User’s 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 2007

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 2.1, 2005 Sep

Published 2005-09-21

Mfm

2 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 1 Welcome

Table of Contents

1. Welcome 4
About this Guide ............................................................................................................. 4
System Diagram  Flatpack2 Power System ................................................................ 4

2. The Smartpack Controller 5

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. Technical Specifications 15

6. Functionality Description 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

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 3
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 Smartpack’s front panel. The booklet also describes
the Smartpack controller’s 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.
PowerSuite
Alarm Outputs NC-C-NO Application
Digital Inputs

Flatpack2 USB cable

Cabinetized Smartpack
(Ctrl. Unit) Fuse Alarm

Flatpack2
CAN Bus (rectifiers)

LVLD Telecom
equipment
AC mains
supply LVBD
AC Fuses, selector
external Load Fuses
(230VAC or & MCBs
400VAC Symmetry
Alarm & DC
Temp. Sensor distribution

AC Supply DC Supply
(Single- or Battery string #1 Battery (24V, 48V
three-phase) Fuses or 60V)

Figure 1 Example of a typical Flatpack2 PS system for DC supply of telecom equipment

4 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 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.
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 All customer-specified functions,
intelligence in Smartpack controller. calibration and log data are stored in
The main program and dynamic Smartpack Controller EEPROM chips
data are stored in Flash memory
chips, easily upgraded via the USB Microprocessor EEPROM
FLASH & EEPROM Memory CAN port (2)
or CAN ports 256Kb 512Kb for communication with rectifiers and
DIP switches for other controllers on the CAN bus
configuring the controller’s DIP switch
CAN bus ID number CAN1 Power supply
Power Bus with regulated supply voltages
24 / 48 / 60VDC Input supply for internal and external use
Power supply Step Down
(plug-in PCB)
Flyback rectifier Reg. ±12V
Inputs signals Step Down
(measurements) Reg.+5V
Output signals (control)
for system reference(1), for LVD latching relays (2)
battery current, battery &
load fuse fail (3) CON5
System Connections (internal)
Inputs signals USB 2.0 type B port (1)
(measurements) for battery serial communication interface with
symmetry (4), temperature CON4 USB PCs and computer devices
sense (1) Battery Connections Serial Bus
(internal) Output signals (control)
Inputs signals for Alarm relays (2)
(measurements) for con- CON1
figurable digital inputs (2) Alarm I/O Connections (customer)
(Plug-in PCB)
Inputs signals CON3
(measurements) for battery Battery Connections (customer) (Plug-in PCB)
symmetry (4), temperature
sense (1), battery current
(1), battery fuse fail (1)
CON2 Output signals (control)
Inputs signals Alarm I/O Connections (customer)
(measurements) for con- for Alarm relays (4)
figurable digital inputs (4)

Figure 2 Block diagram of the Smartpack controller showing the module’s main functions

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 5
 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

You can easily connect the Smartpack
DIP switches controller to a PC, plugging a standard USB
(CAN ID number) 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 controller’s rear panel see Figure 4

 you find two identical RJ45 CAN ports (for
incoming and outgoing CAT5 twisted-pair
USB 2.0 type B port
(PC connection) cables) to connect the controller to the CAN
bus. See also chapter “CAN bus addressing
and termination”, on page 9.

Figure 3 Front access USB port, and DIP switches for ID configuration on the side.

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

Battery Connections  Extended Alarm I/0 Connections  Extended

D-sub, 15 pins, male (Internal) D-sub, 26 pins, female (Customer)

CAN port (2)

RJ45, 8 pins connector
(Internal and customer)

Battery Connections Alarm I/0 Connections

D-sub, 15 pins, male (Internal) Mini power connector,
System Connections 10 pins, male (Customer)
D-sub, 15 pins, female (Internal)

Figure 4 Rear plug connections on the Smartpack controller

6 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 2 The Smartpack Controller

System & Battery Signals  Internal Connections

In standard Flatpack2 DC power systems, the
controller’s 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 system’s specific arrangement drawings.

