User’s Guide

Monit oring and Cont rol Unit

Flat pack2 DC Power Supply Syst em s
350003.013
1 Welcom e

I nform at ion in t his docum ent is subj ect t o change wit hout not ice and does not represent
a com m it m ent on t he part of Elt ek Energy.

No part of t his docum ent m ay be reproduced or t ransm it t ed in any form or by any m eans
— elect ronic or m echanical, including phot ocopying and recording — for any purpose
wit hout t he explicit writ t en perm ission of Elt ek Energy.

Copyr igh t © : Elt e k En e r gy , N or w a y 2 0 0 6

Cert ificat e no: 900005Q

Cert ificat e no: 900005E

Sa fe t y Pr e ca u t ion s

The equipm ent described in t his m anual m ust only be operat ed by

Elt ek Energy personnel or by persons who have at t ended a suit able
Elt ek Energy t raining course
The equipm ent represent s an energy hazard and failure t o observe t his
could cause t erm inal inj ury and invalidat e our warrant y
There are hazardous volt ages inside t he power syst em . As t he m odules
incorporat e large charged capacit ors, it is dangerous t o work inside t he
syst em even if t he m ains supply is disconnect ed
Product s int o which our com ponent s are incorporat ed have t o com ply wit h a
num ber of requirem ent s. I nst allat ion is t o be in accordance wit h t he
recom m endat ions herein
Please read t he m anual carefully before using t he equipm ent

3 5 0 0 0 3 .0 1 3 I ssue 5 , 2 0 0 6 N ov

Published 2006- 11- 25

Mfm

2 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 1 Welcom e

Ta ble of Con t e n t s

1. Welcome 5

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

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

2. The Smartpack Controller 6

Key Features...................................................................................................................6
Block Diagram .......................................................................................................6
Typical Applications ........................................................................................................ 7

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

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

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

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

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

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

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

CAN bus Termination.................................................................................................... 11
Firmware Upgrade of the Smartpack controller ...............................................12

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

Module Options ...................................................................................................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

3. Installation of Smartpack Controller 16

Safety precautions ..............................................................................................16
Mounting and Removing the Controller ............................................................16
Removing Blind Panels ................................................................................................. 16

4. 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

5. Technical Specifications 21

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 3
1 Welcom e

6. 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

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

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

4 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 1 Welcom e

1. Welcome
The Sm art pack cont roller is a powerful and cost - effect ive m odule, developed for
m onit oring and cont rolling a wide range of Elt ek’s DC power supply syst em s, such as
Powerpack, Flat pack2 and Minipack DC power systems.

About this Guide

This booklet provides users of Sm art pack- based DC power syst em s wit h t he required
inform at ion for operat ing t he syst em using t he Sm art pack’s front panel. The booklet also
describes t he Sm art pack cont roller’s building blocks, ext ernal connect ions and t echnical
specificat ions.

Read also t he generic and sit e specific docum ent at ion t hat was delivered wit h your
Sm art pack- based DC power syst em .

System Diagram ⎯ Flatpack2 Power System

I n t he Flat pack2 PS syst em shown in Figure 1, t he Sm art pack cont roller m onit ors and
cont rols t he whole syst em , and serves as t he local user int erface bet ween you and t he
syst em . The PowerSuit e applicat ion is used for rem ot e operat ion and syst em
configurat ion.

Alarm Outputs NC-C-NO PowerSuite

Digital Inputs Remote Application
Monitoring
Flatpack2
Cabinetized Smartpack USB cable
ctrl. unit Fuse Alarm

Flatpack2
CAN Bus rectifiers
LVLD
Telecom
equipment
AC mains
supply
AC Fuses, selector
external Load Fuses
(230VAC or & MCBs
400VAC Symmetry LVBD
Alarm & DC
Temp. Sensor distribution

AC Supply DC Supply
(Single- or (24V, 48V
three-phase) Battery string #1 Battery or 60V*)
Fuses *Available from 2007

Figure 1 Exam ple of a t ypical Flat pack2 PS syst em for DC power supply of t elecom
equipm ent . The syst em is fed from an ext ernal AC m ains supply, and consist s of
rect ifiers in power shelves, a cont rol unit and DC dist ribut ion unit . Bat t ery banks,
LVD cont act ors, et c. are t ypically also a part of t he syst em .

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 5
 2 The Sm art pack Cont roller

2. The Smartpack Controller

The Sm art pack cont roller is a m onit oring and cont rol unit used as t he vit al nerve cent er
of t he DC power plant . You operat e t he syst em from t he elegant front panel, using t hree
front keys and t he LCD- display. They represent t he m ain int erface bet ween you and t he
syst em .
You can also operat e t he syst em locally via a PC using Elt ek’s PowerSuit e applicat ion, or
rem ot ely via m odem , Et hernet and t he Web. The m odule t hen ut ilizes t he USB- or RS-
232 port s t o int erface wit h a local PC, SNMP or Web adapt ers. See also chapt er
“ Technical Specificat ions” , on page 21.

