by, name:
Site Preparations
CARRY OUT FOLLOWING:
OK
1. Organize the installation site
o
o
Prepare a 2U high spare location in existing 19”, 250 mm cabinet; Check min. clearance: front access, 60 cm
Ensure the installation site is suitably ventilated and in a non-explosive atmosphere.
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
CARRY OUT FOLLOWING:
o
o
o
o
o
†
OK
Check you have received all the parts and correct documentation.
Inspect the equipment for physical damage (report any damages)
Leave rectifier modules in their packaging or in the selves, if factory installed. (commissioning task)
†
5. Remove the cabinet’s top cover and dummy front panels
Check that cable entry from the top is possible
Connection terminals are accesses by opening the drawer shelf
6. Position and fasten the subassembly
o
o
Subassemblies in existing 19” or in ETSI cabinets, using brackets.
Start (if applicable) on the lower shelf first, and continue upwards
Do not terminate the battery cables yet!
†
8. Open the Minipack drawer shelf and lift the plastic cover
o
o
o
†
†
Power is OFF!
†
4. Remove packaging and check equipment
Device
hazard
o
o
†
†
7. Mount the external batteries on the shelves
Electric
shock
Unlock the upper and lower screws and slide the drawer shelf open, then lift the Melenex plastic cover
Electrical Installation
Power is OFF!
CARRY OUT FOLLOWING:
OK
9. Make the system completely voltage free
Switch OFF or remove all load fuses (MCB1, MCBx), battery fuses (Fb1, Fbx) and external AC supply fuses
10. AC Connections
o
o
o
Check AC configuration: Make available 3 single phase mains feed and earth (PE)
Connect the AC Earth wire (PE) to the terminals AC Earth (PE)
Connect the AC input cable(s) to the terminals. Cable and terminal block labeling are to correspond
11. DC Connections ⎯ Load Circuits
Electric
shock
Terminate DC Earth (TE): Common DC Output Rail is connected to TE at only one place
For each DC load, connect one of the cables to the common DC output terminal; the other to the fuse terminal
†
†
†
†
12. DC Connections ⎯ Alarm & Signal Circuits
o
o
o
Refer to your system’s connection drawings and configuration, or to the Quick Start Guide
Terminate Alarm Circuit cables to the relay output terminals
Terminate Signal Circuit cables to the digital input/output terminals
13. DC Connections ⎯ Battery Cables
o
o
o
o
Careful! Use correct polarity.
For each battery shelf,
Mount 3 intercell links to connect in series 4 battery blocks
Connect battery cables to fuses and Common Battery, and to the shelf’s outer terminals; black (+); blue (-)
Connect battery symmetry cables, if applicable, to the input terminals
Connect the temperature sensor cable, if applicable, to the D-Sub plug or input terminal, and fix the sensor (at the
end of the cable) to a suitable place in the middle of the installed battery bank
†
Approval
Responsible of installation, sign.:
Date:
Eltek Energy AS
Tel. +47 32 20 32 00
Approved by customer, sign.:
Internet: www.eltekenergy.com
E-Mail: [email protected]
Form 175-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29
Downloaded from www.Manualslib.com manuals search engine
CIRCUIT DISTRIBUTION LIST
System Data
Minipack PSS, type:
Article No.:
Site, name:
Fb1
Fb2
Fb3
Fb4
BATT.
NO.
CIRC.
FUSE TYPE
-
LOAD
MCB
LVLD
DESCRIPTION
CONTROLLED
FUSE
AMPERE
CABLE
mm2
F1
F2
F3
F4
F5
F6
F7
F8
F9
F10
Eltek Energy AS
Tel. +47 32 20 32 00
Internet: www.eltekenergy.com
E-Mail: [email protected]
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Form 176-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29
I
COMMISSIONING PROCEDURE
System Data
Supplier’s Order No.:
Minipack PS System
Minipack Power Supply System, type:
Article No.:
Site, name:
Battery Type:
AC Input Voltage, measured:
Software, version No.:
Serial No.:
Battery Capacity:
Rectifiers, type & number of:
Commissioning carried out by, name:
Pre-Start Check
Power is OFF!
CHECK FOLLOWING:
1.
Device
hazard
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OK
Minipack system installation is completed;
The Minipack Installation Check List is filled in.