System CON5
15 pins D-Sub (female) 10 +

System Specific Interface Terminals

Connections 15 −
Power Input
FUNCTION SIGNAL PIN-OUT
14 System Reference
LVD1A +/− 1 4 + System Voltage
LVD2A +/− 2 Interface 5 −
LVD Common +/− 3 Cable 5 6 + Batt. Current 1
System Voltage + 4 7 −
1 5 System Voltage − 5 12 + Batt. Fuse Fail 1
a
*Batt Current 1 + 6 13 −
b
*Batt Current 1 − 7 9 + Load Fuse Fail 1
11 15 NC 8 11 −
Load Fuse Fail 1 + 9 1 +/− LVD1A
(Orange) LVD1*
Power Input + 10 3 +/− LVD Common
Load Fuse Fail 1 − 11 15-pins 2 +/− LVD2*
c
*Batt Fuse Fail 1 + 12 D-Sub LVD2A
d
*Batt Fuse Fail 1 − 13 male
System Reference 14 (Internal Connections)
Power Input − 15 Notice: the signals available at the
interface terminals may vary. Read In Out
Smartpack controller your system’s specific documents. * To latching relays.

Battery CON4
Connections 15 pins D-Sub (male)
FUNCTION SIGNAL PIN-OUT 3 + Batt. Symmetry 1

System Specific Interface Terminals

Batt Sym 1 − 1 1 −
Temp Sense 1 − 2 6 + Batt. Symmetry 2
Batt Sym 1 + 3 5 −
Interface 11 +
1 5 Temp Sense 1 + 4 Cable 4 Batt. Symmetry 3
Batt Sym 2 − 5 10 −
Batt Sym 2 + 6 15 + Batt. Symmetry 4
a
* NC 7 13 −
11 15 b 4 + Temp. Sense 1
* NC 8
(Blue) NC 9 2 −
Batt Sym 3 − 10 15-pins 7 a b
8 NC *, *
Batt Sym 3 + 11 D-Sub
d
* NC 12 female 14 c d
Batt Sym 4 − 13 12 NC *, *
c
Smartpack * NC 14 Internal
controller Batt Sym 4 + 15 Notice: the signals Connections)
available at the interface
Ext. Battery CON3 terminals may vary. In
Connections Read your system’s
15 pins D-Sub (male) specific documents.
FUNCTION SIGNAL PIN-OUT 3 +
System Specific Interface Terminals

Batt. Symmetry 5
Batt Sym 5 − 1 1 −
Temp Sense 2 − 2 6 + Batt. Symmetry 6
Batt Sym 5 + 3 5 −
Temp Sense 2 + 4 Interface 11 + Batt. Symmetry 7
1 5 Batt Sym 6 − 5 Cable 3 10 −
Batt Sym 6 + 6 15 + Batt. Symmetry 8
Batt Current 2 + 7 13 −
11 15 Batt Current 2 − 8 4 + Temp. Sense 2
NC 9 2 −
(Blue) Batt Sym 7 − 10 7 + Batt Current 2
Batt Sym 7 + 11 15-pins 8 −
Batt Fuse Fail 2 − 12 D-Sub 14 + Batt Fuse Fail 2
Batt Sym 8 − 13 female 12 −
Batt Fuse Fail 2 + 14
Batt Sym 8 + 15 (Internal
Smartpack controller Connections)
In
Figure 5 Overview of internal system and battery connections

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 7
2 The Smartpack Controller

Alarm Relay & Digital Input Signals  Customer Connections

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

Alarm I/O CON1

Connections 10 pins Connector (male) 2 + Input Circuit 1

System Specific Interface

FUNCTION SIGNAL PIN-OUT 1 −
Interface 4 + Input Circuit 2
Config. Input 1A − 1 Cable 1 3 −
Config. Input 1B + 2 6 NO

i l
1 9 Config. Input 2A − 3 5 COM
Config. Input 2B + 4 Alarm Circuit 1
7 NC
Relay Output 1 COM 5 9 NO

T
Relay Output 1 NO 6 10-pins 8 COM
2 10 plug Alarm Circuit 2
Relay Output 1 NC 7 10 NC
(Green) Relay Output 2 COM 8 female
Relay Output 2 NO 9 (Customer
Relay Output 2 NC 10
Connections)
Smartpack controller
In Out
Notice: the signals available at the
Ext. Alarm I/O CON2 interface terminals may vary. Read
Connections 26 pins your system’s specific documents.
FUNCTION SIGNAL PIN-OUT

Config. Input 5B + 1 21 +
Config. Input 5A − 2 Input Circuit 3
20 −
Config. Input 6B + 3 19 +
Config. Input 6A − 4 Input Circuit 4
System Specific Interface Terminals