Key Features
Front panel LCD and but t ons for on- sit e service wit hout PC.
USB- or RS- 232 int erface for PC connect ion locally or rem ot e m onit oring
and cont rol via m odem , Et hernet , web or SNMP.
Main program upgrade via USB port and t he FWLoader applicat ion
6 user program m able relay out put s for t radit ional rem ot e cont rol
6 user program m able input s for m onit oring of ot her equipm ent on sit e
Bat t ery m onit oring and t est ing wit hout sit e at t endance
Tem perat ure com pensat ed charging for increased bat t ery lifet im e
Bat t ery lifet im e indicat ion
Password prot ect ed operat or access levels
Alarm / event log wit h t im e and dat e
Windows- based PC com m unicat ion soft ware

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 (plug-in PCB)
Reg. ±12V
Step Down
Flyback rectifier
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 (internal) (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 t he Sm art pack Bat t ery Ext ended cont roller showing t he m odule’s
m ain funct ions

6 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 2 The Sm art pack Cont roller

Typical Applications
Sm art pack- based DC power syst em ⎯ and ot her bus- connect ed Sm art pack cont rollers in
The Sm art pack cont roller em ploys CAN bus com m unicat ion wit h t he rect ifiers in t he

t he syst em ⎯ t hus enabling flexible expansion of syst em funct ionalit y and num ber of
m easuring point s. Syst em com ponent s can be set up and upgraded t o m eet t he dem and
of any t ailor- m ade power solut ion.

Location of Connectors & Communication Ports

You can easily connect t he Sm art pack
DIP switches cont roller t o a PC, plugging a st andard USB
(CAN ID number) A- B cable t o t he USB port on t he front of t he
cont roller and t o any available USB port on
t he com put er.

fact ory ⎯ via DI P swit ches on t he side ⎯ wit h

The Sm art pack cont roller is configured from

an I D num ber for CAN bus com m unicat ion.

On t he cont roller’s rear panel ⎯see Figure 4

⎯ you find t wo ident ical RJ45 CAN port s ( for
incom ing and out going CAT5 t wist ed- pair
USB 2.0 type B port
(PC connection) cables) t o connect t he cont roller t o t he CAN
bus. See also chapt er “ CAN bus” , on page 10.

Figure 3 Front access USB port , and DI P swit ches for I D configurat ion on t he side.

The Sm art pack cont roller’s syst em cable connect ions are locat ed on t he cont roller’s rear
panel. These connect ions are used for m onit oring and cont rolling t he syst em , t he
bat t eries, alarm relays and st at us of ext ernal equipm ent .

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 connect ions on a Sm art pack Bat t ery Ext ended cont roller

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 7
2 The Sm art pack Cont roller

System & Battery Signals ⎯ Internal Connections

I n st andard Sm art pack- based DC power syst em s, t he
cont roller’s int ernal signals are cabled eit her direct ly t o
t he corresponding m onit oring or m easuring point s, or
t o int ernal t erm inals, as shown in Figure 5. See your
syst em ’s specific arrangem ent drawings.
Smartpack
controller CON5
−
10 +

System Specific Interface Terminals

15 pins D-Sub (female) Power Input
FUNCTION SIGNAL PIN-OUT 15
14 System Reference

−
LVD1A +/− 1 4 + System Voltage
LVD2A +/− 2 Interface 5

−
LVD Common +/− 3 Cable 5 6 + Batt. Current 1
System Voltage −
5 1 System Voltage + 4 7

−
5 12 + Batt. Fuse Fail 1
*Batt Current 1 −
a
*Batt Current 1 + 6 13
b

−
15 11 7 9 + Load Fuse Fail 1
NC 8 11
CON5 Load Fuse Fail 1 + 9 LVD1A
(female; orange) 1 +/−
Load Fuse Fail 1 − 11
Power Input + 10 3 +/− LVD Common LVD1*
15-pins 2 +/− LVD2*

*Batt Fuse Fail 1 − 13

c
*Batt Fuse Fail 1 + 12 D-Sub LVD2A
d male
(Internal Connections)
Power Input − 15
System Reference 14
System Notice: the signals available at the
interface terminals may vary. Read In Out
Connections your system’s specific documents. * To latching relays.

Smartpack
controller
CON4
15 pins D-Sub (male)
FUNCTION SIGNAL PIN-OUT

−
3 +
−

System Specific Interface Terminals

Batt. Symmetry 1

−
Batt Sym 1 1 1

−
Temp Sense 1 2 6 + Batt. Symmetry 2
Batt Sym 1 + 3 5
Interface
−
1 5
−
Temp Sense 1 + 4 11 + Batt. Symmetry 3
Cable 4 10
Batt Sym 2 5

−
Batt Sym 2 + 6 15 + Batt. Symmetry 4
a
11 15 * NC 7 13

−
b 4 +
CON4 * NC 8 Temp. Sense 1

−
(male; 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
NC *, *
Battery Batt Sym 4
c
13 12
Connections * NC 14 Internal
Batt Sym 4 + 15 Connections)
In
Smartpack
controller CON3
15 pins D-Sub (male)
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 Interface 5