All cabling is securely terminated with correct polarity
2. All battery and load MCBs/ fuses are disconnected
3. AC input cable(s) and AC earth wire (PE) are terminated
4. Site specific parameters and settings are known
5. AC supply and all MCBs/ fuses are switched OFF
II
Start-up, No-Load & Load Adjustments
†
†
†
†
†
Power is ON!
CARRY OUT FOLLOWING:
OK
1. Disconnect all rectifier modules, without removing them (keep original location)
Device
hazard
2. Switch ON the system (external AC fuses ON)
3. AC input voltage is correct;
Measure and verify
4. Insert all Minipack rectifiers in their original locations in the power shelves
5. The Smartpack and all rectifier modules are working, LEDs are ON;
6. Connect a PC to the PS system
Verify
Install the PowerSuite software, if required
7. DC output voltage;
Measure and adjust
8. Alarm relay test;
Verify all alarm relays are working correctly
9. System Setup is in accordance with configuration
III
Enter site spec. info in PowerSuite
10. Adjust DC output voltage to equal measured battery voltage
Check correct polarity!
11. Unplug all rectifiers but one, and connect all battery fuses/ MCBs
Device
hazard
12. Adjust DC output voltage to equal nominal battery or load voltage
13. Plug in again all rectifiers, and verify the rectifiers’ current sharing
14. Connect all load MCBs/ fuses, and verify no alarms are displayed
†
†
†
†
†
†
†
†
†
†
†
†
†
†
Approval
Responsible of commissioning, sign.:
Date:
Eltek Energy AS
Tel. +47 32 20 32 00
Approved by customer, sign.:
Internet: www.eltekenergy.com
E-Mail: [email protected]
PULLOUT
Downloaded from www.Manualslib.com manuals search engine
Electric
shock
Downloaded from www.Manualslib.com manuals search engine
MAINTENANCE PROCEDURE
System Data
Minipack PS System
Minipack Power Supply System, type:
Article No.:
Site, name:
Battery Type:
AC Input Voltage, measured:
Software, version No.:
Serial No.:
Battery Capacity:
Rectifiers, type & number of:
Maintenance carried out by, name:
WARNING: Maintenance work on live equipment is only to be performed by authorized and
qualified persons using insulated tools. Hazardous voltages inside may cause terminal injury.
System Inspection
Power is ON!
CARRY OUT FOLLOWING:
OK
†
Carefully vacuum clean or remove any accumulation of dust, corrosion or dirt.
†
At least for 12 hours since start-up or mains failure. Enables correct measurements & calibration
†
User manuals and site specific connection & arrangement drawings are available.
1. Site specific parameters and settings are known.
2. The battery bank has been fully charged in advance.
3. The equipment is free from damage, dust or dirt; verify.
†
6. All rectifier’s functionality & Smartpack’s keys and display work OK; verify
†
5. The Smartpack & all rectifier modules are ON, no alarm present; verify.
†
4. All cabling and copper bars are securely terminated and supported.
Correct any loose connections, excessive cable temperature, defective insulation, etc.
Otherwise, correct and put the PS system in normal mode of operation.
Correct possible abnormalities before continuing.
7. Connect the PS system to a PC (install the PowerSuite application if required)
The PowerSuite program in the PC enables system configuration from the PC.
†
Using the keypad on the Smartpack controller or from the PC.
†
Use the PowerSuite PC application to check all rectifiers output the same amount of current (±1A)
8. Rectifiers’ load current sharing; verify.
9. Display the stored log of Alarm Messages.
Form 177-gb-v1-C01_356808-103_qstart-inst-comm-oper_minipack-pss.doc_mfm_2006-12-29
System Adjustment
CARRY OUT FOLLOWING:
OK
1. DC Output Voltage Calibration; ensure correct display readings.
If measured DC output voltage at the load terminals deviates more than ±1% from the display reading, calibrate the
output voltage from the 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.:
Eltek Energy AS
Tel. +47 32 20 32 00
Date:
Approved by customer, sign.:
Internet: www.eltekenergy.com
E-Mail: [email protected]
Check Lists Pullout
Pull out the pages with the gray outer band,
and use them as check lists
PULLOUT
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Miscellaneous
Communication
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
(standard)
CAN bus
(twisted-pair internal CAT5 cable)
1
120Ω
End-of-Line
Resistor
End-of-Line
Resistor
120Ω
Minipack
DC Power System
01
02
n
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
1. Install PowerSuite
Insert CD in your PC drive and follow & accept the wizard default steps to install PowerSuite
2
2. Switch Smartpack ON and plug USB cable (Part 202073)
to Smartpack and to any available USB port in the PC
3
4
New hardware
is ready to use
3. Wait for Windows to detect the Smartpack controller
If required, a wizard will automatically install necessary USB drivers. Follow & accept the wizard default steps
4. Start PowerSuite and establish connection
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’s contact person.