NC 5 10 −
1 + Input Circuit 5
Relay Output 3 NC 6
Relay Output 4 NC 7 2 −
19 26 3 + Input Circuit 6
Relay Output 5 NC 8 Interface
Relay Output 6 9 4 −
NC Cable 2 15 NO
Config. Input 4A − 10
1 9 NC 11 23 COM
Alarm Circuit 3
(Green) NC 12 6 NC
16 NO
NC 13 COM
NC 14 24 Alarm Circuit 4
Relay Output 3 NO 15 26-pins 7 NC
Relay Output 4 NO 16 D-Sub 17 NO
male 25 COM
Relay Output 5 NO 17 Alarm Circuit 5
Relay Output 6 NO 18 8 NC
18 NO
Config. Input 4B + 19 COM
Config. Input 3A − 20 26 Alarm Circuit 6
Config. Input 3B + 21 9 NC
NC 22 (Customer
Relay Output 3 COM 23 Connections)
Relay Output 4 COM 24
Relay Output 5 COM 25 In Out
Relay Output 6 COM 26
Smartpack controller

Figure 6 Overview of customer connections  alarm relay & digital input signals

8 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 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 automatically assigns the rectifiers with the next available ID
number (software-assignment), and automatically increases the number of
communicating rectifiers on the CAN bus.

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 120Ω resistors at both ends of the line, see Figure 7.

USB A-B cable CAN bus

(standard) (twisted-pair internal CAT5 cable)
1
120Ω
End-of-Line End-of-Line
Resistor Resistor
120Ω
Smartpack assigns ID numbers to the recti-
01 02 n fiers (software-assigned). The Smartpack’s
Flatpack2 ID numbers are assigned by DIP switches
DC Power System on the controller’s side.

Figure 7 CAN bus terminated with a 120Ω resistor on both line ends (60Ω bus impedance)

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

End-of-Line
Resistor 1 2 120Ω

120Ω
01 02 n n+1 n+2 m
Flatpack2 Flatpack2
DC Power System 1 DC Power System 2 End-of-Line
Resistor

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

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 9
 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

Device
plugged to the controller’s rear panel. Open the handles before inserting the
hazard controller into the power shelf.
Mount blind panels in unused module locations.
Electric
shock

Hole to release the

Smartpack handle’s spring Mounting the Smartpack controller
controller mechanism 1. Open the handles
(insert 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
Handle in locked position (push the handles up into their housings (locked
position), so that the module is securely locked)

Removing the Smartpack controller

1. Open the handles
(insert a screwdriver into the holes to release the
spring mechanism)
2. Remove the module
Handle in (use both handles to pull the module loose gently;
unlocked position support from underneath; cables are connected to the
rear panel)

Figure 9 Smartpack controller’s locking mechanism

10 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 4 Front Panel Operation

4. Front Panel Operation

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

Description of Keys, Display and Indicators

The Smartpack controller’s 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 Alarm

16 character x 2 lines LCD display LED Lamp (red)
Upper line Warning
Output voltage or LED Lamp (yellow)
menu options
Power
Lower line LED Lamp (green)
Battery or load current,
alarms, or keys to press

”Down” arrow key

”Enter” key
”Up” arrow key

Figure 10 Smartpack controller’s 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 system’s user interface. The
display is in Status Mode (displays the system’s status) or in Menu Mode (displays the
menu structure).
Depending on the display’s 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 controller’s front keys.
o Press on the key to change from Status Mode to Menu Mode.
o Press the or keys to scroll up or down and navigate to find menu options
(function or parameter).
o Press then the key to select the function.

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 11
4 Front Panel Operation

Modes of Operation
The controller’s 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 controller’s 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 system’s 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 Level 1

menu structures: the User Options menus and the
Service Options menus (password protected, only Display in Status Mode
authorised personnel have access to them).
UserOption
Special, not so frequently used options — such as ServiceOption
calibration and adjustments — are accessible in the
Service Options sub-menus.

12 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 4 Front Panel Operation

User Options
1
When you “enter” Menu Mode, you access the User Options.

How to browse the display menus Level 2 Level 3

User menu <UserOption>
o Entering Menu Mode AlarmReset
Press on the key to change from NomVolt
Status Mode to Menu Mode BoostVolt
LowBatt1
o Browsing “down” to a menu option VoltageInfo LowBatt2
Press the key, to scroll down within HighBatt1
the same menu level, and find menu HighBatt2
LVD 1
options (functions or parameters)
LVD 2
o Selecting a menu option DisplayMessages Message ↓↑
Press on the key to select the SoftwareInfo
NoOfRects. Nn
displayed menu option or parameter RectCurrent V1
V1
Rectifier Info RectSerialNumber
V1
o Browsing “up” to a menu option Rect.PrimaryVolt
V1
or level Rectifier Status
V1
Rectifier Temp
Press the key to scroll up to the
previous menu option, and out to the NoOfPhases nn
Mains Info Mains Status
previous menu level. Mains Voltage
V1
Temp Level Info Level ↓↑

1
The “Vx” references, if any, on the right hand of the option, are not shown in the
display. They only indicate in which software version (x) the option was first implement.