−
1 5
−
Temp Sense 2 + 4 Cable 3 11 + Batt. Symmetry 7
Batt Sym 6 5 10

−
Batt Sym 6 + 6 15 + Batt. Symmetry 8

−
11 15 Batt Current 2 + 7 13

−
CON3 Batt Current 2 8 4 + Temp. Sense 2

−
(male; blue) NC 9 2

−
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
Ext. Battery Batt Fuse Fail 2 + 14
(Internal
Connections Batt Sym 8 + 15
Connections)
In
Figure 5 Overview of int ernal syst em and bat t ery connect ions

8 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 2 The Sm art pack Cont roller

Alarm Relay & Digital Input Signals ⎯ Customer Connections

I n st andard Sm art pack- based DC power syst em s, t he cont roller’s cust om er alarm relay
and digit al input signals are cabled t o dedicat ed easy accessible t erm inals, as shown in
Figure 6. See also your syst em ’s specific arrangem ent drawings.

Smartpack
controller CON1

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

System Specific Interface

FUNCTION SIGNAL PIN-OUT 1
Config. Input 1A − −
Interface 4 + Input Circuit 2
1 Cable 1 3
1 9
Config. Input 2A −
Config. Input 1B + 2 6 NO

i l
3 5 COM
Config. Input 2B + 4 Alarm Circuit 1
7 NC
2 10 Relay Output 1 COM 5 NO
9

T
CON1 Relay Output 1 NO 6 10-pins 8 COM
(male; green) Relay Output 1 NC 7 plug Alarm Circuit 2
10 NC
Relay Output 2 COM 8 female
Alarm I/O Relay Output 2 NO 9 (Customer
Connections)
Connections Relay Output 2 NC 10
In Out

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

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

NC 5 10

−
1 + Input Circuit 5
Relay Output 3 NC 6
Relay Output 4 NC 7 2

−
Relay Output 5 8 3 + Input Circuit 6
19 26 NC Interface 4
−
Relay Output 6 NC 9 Cable 2 NO
Config. Input 4A 10 15
23 COM
1 9 NC 11 Alarm Circuit 3
NC 12 6 NC
CON2 16 NO
NC 13
(female; green) NC 14 24 COM
Alarm Circuit 4
Relay Output 3 NO 15 26-pins 7 NC
D-Sub 17 NO
Relay Output 4 NO 16 COM
Relay Output 5 17 male 25
NO 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
Ext. Alarm I/O
Relay Output 6 COM 26
Connections

Figure 6 Overview of cust om er connect ions ⎯ alarm relay & digit al input signals

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 9
2 The Sm art pack Cont roller

CAN Port Signals ⎯ Internal Connections

Smartpack
controller CAN1 & 2 CAN port 1 and 2 are elect rically ident ical, and
2x8 pins RJ45 Connectors are used t o enable connect ion of t he CAN bus
CAN port 2 SIGNAL PIN-OUT
RJ45, 8 pins incom ing and out going CAT5 cables.
−12VCS
+12VCS 1
8 1 2
+5VCAN1 3 A special RJ45 plug wit h built - in 120Ω end- of-
1 8
CANH 4 line resist or can be connect ed t o one of t he
CANL 5
GNDCAN1 6
CAN port s; refer t o Figure 8, page 11.
CAN port 1 +12VCS 7
RJ45, 8 pins GNDBC/CS 8 CAN port s’ pin 1&2 m ay supply t he slave
CAN Bus Connections cont roller wit h 12VDC, 16W via t he CAN bus.

Figur 7 CAN port signals

CAN bus
The Sm art pack- based DC power syst em s ut ilize t he CAN 1 bus ⎯ a digit al int erface
archit ect ure t hat support s a dedicat ed com m unicat ion channel bet ween t he cont rollers
and each of t he rect ifiers.

CAN bus Addressing

Elt ek’s CAN bus m ay address a m axim um of 60 nodes. Am ong t hem , you m ay connect a
m axim um of 8 Sm art pack cont rollers and or 50 rect ifiers.

Hardware Assignment ⎯ Controllers

The Sm art pack cont roller is fact ory configured wit h a
unique CAN bus I D num ber, using DI P swit ches on t he
side of cont roller ( hardware- assignm ent ) . See Figure
1 ⎯2 ⎯3 ⎯4
Cont roller ID DI P Swit ch Posit ion
3, page 7. #

ON ⎯OFF⎯OFF⎯OFF
I n a dist ribut ed DC power syst em wit h several Mast er 1 OFF⎯OFF⎯OFF⎯OFF

OFF⎯ ON ⎯OFF⎯OFF
Slave 1 2
Sm art pack cont rollers, t he m ast er is configured wit h
ON ⎯ ON ⎯OFF⎯OFF
Slave 2 3
I D # < 1> , t he slave wit h I D # < 2> and so on. Refer Slave 3 4
t o t he t able in t his chapt er and Figure 9, page 11. Note that the controller’s ID # corresponds to
the DIP switch’s binary value plus one.
When a new Sm art pack cont roller is insert ed in an exist ing syst em , t he cont roller will
recalculat e t he num ber of connect ed rect ifiers, reassigning t hem wit h t he sam e I D
num bers as t hey already have in m em ory. Read “ Soft ware Assignm ent ” , page 11.