Quick Start Guide Minipack PS System
Downloaded from www.Manualslib.com manuals search engine
356808.103, v1-2006-12
13
Miscellaneous
AC Mains
Minipack
System
Mains Feed 3
Mains Feed 1
Mains Feed 2
Mains Feeds versus Rectifier ID
Distribution of Minipack rectifiers (ID #)
on the 3 AC Mains Input Circuits
Mains Feed 2
One-phase, 230VAC
Mains Feed 1
One-phase, 230VAC
04
02
05
Position 1
03
06
Position 6
ID number
(Assigned CAN
bus address)
AC
Mains
230VAC
01
L(L1)
AC
Mains
230VAC
L(L1)
01
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
pattern that loads the 3 circuits evenly.
02
03
04
Mains Feed 3
One-phase, 230VAC
L(L1)
AC
Mains
230VAC
05
06
N(L2)
N(L2)
N(L2)
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
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Quick Start Guide Minipack PS System
356808.103, v1-2006-12
Miscellaneous
Battery Monitoring
Connections
Each Smartpack controller is equipped with 8 battery symmetry inputs (on connectors
CON4 and CON3), enabling symmetry measurement of:
• 8 battery strings
using the Mid-Point Measurement Method
• 4 battery strings
using the more accurate Double Mid-Point Measurement Method
• 2 battery strings
using the even more accurate Block Measurement Method
You can implement any of these methods using one or two Battery Connection Kits (see
the illustration next page) and the appropriate number of Battery Symmetry Kits, which
contain a single cable strand with suitable cable eyes, etc.
Single Cable Strand
Cable
Eyes
Battery Symmetry
Mid-point Measurement
Battery Symmetry
Block Measurement
One measurement per string
Four measurements per string
(Serial measurement)
-
3
5
7
+
+
Symmetry 4
Set all 4 switches
ON (down)
Symmetry 1
Set all 4
switches
OFF (up)
2-1
X:****
Symmetry 3
Card, Art. 200576
Serial Switches
2-1
X:****
Symmetry 2
Card, Art. 200576
Serial Switches
Symmetry 1
Batt. Symmetry Kit, Art. 200830
Battery Symmetry Connections
+
+
+
− + B+ - + - +
—
(-48V) Outer
Terminal
Block1
−
(From
+
Intercell Links
Two measurements per string, from the
middle to the outer terminals
Symmetry 1
Set all 4
switches ON
(down)
-
Block1
Intercell Links
Block4
+
0V Outer
Terminal
Notice that, if you open the serial switches in card, Art.
200576 ⎯ setting all to OFF (up) ⎯ you have to connect the
+ and – wires of every symmetry input.
Battery Terminology
+
Battery Block, Battery String and Battery Bank
Battery
Block (12V)
+
Battery
String #1
(48V)Batt.
- + - + - + - +
—
(-48V) Outer
Terminal
Block3
3
Symmetry 2
2-1
X:****
Block1
Intercell Links
0V Outer
Terminal
Battery Symmetry
Double-point Measurement
Card, Art. 200576
Serial Switches
- + - + - + - +
—
(-48V) Outer
Terminal
Block3
Block4
+
0V Outer
Terminal
Quick Start Guide Minipack PS System
Downloaded from www.Manualslib.com manuals search engine
48V Battery Bank
356808.103, v1-2006-12
Battery
String #2
(48V)
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.
Using the Battery Connection Kit ⎯ which consists of a Battery
Interface Card (Art. 200576) and a standard 15 pins D-Sub cable
⎯ you can make the signals on CON4 accessible at any suitable
location inside your system, e.g. near the battery blocks.
Battery Connection Kit
15 pins D-Sub cable
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.
