Eltek Smartpack Manuale utente

350003.013

User’s Guide

Monitoring and Control Unit

Flatpack2 DC Power Supply Systems

1 Welcome

2User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

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.

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 5, 2006 Nov

Published 2006-11-25

Mfm

1 Welcome

User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

Table of Contents

Welcome 5

About this Guide .............................................................................................................5

System Diagram ⎯Flatpack2 Power System................................................................5

The Smartpack Controller 6

Key Features...................................................................................................................6

Block Diagram.......................................................................................................6

Typical Applications........................................................................................................7

Location of Connectors & Communication Ports ..............................................7

System & Battery Signals ⎯Internal Connections.........................................................8

Alarm Relay & Digital Input Signals ⎯Customer Connections......................................9

CAN Port Signals ⎯Internal Connections....................................................................10

CAN bus...............................................................................................................10

CAN bus Addressing.....................................................................................................10

Hardware Assignment ⎯Controllers .....................................................................10

Software Assignment ⎯Rectifiers.........................................................................11

CAN bus Termination....................................................................................................11

Firmware Upgrade of the

Smartpack

controller ...............................................12

Module Options...................................................................................................13

Smartpack Controller ⎯Standard................................................................................13

Smartpack Controller ⎯Ethernet.................................................................................13

Smartpack Controller ⎯RS232....................................................................................14

RS232 option Front Access.....................................................................................14

RS232 option Rear Access......................................................................................14

RS232 Port Signals..................................................................................................14

Smartnode Module........................................................................................................15

Installation of Smartpack Controller 16

Safety precautions ..............................................................................................16

Mounting and Removing the Controller............................................................16

Removing Blind Panels.................................................................................................16

Front Panel Operation 17

Description of Keys, Display and Indicators.....................................................17

LED indicators...............................................................................................................17

LCD Display..................................................................................................................17

Front Keys.....................................................................................................................17

Modes of Operation.............................................................................................18

Status Mode..................................................................................................................18

Menu Mode...................................................................................................................18

Operating Menus, Overview...............................................................................18

User Options

UO........................................................................................................19

Service Options

SO...................................................................................................20

Technical Specifications 21

1 Welcome

4User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

Functionality Description 22

Alarm Reset

UO (AlarmReset)...................................................................................22

Display System Voltages

UO (VoltageInfo) ...............................................................22

Display Alarm Messages, (Log)

UO (DisplayMessages)...........................................22

Display Controller’s Firmware Version

UO (SoftwareInfo).........................................23

Display Controllers’ Serial Numbers

UO (SerialNumber)...........................................23

Display Rectifier Information

UO (Rectifier Info)........................................................23

Plug-and-Play Rectifier ...........................................................................................................24

Mains Phase Assignment versus Rectifier ID.........................................................................24

Resetting the Number of Rectifiers.........................................................................................24

Display System Mains Data

UO (Mains Info).............................................................25

Display Battery Temperature Levels

UO (TempLevel Info) .......................................25

Display Battery Information

UO (BatteryInfo).............................................................26

About Battery Banks, Strings and Blocks ...............................................................................26

Battery Symmetry Measurements ⎯48V Systems................................................................27

1 Welcome

User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

1. Welcome

The Smartpack controller is a powerful and cost-effective module, developed for

monitoring and controlling a wide range of Eltek’s DC power supply systems, such as

Powerpack, Flatpack2 and Minipack DC power systems.

About this Guide

This booklet provides users of Smartpack-based 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 generic and site specific documentation that was delivered with your

Smartpack-based 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.

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

equipment. The system is fed from an external AC mains supply, and consists of

rectifiers in power shelves, a control unit and DC distribution unit. Battery banks,

LVD contactors, etc. are typically also a part of the system.