1
Cont rol Area Net work. Serial prot ocol ut ilised for com m unicat ion bet ween Elt ek’s
rect ifiers and cont rollers

10 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 2 The Sm art pack Cont roller

Software Assignment ⎯ Rectifiers

Each rect ifier in t he Sm art pack- based DC power syst em is aut om at ically configured by
t he Sm art pack cont roller wit h a unique CAN bus I D num ber ( soft ware- assignm ent ) .

When t he rect ifiers are hot - plugged in t he power shelves t he first t im e, t he Sm art pack
cont roller dynam ically assigns t he rect ifiers wit h t he next available I D num ber ( soft ware-
assignm ent ) , and aut om at ically increases t he num ber of com m unicat ing rect ifiers on t he
CAN bus. Also, t he cont roller regist ers t he rect ifiers’ I D num bers, or CAN bus address
( 01, 02…) , t oget her wit h t heir serial num bers.

When a previously inst alled rect ifier is hot - plugged in t he power shelf again, it ret ains it s
previous I D and serial num ber, unless reassigned during a Reset Rect ifier com m and.

CAN bus Termination

t erm inat e t he CAN bus wit h t wo 120Ω resist ors at bot h ends of t he line ( 60 Ω bus
To ensure a correct bus com m unicat ion and avoid dat a reflect ion, you m ust always

im pedance) , see Figure 8. The CAN bus is connect ed using CAT5 t wist ed- pair cables.

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 8 CAN bus t erm inat ed wit h a 120Ω resist or on bot h line ends ( 60Ω bus im pedance)

The exam ple in Figure 9 shows a Flat pack2 DC power syst em expanded wit h a slave
cont roller t o im plem ent addit ional digit al input s, relay out put s or sim ilar funct ionalit y.
Slave controller
DIP switch
configuration
Master controller Alarm Outputs Alarm Outputs
DIP switch configuration NC-C-NO NC-C-NO
Digital Inputs Digital Inputs
ID <2>
(Switch #1 ON, the
ID <1> rest OFF)
(All switches OFF)
1 Smartpack controller 2 Smartpack controller
Master Slave 1 120Ω
End-of-Line
End-of-Line Resistor
Resistor
120Ω
01 02 3 4 n n+1 n+2 m
Flatpack2
DC Power System

Figure 9 A Flat pack2 DC power syst em expanded wit h t wo cont rollers

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 11
2 The Sm art pack Cont roller

Firmware Upgrade of the Smartpack controller

You can use t he FWLoader program 2 running on a PC t o upgrade t he Sm art pack
cont roller’s firm ware. To find your cont roller’s firm ware version, refer t o page 23. The
PowerSuit e program has t o be inst alled previously on t he PC. Do following:

1. Conn e ct a PC t o t he Sm a r t pa ck
using a st andard USB cable
2. St a r t t h e FW Loa de r pr ogr a m on t he PC;

On t he FWLoader dialog box:

3. Se le ct “Sm a r t pa ck ”, in Target Select ion
4. Se le ct “1 ”, in Target Address
5. Se le ct “COM x ”
in Com m unicat ion Type. Refer t o t he
PowerSuit e program t o find t he
com m unicat ion port t he PC uses t o 6
3 4
com m unicat e wit h t he cont roller.
6. Click on t he “ Open Source File” but t on and,
Se le ct t h e file “* .m hx ”
t hat cont ains t he firm ware t o upgrade t he
cont roller wit h
7. Click on t he “W r it e t o Ta r ge t ” bu t t on, 5
7
t o load t he firm ware t o t he Sm art pack
cont roller
Figure 10
FWLoader dialog box
While t he firm ware is loaded t o t he Sm art pack cont roller, t he FWLoader program displays
a progress bar, and t he cont roller’s display shows t he current ly program m ed segm ent .

Once t he firm ware has loaded, t he Sm art pack cont roller will aut om at ically rest art .

2
You can get a copy of t he FWLoader progam by cont act ing Elt ek’s Service Dep.

12 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 2 The Sm art pack Cont roller

Module Options
The Sm art pack is a scalable cont roller wit h m odular design. I t can be opt im ized for
different requirem ent s by m eans of plug- in- kit s. Various Sm art pack cont roller opt ions are
available offering rem ot e cont rol m anagem ent via m odem , Web, e- m ail and SNMP.

Smartpack Controller ⎯ Standard

CAN port (2) Battery Connections

Smartpack controller Alarm I/0 Connections

Standard

Front View Rear View

USB port Battery Connections

Alarm I/0 Connections

System Connections
Figure 11 The st andard Sm art pack cont roller. Front and rear connect ions
The Sm art pack cont roller – in st andard opt ion, Art 242100.110 – allows local m onit oring
and cont rol via t he m odule’s front keys, LED lam ps, LCD display and via a PC connect ed
t o t he USB port .
The cont roller’s funct ionalit y can be expanded by connect ing several Sm art pack
cont rollers t o t he CAN bus ( dist ribut ed DC power syst em ) . See Figure 9, page 11.
For m ore det ailed descript ion of connect ors, see Figure 4, page 7.