Battery Connections (Internal)
Terminals & Pin-out Location
Configurable monitoring digital inputs
FUNCTION
SIGNAL PIN-OUT
CON2
CON5
PCB 200576
CON3A or CON4A
For Temp. Sense Kit
X**/X*
X3/X4
14
To Smartpack,
CON4
1
Serial Switch
1
Battery Interface Card, Art. 200576
15-pins
D-Sub female
1
5
11
15
Temperature
sensor
(Internal Connections)
2
1.5 mm , max.
wire
section
X**/X*
15-pins D-Sub male
15-pins
D-Sub female
Temperature Sense Kit
(From area with
internal batteries)
CON1
CON4
1
Batt. Symmetry 1 +
− 2
3
Batt. Symmetry 2 +
− 4
Batt. Symmetry 3 + 5
− 6
+
Batt. Symmetry 4 − 7
8
+ 9
Temperature
Sense
1
1
11
− 10
11
(NA)
5
15
12
13
(NA)
CON3A or
14
CON4A
Temperature Sense 1
(Alternative use of Temp. Sense Kit,
instead of connecting to X4: 9-10)
Temperature
sensor
Temp. Sensor cable
Battery Connections (Internal)
Temp. sensor
Configurable monitoring digital inputs
FUNCTION
Card Art.200576
SIGNAL PIN-OUT
X3
In
To Smartpack,
CON3
15-pins
D-Sub female
1
5
11
15
(From area with
internal batteries)
The Temperature Sense Kit is connected to
the Battery Interface Card (Art. 200576), or
directly to the controller’s CON3 or CON4,
if unused.
1
Batt. Symmetry 5 +
− 2
3
Batt. Symmetry 6 +
− 4
Batt. Symmetry 7 + 5
− 6
+ 7
Batt. Symmetry 8 −
8
+ 9
Temperature
Sense
2
1
11
− 10
11
Batt Current 2
5
15
12
13
CON3A or Batt Fuse Fail 2
14
CON4A
(From internal
batteries)
For temperature monitoring of the battery
compartment, we recommend the use of the
Temperature Sense Kit, instead of
connecting the sensor cable directly to the
terminals, pin 9-10.
Temperature
sensor
(Internal Connections)
2
1.5 mm , max.
wire
section
X**/X*
15-pins D-Sub male
15-pins
D-Sub female
Temperature Sense 2
(Alternative use of Temp. Sense Kit,
instead of connecting to X3: 9-10)
Temperature
sensor
The Temperature Sense Kits may also be connected directly to the
Smartpack controller’s CON3 or CON4, if these connectors are unused.
16
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Quick Start Guide Minipack PS System
356808.103, v1-2006-12
(From area with
internal batteries)
PCB 200576
X4
In
Smartpack
(From area with
internal batteries)
Card Art.200576
(From internal
batteries)
CON3
Miscellaneous
Alarms & Monitoring
Standard Alarm Relays & Digital Inputs
Connections
Standard Relays & Digital Inputs
NO
Com
NC
Normal Mode
Relay X
(Energized coil)
+
The alarm outputs in Minipack systems use the Fail-Safe
Operation Mode (relay coils energized in the system’s
normal operation mode). When the system is in alarm
mode, the alarm relay coils are de-energized.
—
NO
Com
NC
Minipack PS System
Alarm Mode
+
Relay X
(De-energized coil)
—
Correct Use of Alarm Outputs (example)
Normal Mode
+
Digital Input X
(Normal mode)
Alarm Mode
+
Digital Input X
(Activated)
In order to implement monitored fail-safe digital inputs
circuits, the external relay coil must be energized and the
contact closed in the system’s normal mode of operation.
See the figures.
External Relay Y
(Energized coil)
—
External Relay Y
(De-energized coil)
—
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
Smartpack
10
CON4
CON5
CON1
X1
Alarm Outputs & Digital Inputs
1
Card 218470
Alarm Outputs & Digital Inputs Card
Art. 218470
Voltage free relay outputs and Configurable monitoring digital inputs
In
1
X1
To Smartpack,
CON1
10
Quick Start Guide Minipack PS System
Downloaded from www.Manualslib.com manuals search engine
FUNCTION
Card Art.218470
To CON1
356808.103, v1-2006-12
Out
SIGNAL PIN-OUT
X1
1
2
3
Digital Input 2
4
Relay 1 NO 5
Common Alarm COM 6
NC 7
NO 8
COM 9
NC 10
(Customer Connections)
Digital Input 1
+
−
+
−
Input Circuit 1
Input Circuit 2
Alarm Circuit 1
Alarm Circuit 2
2
1.5 mm , max.