Flatpack

Cabinetize

Batte

y st

ing #1

C mains

supply

selector

Symmetry

Alarm &

Temp. Senso

LVLD

LVBD

Fuse Alarm

AC Fuses,

external

(230VAC or

400VAC

Telecom

equipment

AC Supply

(Single- or

three-

hase

)

larm Outputs NC-C-NO

Digital Inputs

Batte

Fuses

Load Fuses

& MCBs

Smartpack

ctrl. unit

Flatpack

rectifiers

PowerSuite

pplication

CAN Bus

USB cable

distribution

DC Supply

(24V, 48V

or 60V*

)

*Available from 2007

Remote

Monitorin

2 The Smartpack Controller

6User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

2. The Smartpack Controller

The Smartpack controller is a monitoring and control unit used as the vital nerve center

of the 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 locally via a PC using Eltek’s PowerSuite application, or

remotely via modem, Ethernet and the Web. The module then utilizes the USB- or RS-

232 ports to interface with a local PC, SNMP or Web adapters. See also chapter

“Technical Specifications”, on page 21.

Key Features

Front panel LCD and buttons for on-site service without PC.

USB- or RS-232 interface for PC connection locally or remote monitoring

and control via modem, Ethernet, web or SNMP.

Main program upgrade via USB port and the FWLoader application

6 user programmable relay outputs for traditional remote control

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

Figure 2 Block diagram of the Smartpack Battery Extended controller showing the module’s

main functions

Smartpack Controller

Microprocessor

FLASH & EEPROM Memory

256Kb

EEPROM

512Kb

CAN1

Power Bus

The microprocessor is the heart o

the system and represents the

intelligence in Smartpack controller.

The main program and dynamic

data are stored in Flash memory

chips, easily upgraded via the USB

or CAN ports CA

port (2)

for communication with rectifiers and

other controllers on the CAN bus

DIP switches fo

configuring the controller’s

CAN bus ID numbe

24 / 48 / 60VDC Input supply

Power supply

with regulated supply voltages

for internal and external use

(plug-in PCB)

ll customer-specified functions,

calibration and log data are stored in

EEPROM chips

DIP switch

Power supply

Flyback rectifier

Step Down

Reg.+5V

Step Down

Reg. ±12V

CON5

System Connections (internal)

Inputs signals

(measurements)

for system reference(1),

battery current, battery &

load fuse fail (3)

Output signals (control)

for LVD latching relays (2)

CON4

Battery Connections

(internal)

Inputs signals

(measurements) for battery

symmetry (4), temperature

sense (1)

CON1

Alarm I/O Connections (customer)

Inputs signals

(measurements) for con-

figurable digital inputs (2)

Output signals (control)

for Alarm relays (2)

CON3

Battery Connections (internal)

Inputs signals

(measurements) for battery

symmetry (4), temperature

sense (1), battery current

(1), battery fuse fail (1) CON2

Alarm I/O Connections (customer)

Output signals (control)

for Alarm relays (4)

(

Plu

-in PCB

)

(

Plu

-in PCB

)

Inputs signals

(measurements) for con-

figurable digital inputs (4)

USB

Serial Bus

USB 2.0 type B port (1)

serial communication interface with

PCs and computer devices

2 The Smartpack Controller

User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

Typical Applications

The Smartpack controller employs CAN bus communication with the rectifiers in the

Smartpack-based DC power system ⎯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

controller to a PC, plugging a standard USB

A-B cable to the USB port on the front of the

controller and to any available USB port on

the computer.

The Smartpack controller is configured from

factory ⎯via DIP switches on the side ⎯with

an ID number for CAN bus communication.

On the controller’s rear panel ⎯see Figure 4

⎯you find two identical RJ45 CAN ports (for

incoming and outgoing CAT5 twisted-pair

cables) to connect the controller to the CAN

bus. See also chapter “CAN bus”, on page 10.

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

The Smartpack controller’s system cable connections are located on the controller’s rear

panel. These connections are used for monitoring and controlling the system, the

batteries, alarm relays and status of external equipment.