Smartpack Controller ⎯ Ethernet

Smartpack controller
Ethernet
Ethernet port
RJ45 connector

Other connectors are

compatible with the
Smartpack standard
option
Front View Rear View

Figure 12 The Sm art pack cont roller, Et hernet opt ion. Front and rear connect ions
The Sm art pack cont roller – in Et hernet opt ion, Art 242100.113 – allows rem ot e syst em
m onit oring and cont rol via t he Et hernet port , using TCP/ I P net work prot ocol. Connect a
10/ 100 Base T screened Et hernet cable t o t he Et hernet port .

The Et hernet plug- in- kit incorporat es an em bedded Web adapt er, support ing Web/ HTML
int erface, rem ot e logon by PowerSuit e, SNMP prot ocol ( Get , Set , Traps) and e- m ail alert
via your net work e- m ail server. For descript ion of t he funct ionalit y provided by t he
em bedded t he Web adapt er, read t he WebPower Adapt er m anual, Art . 356943.013.

The Sm art pack’s st andard and Et hernet opt ions offer ot herwise t he sam e funct ionalit y,
except for t he Alarm I / O Connect ions on CON2, which are replaced by t he Et hernet plug-
in- kit .
Thus t he Et hernet m odule opt ion support s fewer I / O connect ions - - four input circuit s
and four relay out put circuit s less. See Figure 6, page 9.

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 13
2 The Sm art pack Cont roller

Smartpack Controller ⎯ RS232

The Sm art pack cont rollers – in RS232 opt ion, Art 242100.111 ( front access) and Art
242100.112 ( rear access) – allow rem ot e syst em m onit oring and cont rol by connect ing
t o t he RS232 port eit her a m odem or Elt ek’s st and- alone WebPower unit ( Et hernet
support ) .

RS232 option Front Access

RS232C port
Smartpack controller RJ45 connector
RS232, front

Other connectors are

compatible with the
Smartpack standard
option

Front View Rear View

Figure 13 The Sm art pack cont roller, RS232 opt ion, front . Front and rear connect ions

The Sm art pack’s st andard and front - access RS232 opt ions offer ot herwise t he sam e
funct ionalit y.

RS232 option Rear Access

RS232C port
RJ45 connector
Smartpack controller
RS232, rear

Other connectors are

compatible with the
Smartpack standard
option

Front View Rear View

Figure 14 The Sm art pack cont roller, RS232 opt ion, rear. Front and rear connect ions

The Sm art pack’s st andard and rear- access RS232 opt ions offer ot herwise t he sam e
funct ionalit y, except for t he Bat t ery Connect ions on CON3, which are replaced by t he
RS232 plug- in- kit .
Thus t he rear- access RS232 m odule opt ion support s fewer bat t ery connect ions – seven
bat t ery m onit oring input circuit s less. See Figure 5, page 8.

RS232 Port Signals

CON3
9 pins D-Sub (female)
(On the controller’s front) The RS232 port s on t he front - access and t he
1 rear- access m odule opt ions are elect rically
RS232C, TxD 2 ident ical.
RS232C, RxD 3
Connect an end of t he RS232 cable t o t he
(Not Used) 4
GND 5 Communication Cable Sm art pack’s RS232 port , and t he ot her end t o
9 pins D-Sub (male)
(Not Used) 6 t he m odem ’s or WebPower’s RS232 port .
RS232C, CTS 7
RS232C, RTS 8 Verify t hat bot h unit s have t he sam e
(Not Used) 9 com m unicat ion param et ers ( Baud rat e, parit y,
et c.)
Figure 15 RS232 port signals

14 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 2 The Sm art pack Cont roller

Smartnode Module
Smartnode RS485 port RS232C port
RJ45 connector
module RJ45 connector

Front View Rear View

CAN port (2)

Figure 16 The Sm art node m odule. Front and rear connect ions
The Sm art node m odule is a soft ware prot ocol t ranslat or. I t can be cust om ized t o enable
t he Sm art pack cont roller t o com m unicat e wit h t hird- part y equipm ent using specific
RS232 and RS485 serial prot ocols.
RS232 cable
(to external equipment)
CAN bus
(twisted-pair CAT5 cable)
RS485 cable
(to external equipment)
Smartpack
Smartnode controller
module

Figure 17 The Sm art pack cont roller com m unicat ing wit h t he Sm art node m odule
The exam ple in Figure 17 shows schem at ics of how t he Sm art pack cont roller can
com m unicat e wit h ext ernal equipm ent wit h specific prot ocols, using t he Sm art node as a
prot ocol t ranslat or.

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 15
 3 I nst allat ion of Sm art pack Cont roller

3. Installation of Smartpack Controller

Safety precautions
Get acquant ied wit h t he sat et y precaut ions on page 2, before inst alling or handling
t he equipm ent .