wire section
17
(To and from
external equipment)
Card neck for
cable fastening
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
CON2
20
CON3
CAN1
11
Card neck for
cable fastening
Smartpack
1
10
CON4
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
11
X2B
20
10
X2A
1
Out
Digital Input 3
Digital Input 4
To Smartpack,
CON2
Digital Input 5
18
Downloaded from www.Manualslib.com manuals search engine
Digital Input 6
Relay 3
Fuse Alarm
Load & Battery
SIGNAL PIN-OUT
X2A
1
2
3
4
5
6
7
8
NO 9
COM 10
+
−
+
−
+
−
+
−
X2B
11
12
Relay 4 NO
High Battery Alarm COM 13
NC 14
NO 15
Relay 5
Low Battery Alarm COM 16
NC 17
Relay 6 NO 18
Rectifier Alarm COM 19
NC 20
(Customer Connections)
NC
Input Circuit 3
Input Circuit 4
Input Circuit 5
Input Circuit 6
Alarm Circuit 3
Alarm Circuit 4
Alarm Circuit 5
(From external equipment)
FUNCTION
In
(To external equipment)
Card Art. 218473
To CON2
Alarm Circuit 6
2
1.5 mm , max.
wire section
Quick Start Guide Minipack PS System
356808.103, v1-2006-12
Miscellaneous
Internal Connections
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
5
1
15
11
SIGNAL PIN-OUT
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
CON5
(female; orange)
System
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
reversed pulse voltage is applied to its coil
OFF
ON
+ Pulse
+
- Pulse
Minipack
Main PCB
X:*****
8
9
10
11
Bidirectional
diode
LVD1A
X
Latching
Contactor
LVD1
LVD Common
LVD2A
X
Y
X
Latching
Contactor
Latching Contactor
LVD2
—
Smartpack
controller
Y
Warning! The bidirectional
diode must always be
mounted to avoid damaging the controller.
Y
LVD Common
Minipack PS System (internal)
Correct Use of Latching Contactors (example)
Quick Start Guide Minipack PS System
Downloaded from www.Manualslib.com manuals search engine
356808.103, v1-2006-12
19
20
Downloaded from www.Manualslib.com manuals search engine
Quick Start Guide Minipack PS System
356808.103, v1-2006-12
Mains input
terminals
Customer
connections
8
7
6
5
4
3
2
1
* To be labeled
L1
N
L2
N
L3
N
PE
PE
X5*
+
-
+
-
+
-
L
N
PE
+
-
Power module 4
L
N
PE
Power module 3
L
N
PE
Power module 2
L
N
PE
Power module 1
2
JP2
CAN1
Smartpack
Power -/CAN bus
Interconnections
pin 1-8
X
3
Smartpack Connection
Con5A*
Optional
Y
K1
LVLD
Y2 Power input -
1
Power
output – Y8
3
Y1 Power input +
2
POS. DIST.
NEG. DIST.
Power
output + Y7
JP1
NEG. DIST.
1
POS. DIST.
Y9
Y12
Y18
Y19
Y20
TB1
To Dist
board 2
Y1
Y4
Y3
Y25
Y24
Y7
Y6
1
F10
SERIAL
S1
DIFF
Load circuits -48Vdc
+
+
+
+
+
+
+
-
1
2
3
4
5
6
7
8
9
10
11
12
13
14
*Con 7
Temp sense
Battery Fuse Fail 2
Battery Current 2
Temperature Sense 2
Batt. Symmetry 8
Batt. Symmetry 7
Batt. Symmetry 6
Batt. Symmetry 5
*X3
Battery Connections
Battery Connections
200576
2
3
F8
F9
4
5
6
7
8
9
DC output 10
F7
F6
F5
F4
F3
F2
F1
X6B*
DC Earth (TE)
Con 3A*
Battery Connections
Y2 high
pri load
Y5
Y4
Y3 Fuse
alarm
Y5 low pri load
Y6
15
Customer
connections
215792
Dist.Board 2 MPBB 100A
10pos G1
0V
Y7
System connections
Batt. Fuse Fail + 1
Batt. Fuse Fail - 2
3
LVD 1A
4
LVD Common
SH1
To battery contactor
X7A*
To battery +
1
2
3
4
5
6
7
8
9
10
DC output +
217915
Dist board 1 Minipack System MCB
10 pos load
4 pos batt
X6A*
Customer connections
15
Y
X
LVBD
See Std. Documentation
356804.10x
213333
Underwiring MPBB 6pos 3AC
15
SERIAL
S1
DIFF
Con 4A*
Battery Connections
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Sym.