Figure 4 Rear plug connections on a Smartpack Battery Extended controller

USB 2.0 type B port

(PC connection)

DIP switches

(CAN ID number)

larm I/0 Connections

⎯

Extended

D-sub, 26 pins, female (Customer)

CAN port (2)

RJ45, 8 pins connecto

(Internal and customer)

Battery Connections

⎯

Extended

D-sub, 15 pins, male (Internal)

Battery Connections

D-sub, 15 pins, male (Internal)

System Connections

D-sub, 15 pins, female (Internal)

larm I/0 Connections

Mini power connector,

10 pins, male (Customer)

2 The Smartpack Controller

8User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

System & Battery Signals ⎯Internal Connections

In standard Smartpack-based 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 your

system’s specific arrangement drawings.

Figure 5 Overview of internal system and battery connections

System Specific Interface Terminals

−

1015

144

712

139

111

Power Input

Batt. Fuse Fail 1

Load Fuse Fail 1

System Voltage

System Reference

Batt. Current 1

(Internal Connections)

LVD1A

LVD Common

LVD2A

LVD1*

LVD2*

Out

* To latching relays.

15-pins

D-Sub

male

Interface

Cable 5

Notice: the signals available at the

interface terminals may vary. Read

your system’s specific documents.

System

Connections

CON5

15 pins D-Sub (female)

LVD1A +/−1

LVD2A +/−2

LVD Common +/−3

System Voltage + 4

System Voltage −5

*Batt Current 1 + 6

*Batt Current 1 −7

NC 8

Load Fuse Fail 1 + 9

Power Input + 10

Load Fuse Fail 1 −11

*Batt Fuse Fail 1 + 12

*Batt Fuse Fail 1 −13

System Reference 14

Power Input −15

FUNCTION SIGNALPIN-OUT

5 1

15 11

CON5

(female; orange)

Smartpack

controller

15-pins

D-Sub

female

Interface

Cable 4

−

1110

1513

1412

Batt. Symmetry 1

Temp. Sense 1

Batt. Symmetry 3

Batt. Symmetry 2

Batt. Symmetry 4

Internal

Connections)

System Specific Interface Terminals

FUNCTION SIGNALPIN-OUT

CON4

15 pins D-Sub (male)

Batt Sym 1

−

Temp Sense 1 −2

Batt Sym 1 + 3

Temp Sense 1 + 4

Batt Sym 2 −5

Batt Sym 2 + 6

* NC 7

* NC 8

NC 9

Batt Sym 3 −10

Batt Sym 3 + 11

* NC 12

Batt Sym 4 −13

* NC 14

Batt Sym 4 + 15

Battery

Connections

1 5

11 15

CON4

(male; blue)

Smartpack

controller

15-pins

D-Sub

female

Interface

Cable 3

System Specific Interface Terminals

−

1110

1513

1412

Batt. Symmetry 5

Temp. Sense 2

Batt Current 2

Batt Fuse Fail 2

Batt. Symmetry 7

Batt. Symmetry 6

Batt. Symmetry 8

(Internal

Connections)

Ext. Battery

Connections

CON3

15 pins D-Sub (male)

Batt Sym 5

−

Temp Sense 2 −2

Batt Sym 5 + 3

Temp Sense 2 + 4

Batt Sym 6 −5

Batt Sym 6 + 6

Batt Current 2 + 7

Batt Current 2 −8

NC 9

Batt Sym 7 −10

Batt Sym 7 + 11

Batt Fuse Fail 2 −12

Batt Sym 8 −13

Batt Fuse Fail 2 + 14

Batt Sym 8 + 15

FUNCTION SIGNALPIN-OUT

1 5

11 15

CON3

(male; blue)

Smartpack

controller

2 The Smartpack Controller

User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

Alarm Relay & Digital Input Signals ⎯Customer Connections

In standard Smartpack-based 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.