Mounting and Removing the Controller

The Sm art pack cont roller incorporat es handles t hat serve bot h t o lock t he m odule
int o posit ion and t o pull it out of it s housing.

CAUTI ON : D o n ot h a nd- ca r r y t he cont roller by it s handles. Ca ble s a r e

Device
plu gge d t o t he cont roller’s rear panel. Ope n t h e ha ndle s be for e in se r t ing t he
hazard cont roller int o t he power shelf.
Mount blind pa n e ls in unused m odule locat ions.
Electric
shock

Hole to release the

Smartpack handle’s spring Mount ing t he Sm art pack cont roller
controller mechanism
1. Ope n t h e h a ndle s by
insert ing a screwdriver int o t he holes t o release t he
spring m echanism
2. I n se r t t he m odu le fully int o t he power shelf, aft er
plugging t he cables t o t he rear panel
3. Lock t h e ha n dle s by
Handle in locked position pushing t he handles up int o t heir housings ( locked
posit ion) , so t hat t he m odule is securely locked

Rem oving t he Sm art pack cont roller

1. Ope n t h e h a ndle s by
insert ing a screwdriver int o t he holes t o release t he
spring m echanism
2 . Re m ove t he m odu le by
Handle in using bot h handles t o pull t he m odule loose gent ly;
unlocked position
support from underneat h; unplug t he cables connect ed
t o t he rear panel

Figure 18 Sm art pack cont roller’s locking m echanism

Removing Blind Panels

Release t he panel’s upper left and right corners by insert ing a sm all screwdriver
int o t he panel’s upper left gap, and carefully press down and out t o release t he
locking t abs. Repeat on t he upper right gap. Refer t o t he Flat pack2 syst em ’s quick
st art guide for m ore inform at ion.

16 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 4 Front Panel Operat ion

4. Front Panel Operation

This chapt er describes t he Sm art pack cont roller’s keys and indicat ors, and how t o
operat e t he Sm art pack- based DC power syst em from t he cont roller’s front panel.

Description of Keys, Display and Indicators

The Sm art pack cont roller’s front panel consist s of t wo funct ional areas: t he present at ion
area ( LCD display and LED lam ps) and t he cont rol area ( keys) . For inform at ion about t he
handles and t he USB port , read pages 7 and 16.

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 19 Sm art pack cont roller’s front keys and indicat ors

LED indicators

• “ Power” ( green) indicat es t hat t he power supply is ON or OFF

The Sm art pack cont roller has t he following LED indicat ions:

• Alarm ( red) indicat es an alarm sit uat ion ( m aj or alarm )

• Warning ( yellow) indicat es an abnorm al sit uat ion ( m inor alarm )

LCD Display
The graphic display is an im port ant part of t he power supply syst em ’s user int erface. The
display is in St at us Mode ( displays t he syst em ’s st at us) or in Menu Mode ( displays t he
m enu st ruct ure) .
Depending on t he display’s m ode, t he upper line shows t he out put volt age or m enu
opt ions, while t he lower line displays bat t ery and load current , alarm s, or inform at ion
about which key t o press. See also chapt er “ Modes of Operat ion” , on page 18.

Front Keys
You can cont rol t he whole Sm art pack- based DC power syst em via a net work of soft ware
m enus accessed wit h t he cont roller’s front keys.
o Press on t he key t o change from St at us Mode t o Menu Mode.
o Press t he or keys t o scroll up or down and navigat e t o find m enu opt ions
( funct ion or param et er) .
o Press t hen t he key t o select t he funct ion.

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 17
4 Front Panel Operat ion

Modes of Operation
The cont roller’s display is eit her in St at us Mode or in Menu Mode.

Status Mode
When t he front keys are not in operat ion, t he display is in St at us Mode. The following
inform at ion is t hen scrolled t hrough t he display:

•
•
The upper line cont inuously displays t he bat t ery volt age.
The lower line cont inuously scrolls t he following inform at ion:
o Bat t ery Current
o Load Current
o Act ive alarm s
o Ot her m essages

Menu Mode
When t he front keys are in operat ion, t he cont roller’s display swit ches t o Menu Mode and
t he following inform at ion is scrolled t hrough t he display:

•
•
The upper line shows t he nam e of t he act ive m enu or sub- m enu
The lower line indicat es which key t o press

Not ice t hat if no keys are pressed wit hin 30 seconds, t he display will aut om at ically swit ch
from Menu Mode and t o back t o St at us Mode.

Operating Menus, Overview

The Sm art pack- based DC power syst em ’s funct ionalit y is accessed via a net work of
soft ware m enus and subm enus, enabling you t o configure and cont rol t he whole power
syst em .

The funct ionalit y is divided in t wo different hierarchical Level 1

m enu st ruct ures: t he User Opt ions m enus and t he
Service Opt ions m enus ( password prot ect ed, only Display in Status Mode
aut horised personnel have access t o t hem ) .
UserOption
Special, not so frequent ly used opt ions — such as ServiceOption
calibrat ion and adj ust m ent s — are accessible in t he
Service Opt ions sub- m enus.