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 13
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. 2

The Service Option’s password is factory-programmed to <0003>. We strongly

recommend that this password is changed as soon as the system is installed

How to browse the display menus Level 2 Level 3

Service menu <ServiceOption>
o Entering Menu Mode NomVolt ↓↑
Press on the key to change from BoostVolt ↓↑
LowBatt1 ↓↑
Status Mode to Menu Mode VoltAdjustment LowBatt2 ↓↑
o Browsing “down” to a menu option HighBatt1 ↓↑
HighBatt2 ↓↑
Press the key, to scroll down within LVD 1 ↓↑
LVD 2 ↓↑
the same menu level, and find menu VoltCalibration VoltCal ↓↑
options (functions or parameters) ChangePassword Password ↓↑
SetBoostTime ↓↑
o Selecting a menu option Start/StopBoost
Auto Boost Conf. Enable/Disable & AutoBThrs ↓↑
Press on the key to select the Nxt Test DateTime
displayed menu option or parameter End Volt ↓↑
Batt Test Setup MaxTestDur ↓↑
Test int ↓↑
o Browsing “up” to a menu option Guard time ↓↑
Start/Stop Test
or level Charge Curr Lim. Enable/Disable & Max C.Curr ↓↑
Press the key to scroll up to the Battery Setup NumOfString ↓↑
Output Control VoltageCtrl / TempComp
previous menu option, and out to the Change Date/Time
previous menu level. Alarm Output 1
RelayTest Alarm Output 2
Batt Contactor
Load Contactor
Alarm Output nn
BattLifeTime Rst V1

2
The “Vx” references, if any, on the right hand of the option, are not shown in the
display. They only indicate in which software version (x) the option was first implement.

14 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 5 Technical Specifications

5. Technical Specifications

Remote Monitoring / Control Local 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).
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.

Using alarm relays (voltage free contacts)

6 internal failsafe alarm relays provide voltage free
contacts that can be connected to equipment used Available Alarms
for traditional alarm monitoring. All alarms can be set up with monitoring of
minor, major, average and peak levels.

System
Mains Failure (individual phases)
Digital Inputs (programmable names)
Features Load Disconnect (voltage or timer)
System Load Fuse
Output Voltage Measurement Load Current
Total Load Current Measurement
Load/Battery Disconnect Battery
Alarm Level Settings (major / minor) High Battery voltage
Low Battery voltage
Alarm Log (up to 1000 events)
High Battery temperature
Real Time Clock with Battery Backup
Low Battery temperature
Site Text/ID Battery Capacity
Test of Relay Outputs Battery Disconnect
Voltage Level setup Battery Fuse
Symmetry Failure
Battery Battery quality indication
Battery Current Measurement Battery discharge current
Battery Temperature Measurement (optional)
Rectifier
Battery Testing (acc. to discharge table or set time
Rectifier Failure
limit)
Critical Rectifier Failure (> 1, programmable)
Battery Test Information (10 latest tests) Rectifier Capacity w. programmable level
Setup of Battery Data Rectifier Current Limit
Battery shunt setup Rectifier Over voltage Protection
Battery quality indication Rectifier Current
Battery Boost Charging
Battery Cable Voltage Drop Compensation
Temperature Compensated Charging
Protection against Temperature Probe Failure

Rectifier Specifications
Available information about each rectifier, e.g. serial
Input Voltage 24/48/60 VDC
number, version, internal temperature
Individual Rectifier Current Measurement Dimensions 109 x 44 (1U) x 140mm (wxhxd)
Individual Rectifier Input Voltage (4.3 x 1.7 x 5.5”)

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 15
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 controller’s 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 controller’s front keys.

Following voltages may be displayed selecting the VoltageInfo sub options (level 3):

Option Description
NomVolt Nominal output voltage
BoostVolt Battery boost-charging voltage
LowBatt1 Voltage limit for Low Battery Alarm 1
LowBatt2 Voltage limit for Low Battery Alarm 2
HighBatt1 Voltage limit for High Battery Alarm 1
HighBatt2 Voltage limit for High Battery Alarm 2
LVD 1 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 controller’s front keys.

The Smartpack controller’s 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 controller’s front keys.