Figure 6 Overview of customer connections

⎯

alarm relay & digital input signals

larm I/O

Connections

CON1

10 pins Connecto

(male)

Config. Input 1A

−

Config. Input 1B + 2

Config. Input 2A −3

Config. Input 2B + 4

Relay Output 1

COM

Relay Output 1

Relay Output 2

COM

Relay Output 2

FUNCTION SIGNALPIN-OUT

Smartpack

controller

CON1

(male; green)

1 9

2 10

Interface

Cable 1

−

810

COM

NCNO

COM

10-pins

plug

female (Customer

Connections)

Input Circuit 1

Input Circuit 2

larm Circuit 1

larm Circuit 2

OutIn

System Specific Interface

Til

System Specific Interface Terminals

Input Circuit 3

larm Circuit 3

Input Circuit 4

Input Circuit 5

Input Circuit 6

larm Circuit 4

m Circuit 5

larm Circuit 6

(Custome

Connections)

Out

26-pins

D-Sub

male

Interface

Cable 2

−

2120

1910

1523

616

247

COM

NCNO

COM

1725

COM

269

COM

Ext. Alarm I/O

Connections

CON2

26 pins D-Sub (female)

Config. Input 5B + 1

Config. Input 5A −2

Config. Input 6B + 3

Config. Input 6A −4

NC 5

Relay Output 3

Relay Output 4

Relay Output 5

Relay Output 6

Config. Input 4A −10

NC 11

NC 12

NC 13

NC 14

Relay Output 3

Relay Output 4

Relay Output 5

Relay Output 6

Config. Input 4B + 19

Config. Input 3A −20

Config. Input 3B + 21

NC 22

Relay Output 3

COM

Relay Output 4

COM

Relay Output 5

COM

Relay Output 6

COM

FUNCTION SIGNALPIN-OUT

19 26

1 9

CON2

(female; green)

Smartpack

controller

2 The Smartpack Controller

10 User’s Guide Smartpack Monitoring & Ctrl Unit,

350003.013, v5-2006-11

CAN Port Signals ⎯Internal Connections

CAN port 1 and 2 are electrically identical, and

are used to enable connection of the CAN bus

incoming and outgoing CAT5 cables.

A special RJ45 plug with built-in 120Ωend-of-

line resistor can be connected to one of the

CAN ports; refer to Figure 8, page 11.

CAN ports’ pin 1&2 may supply the slave

controller with 12VDC, 16W via the CAN bus.

Figur 7 CAN port signals

CAN bus

The Smartpack-based DC power systems utilize the CAN1bus ⎯a digital interface

architecture that supports a dedicated communication channel between the controllers

and each of the rectifiers.

CAN bus Addressing

Eltek’s CAN bus may address a maximum of 60 nodes. Among them, you may connect a

maximum of 8 Smartpack controllers and or 50 rectifiers.

Hardware Assignment ⎯Controllers

The Smartpack controller is factory configured with a

unique CAN bus ID number, using DIP switches on the

side of controller (hardware-assignment). See Figure

3, page 7.

In a distributed DC power system with several

Smartpack controllers, the master is configured with

ID # <1>, the slave with ID # <2> and so on. Refer

to the table in this chapter and Figure 9, page 11.

When a new Smartpack controller is inserted in an existing system, the controller will

recalculate the number of connected rectifiers, reassigning them with the same ID

numbers as they already have in memory. Read “Software Assignment”, page 11.

1Control Area Network. Serial protocol utilised for communication between Eltek’s

rectifiers and controllers

CAN Bus Connections

Smartpack

controller

CAN port 2

RJ45

ins

CAN port 1

RJ45

ins

CAN1 & 2

2x8 pins RJ45 Connectors

+12V

−12V

+5V

CAN1

CANH 4

CANL 5

GND

CAN1

+12V

GND

BC/CS

SIGNAL PIN-OUT

Controller ID

# DIP Switch Position

⎯

Master 1 OFF⎯OFF⎯OFF⎯OFF

Slave 1 2 ON⎯OFF⎯OFF⎯OFF

Slave 2 3 OFF⎯ON⎯OFF⎯OFF

Slave 3 4 ON⎯ON⎯OFF⎯OFF

Note that the controller’s ID # corresponds to

the DIP switch’s binary value plus one.

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