18 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 4 Front Panel Operat ion

User Options UO

When you “ ent er” Menu Mode, you access t he User Opt ions.

How t o browse t he display m enus Level 2 Level 3

User menu <UserOption>
o En t e r ing M e n u M ode
AlarmReset
Press on t he key t o change from NomVolt
St at us Mode t o Menu Mode BoostVolt
LoBattMaj
o Br ow sin g “dow n ” t o a m e n u opt ion VoltageInfo LoBattMin
HiBattMaj
Press t he key, t o scroll down wit hin
HiBattMin
t he sam e m enu level, and find m enu LVBD

Message ↓↑
opt ions ( funct ions or param et ers) LVLD 1.1
DisplayMessages
Se le ct in g a m e n u opt ion
Firmware 402073.003 1v00
o SoftwareInfo
Press on t he key t o select t he SerialNumber
NoOfRects. nn
displayed m enu opt ion or param et er RectCurrent
Rectifier Info RectSerialNumber
Rect.PrimaryVolt
o Br ow sin g “u p” t o a m e nu opt ion Rectifier Status
or le ve l Rectifier Temp
Rect. OutputVolt
Press t he key t o scroll up t o t he Rectifier SW Ver
previous m enu opt ion, and out t o t he
NoOfPhases nn
previous m enu level. Mains Info Mains Status

Level ↓↑
Mains Voltage
Temp Level Info

BattStringCurr ↓↑
NoOfString Nn

BattStringTemp ↓↑
BattBlockVolt ↓↑
Battery Info

For descript ion of t he User m enu opt ions, read chapt er “ Funct ionalit y Descript ion” page
22. Also, refer t o t he PowerSuit e online Help syst em .

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 19
 4 Front Panel Operat ion

Service Options SO
When you ent er Menu Mode, you access t he User Opt ions. You m ay t hen scroll down t o
t he password prot ect ed Service Opt ions.

The Service Opt ion’s password is fact ory- program m ed t o < 0003> . We st rongly
recom m end t hat t his password is changed as soon as t he syst em is inst alled

Level 2 Level 3
How t o browse t he display m enus
Service menu <ServiceOption>
↓↑
↓↑
o En t e r ing M e n u M ode NomVolt

↓↑
BoostVolt
Press on t he key t o change from
↓↑
LoBattMaj

↓↑
St at us Mode t o Menu Mode VoltAdjustment LoBattMin

↓↑
HiBattMaj

↓↑
o Br ow sin g “dow n ” t o a m e n u opt ion HiBattMin

↓↑
LVBD
Press t he key, t o scroll down wit hin
↓↑
LVLD 1.1

↓↑
t he sam e m enu level, and find m enu VoltCalibration VoltCal

↓↑
ChangePassword Password
opt ions ( funct ions or param et ers) SetManBoostTime
Firmware 402073.003 1v00

Enable/Disable ↓↑ & Threshold

Start/StopBoost
o Se le ct in g a m e n u opt ion
Nxt Test DateTime Date ↓↑ Time
Auto Boost Conf.

↓↑
Press on t he key t o select t he
MaxTestDur ↓↑
End Volt
displayed m enu opt ion or param et er
↓↑
Batt Test Setup

Guard Time ↓↑
Test Int
o Br ow sin g “u p” t o a m e nu opt ion Start/Stop Test

Enable/Disable ↓↑ & Max

or le ve l NoOfRects. ; nn Reset
Charge Curr Lim.
↓↑
Press t he key t o scroll up t o t he
CellCap Ah nn ↓↑
Battery Setup NumOfString
previous m enu opt ion, and out t o t he
VoltageCtrl / TempComp ↓
Date ↓↑ Time ↓↑
previous m enu level. Output Control

↑
Change Date/Time

↑
Alarm Output 1

↑
RelayTest Alarm Output 2

↑
Batt Contactor

…
↑
Load Contactor
Alarm Output nn
BattLifeTime Rst

For descript ion of t he Service m enu opt ions, refer t o t he PowerSuit e online Help syst em .

20 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 5 Technical Specificat ions

5. Technical Specifications

Re m ot e M on it or in g / Con t r ol Loca l M on it or ing / Con t r ol

Fr om a PC r u n n in g W in dow s- ba se d Fr om a PC r u n n in g W in dow s- ba se d
com m u n ica t ion soft w a r e ( Pow e r Su it e ) com m u n ica t ion soft w a r e ( Pow e r Su it e )
Wit h t he Windows- based com m unicat ion program Windows- based com m . soft w are can also
inst alled on a rem ot e com put er , t he syst em can be com m unicat e wit h t he Sm art pack t hrough an USB
serial or RS- 232 cable.
m onit ored and cont rolled via m odem or Et hernet
net work . LCD a n d t h r e e k e ypa ds for loca l ope r a t ion s.
I f any alarm ( m aj or or m inor ) is act ivat ed, a ( red or
Fr om a n N M S via Et h e r n e t ( SN M P) yellow) LED is lit in t he front panel, t he alar m t ext
Wit h an SNMP agent connect ed t o t he Sm art pack, t he appears in t he LCD and t he corresponding alarm relay
syst em can be m onit ored and cont rolled from a is act ivat ed.
Net work Managem ent Syst em ( NMS) t hrough
I n norm al oper at ion, t he front LCD will display t he
Et hernet on Sim ple Net work Managem ent Prot ocol out put volt age, bat t ery current , load current and
( SNMP) . charge m ode.