Following information may be displayed selecting the Rectifier Info sub options (level 3):

Option Description
NoOfRects. Number of rectifiers installed in the system.
RectCurrent Rectifier current
RectSerialNumber Rectifier ID and serial number
Rect.PrimaryVolt Rectifier input voltage
Rectifier Status Rectifier status
Rectifier Temp Rectifier temperature

While the controller is accessing information from a specific rectifier, the green LED on
the rectifier’s 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 The Smartpack controller’s status
o Current Limit Reference
o Measured Output Voltage
o Reference Output Voltage
o Over-voltage Protection Reference
o 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 rectifier’s 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 system’s quick start guide and specific
documentation for more information.

Do not relocate already hot-plugged rectifiers.

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 17
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 3 or 2AC
Power Shelves 4 . Refer to your system’s 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)
ID “04”
Rectifier ID 01 Rectifier ID 02 Rectifier ID 03 Rectifier ID 04 SNo.: 04
Serial No. 01 Serial No. 02 Serial No. 03 Serial No. 04 04
Rectifier ID 05 Rectifier ID 06 Rectifier ID 07 Rectifier ID 08 01 02 03 Flatpack2
Serial No. 05 Serial No. 06 Serial No. 07 Serial No. 08 07 08 rectifier
05 06
Rectifier ID 09 Rectifier ID 10
Serial No. 09 Serial No. 10 10
09 ---
---ID “10”
--- --- SNo.: 10

After rectifier reset:

3 power shelves with 9 rectifiers ID “04”
(rectifier ID #10 reassigned to #04) SNo.: 10
Rectifier ID 01 Rectifier ID 02 Rectifier ID 03 Rectifier ID 04 04
Serial No. 01 Serial No. 02 Serial No. 03 Serial No. 10 01 02 03 Flatpack2
07 08 rectifier
Rectifier ID 05 Rectifier ID 06 Rectifier ID 07 Rectifier ID 08 06
Serial No. 05 Serial No. 06 Serial No. 07 Serial No. 08 05
Rectifier ID 09 09 ---
Serial No. 09 ---
--- ---

3
4AC Power Shelves (Single AC feed: 4 AC inputs per shelf, each feeding 1 rectifier).
4
2AC Power Shelves (Dual AC feed: 2 AC inputs per shelf, each feeding 2 rectifiers).

18 User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09
 6 Functionality Description

About Battery Banks, Strings and Blocks

Battery Normally, battery banks are implemented by
Block (12V)
connecting in parallel several battery strings; each
string is formed by battery blocks connected in series.
Battery
String #1
(48V) Figure 11 Example of a 48V battery bank
implemented with two 48V battery strings; each
Battery string consists of four 12V battery blocks
48V Battery Bank String #2
(48V)

Battery Symmetry Measurements

Symmetry measurement is a battery monitoring

Battery Symmetry method for automatically detecting unbalanced battery
Card, Art. 200576
Block Measurement blocks. Symmetry monitoring of a battery string may
Diff. Switches Symmetry cables be performed after three different methods:
4 3 2 1
o Block measurement method
— (-48V)

- + - + - + - +
+ (0V)

Measuring each battery block

o Mid-point measurement method
Set all 4 switches Measuring from the mid-point of the battery
OFF (up)
Four measurement points per string
string to one end
(Diff. measurement) o Double mid-point measurement method
Measuring from the mid-point of the string to
both ends
Battery Symmetry
Mid-point Measurement The mid-point measurement method requires one
Symmetry symmetry cable per battery string; the double mid-
cable 1 point measurement method requires two symmetry
— (-48V)

+ (0V)

- + cables per battery string, while the block measurement

method requires 4 symmetry cables per battery string.

Flatpack2 cabinetized systems are normally delivered

One measurement point per string
with the symmetry measurement method and the
number of measurement points already
preprogrammed in the Smartpack controller. Any
Battery Symmetry deviation from factory settings requires Symmetry
Double Mid-point Measurement
reconfiguration via the PowerSuite PC program.
Symmetry Symmetry
cable 2 cable 1
— (-48V)

Each Smartpack controller is equipped with 8 battery

+ (0V)

- + - +
symmetry inputs, enabling symmetry measurement of:
o 2 battery strings (block meas. method)
o 4 battery strings (double mid-point meas. method)
Two measurement points per string, o 8 battery strings (mid-point meas. method)
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

User’s Guide Smartpack Monitoring & Ctrl Unit, Art. 350003.013, v2.1-2005-09 19
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