*Con 6
Temp sense
Not Connected
Not Connected
Temperature Sense 1
Batt. Symmetry 4
Batt. Symmetry 3
Batt. Symmetry 2
Batt. Symmetry 1
+
+
+
+
+
+
+
-
*X4
Battery Connections
Battery Connections
200576
NA for Smartpack RS232 rear
Alteration
15
NA for Smartpack Web/SNMP
Date/Sign
See Std. Documentation
356804.10x
Downloaded from www.Manualslib.com manuals search engine
15
8
8
8
10
8/26
9/15
15
15
CON1
Alarm I/O Connections
+
+
+
Digital Input 5
+
Digital Input 6
NO
COM
2A*
1
2
3
4
5
6
7
8
9
10
NO
COM
NC
NC
NO
COM
NC
NO
COM
NC
11
12
13
14
15
16
17
18
19
20
USB
Consultant
ORSKNO
ORSKNO
Draw
FRNONO
Approved
Scale
9
-
A3
Format
Page
1 of 1
2023227
Draw. No.
-
Replace for
1a
Rev.
Replaced by
Copyright A/S Eltek. All rights reserved
Eltek
Customer
connections
Battery Strings
Circuits -48Vdc
Projection
Block Diagram Minipack 48Vdc
3,2kW
22 Dec. 2006
Design
Optional Web/SNMP (ENET) connection.
Replaces ”Ext. Alarm I/O Connections”
2:
Date
Optional 9 pin D-sub RS232 connection.
Can be mounted in front or on rear side of
Smartpack. Replaces ”Ext. Battery Connections”
when mounted on the rear side of Smartpack
1: Optional: RS232
USB 2.0 type B port
(PC connection)
Front connections
Relay 6
Relay 5
Relay 4
Relay 3
X2B*
Ext. Alarm I/O Connections
Con
Ext. Alarm I/O
Connections
Digital Input 4
Digital Input 3
1:
CAN port
CAN port
1
2
3
4
5
6
7
8
9
10
X2A*
Ext. Alarm I/O Connections
CON3
Ext. Battery connections
1: Optional: RS 232
CON2
Ext. Alarm I/O Connections
2: Optional: Web/SNMP (ENET)
CON4
Battery connections
+
+
NO
COM
NC
NO
COM
NC
Alarm Outputs and
Digital Inputs
218473
Relay 2
Con 1A*
Relay 1
Alarm I/O
Connections
Smartpack
monitoring and
control unit
26
CON5
System Connections
Rear connections
10
Digital Input 2
Digital Input 1
X1*
Alarm I/O Connections
Alarm Outputs and
Digital Inputs
218470
- FBn
- FB1
Customer
connections
Mains input
terminals
Customer
connections
8
7
6
5
4
3
2
1
* To be labeled
L1
N1
L2
N2
L3
N3
PE
PE
X5*
+
-
+
-
+
-
+
-
+
-
L
N
PE
+
-
Power module 6
L
N
PE
Power module 5
L
N
PE
Power module 4
L
N
PE
Power module 3
L
N
PE
Power module 2
L
N
PE
CAN1
Smartpack
Power -/CAN bus
Interconnections
pin 1-8
Power
output – Y8
Power
output + Y7
2
3
1
POS. DIST.
NEG. DIST.
2
JP2
X
3
Con5A*
Smartpack Connection
Optional
Y
K1
LVLD
Y2 Power input -
Y1 Power input +
JP1
NEG. DIST.
1
POS. DIST.
Mains input
connection terminals
Power module 1
TB1
To Dist
board 2
Y1
Y4
Y3
Y24
Y7
Y6
SERIAL
S1
DIFF
Load circuits -48Vdc
+
+
+
+
+
+
+
-
1
2
3
4
5
6
7
8
9
10
11
12
13
14
*Con 7
Temp sense
Battery Fuse Fail 2
Battery Current 2
Temperature Sense 2
Batt. Symmetry 8
Batt. Symmetry 7
Batt. Symmetry 6
Batt. Symmetry 5
*X3
Battery Connections
Battery Connections
200576
1
F8
3
4
5
6
7
8
2
DC output -
F7
F6
F5
F4
F3
F2
F1
X6B*
DC Earth (TE)
Customer
connections
Con 3A*
Battery Connections
Y2 high
pri load
Y5
Y4
Y3 Fuse
alarm
Y5 low pri load
Y6
15
Customer
connections
213336
Dist.Board 2 MPBB 100A
8pos G1
0V
Y7
Y8
System connections
Batt. Fuse Fail + 1
Batt. Fuse Fail - 2
3
LVD 1A
4
LVD Common
SH1
To battery contactor
X7A*
To battery + Y9
2
3
4
5
6
7
8
213335
Dist board 1 Minipack System MCB
8 pos load
2 pos batt
X6A*
DC output
+1
Customer connections
15
Y
X
LVBD
See Std. Documentation
356804.10x
213333
Underwiring MPBB 6pos 3AC
15
SERIAL
S1
DIFF
Con 4A*
Battery Connections
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Sym.
*Con 6
Temp sense
Not Connected
Not Connected
Temperature Sense 1
Batt. Symmetry 4
Batt. Symmetry 3
Batt. Symmetry 2
Batt. Symmetry 1
+
+
+
+
+
+
+
-
*X4
Battery Connections
Battery Connections
200576
NA for Smartpack RS232 rear
Alteration
15
NA for Smartpack Web/SNMP
Date/Sign
See Std. Documentation
356804.10x
Downloaded from www.Manualslib.com manuals search engine
15
8
8
8
10
8/26
9/15
15
15
CON1
Alarm I/O Connections
+
+
+
Digital Input 5
+
Digital Input 6
NO
COM
2A*
1
2
3
4
5
6
7
8
9
10
NO
COM
NC
NC
NO
COM
NC
NO
COM
NC
11
12
13
14
15
16
17
18
19
20
USB
Consultant
ORSKNO
ORSKNO
Draw
HAHANO
Approved
Scale
9
-
A3
Format
Page
1 of 1
2021886
Draw. No.
-
Replace for
1a
Rev.
Replaced by
Copyright A/S Eltek. All rights reserved
Eltek
Customer
connections
Battery Strings
Circuits -48Vdc
Projection
Block Diagram Minipack 48Vdc
4,8kW
Design
31 oct. 2006
Optional Web/SNMP (ENET) connection.
Replaces ”Ext. Alarm I/O Connections”
2:
Date
Optional 9 pin D-sub RS232 connection.
Can be mounted in front or on rear side of
Smartpack. Replaces ”Ext. Battery Connections”
when mounted on the rear side of Smartpack
1: Optional: RS232
USB 2.0 type B port
(PC connection)
Front connections
Relay 6
Relay 5
Relay 4
Relay 3
X2B*
Ext. Alarm I/O Connections
Con
Ext. Alarm I/O
Connections
Digital Input 4
Digital Input 3
1:
CAN port
CAN port
1
2
3
4
5
6
7
8
9
10
X2A*
Ext. Alarm I/O Connections
CON3
Ext. Battery connections
1: Optional: RS 232
CON2
Ext. Alarm I/O Connections
2: Optional: Web/SNMP (ENET)
CON4
Battery connections
+
+
NO
COM
NC
NO
COM
NC
Alarm Outputs and
Digital Inputs
218473
Relay 2
Con 1A*
Relay 1
Alarm I/O
Connections
Smartpack
monitoring and
control unit
26
CON5
System Connections
Rear connections
10
Digital Input 2
Digital Input 1
X1*
Alarm I/O Connections
Alarm Outputs and
Digital Inputs
218470
- FB2
- FB1
Customer
connections
Quick Start Guide Minipack PS System
Downloaded from www.Manualslib.com manuals search engine
356808.103, v1-2006-12
23
This product is CE marked and
complies with all current requirements
for relevant standards and directives.
Head Office
Eltek Energy AS
PO Box 2340 Strømsø; N-3003 Drammen; Norway
Tel:+47 32 20 32 00 — Fax:+47 32 20 32 10
E-mail: [email protected] Internet: www.eltekenergy.com
Downloaded from www.Manualslib.com manuals search engine
Copyright © Eltek Energy AS, Norway 2005
This document may be changed without notice
Art. No. 356808.103, Issue 1, 2006 Dec
Published 2006-12-29