Usin g a la r m r e la ys ( volt a ge fr e e con t a ct s)

6 int ernal failsafe alar m relay s provide volt age free Ava ila ble Ala r m s
cont act s t hat can be connect ed t o equipm ent used All a la r m s ca n be se t u p w it h m on it or in g of
for t radit ional alarm m onit or ing. m in or , m a j or , a ve r a ge a n d pe a k le ve ls.

Syst e m
Mains Failure ( individual phases)
Digit al I nput s ( program m able nam es)
Load Disconnect ( volt age or t im er)
Fe a t u r e s
Load Fuse
Syst e m Load Current
Out put Volt age Measurem ent
Tot al Load Cur rent Measurem ent Ba t t e r y
Load/ Bat t ery Disconnect High Bat t ery v olt age
Alarm Level Set t ings ( m aj or / m inor) Low Bat t ery volt age
Alarm Log ( up t o 1000 event s) High Bat t ery t em perat ure
Low Bat t ery t em perat ure
Real Tim e Clock wit h Bat t ery Backup
Bat t ery Capacit y
Sit e Tex t / I D
Bat t ery Disconnect
Test of Relay Out put s Bat t ery Fuse
Volt age Lev el set up Sym m et ry Failure
Bat t ery qualit y indicat ion
Ba t t e r y Bat t ery dischar ge current
Bat t ery Current Measurem ent
Bat t ery Tem perat ure Measurem ent ( opt ional) Re ct ifie r
Bat t ery Test ing ( acc. t o discharge t able or set t im e Rect ifier Failur e
Crit ical Rect ifier Failure ( > 1, program m able)
lim it )
Rect ifier Capacit y w . program m able level
Bat t ery Test I nform at ion ( 10 lat est t est s)
Rect ifier Current Lim it
Set up of Bat t ery Dat a Rect ifier Over volt age Prot ect ion
Bat t ery shunt set up Rect ifier Current
Bat t ery qualit y indicat ion
Bat t ery Boost Charging
Bat t ery Cable Volt age Drop Com pensat ion Spe cifica t ion s
Tem perat ure Com pensat ed Charging I nput Volt age 24/ 48/ 60 VDC
Prot ect ion against Tem perat ure Probe Failur e ( Nom inal syst em volt ages)
Fir m ware The Sm art pack m ain program can
Re ct ifie r be upgraded v ia t he USB por t ,
Available infor m at ion about each rect ifier, e.g. ser ial using a PC running t he FWLoader
num ber, v ersion, int ernal t em perat ur e applicat ion
I ndiv idual Rect ifier Current Measur em ent Dim ensions 109 x 44 ( 1U) x 140m m ( wxhxd)
I ndiv idual Rect ifier I nput Volt age ( 4.3 x 1.7 x 5.5” )

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 21
6 Funct ionalit y Descript ion

6. Functionality Description
I n t his chapt er you can find helpful and m ore det ailed descript ions of expressions,
t echnical t erm s, funct ions, et c. used in Sm art pack- based DC power syst em s.

Alarm Reset UO (AlarmReset)

You can reset all act ive alarm s by select ing “ Use r Opt ion > Ala r m Re se t ” , via t he
Sm art pack cont roller’s front keys. The cont roller will im m ediat ely report alarm condit ions
t hat are st ill act ive.

The Sm art pack- based DC power syst em can be configured wit h aut om at ic or m anual
alarm reset .

When Aut om at ic Alarm Reset is enabled ( default ) ⎯ and t he alarm condit ion no longer
exist s ⎯ t he Sm art pack cont roller will deact ivat e t he alarm lam ps and relays t o indicat e
t hat norm al operat ion is est ablished.

When Manual Alarm Reset is enabled ⎯ and t he alarm condit ion no longer exist s ⎯ t he
operat or m ust reset t he alarm m anually.

Display System Voltages UO (VoltageInfo)

You can display im port ant syst em volt ages by select ing “Use r Opt ion > Volt a ge I n fo”,
via t he Sm art pack cont roller’s front keys.

Following volt ages m ay be displayed select ing t he Volt ageI nfo sub opt ions ( level 3) :

Opt ion D e scr ipt ion

N om V olt Nom inal out put volt age
Boost V olt Bat t ery boost - charging volt age
LoBa t t M a j Volt age lim it for Low Bat t ery Maj or Alarm
LoBa t t M in Volt age lim it for Low Bat t ery Minor Alarm
H iBa t t M a j Volt age lim it for High Bat t ery Maj or Alarm
H iBa t t M in Volt age lim it for High Bat t ery Minor Alarm
LV BD Volt age lim it for Low Volt age Bat t ery Disconnect
LV LD 1 .1 Volt age lim it for Low Volt age Load Disconnect

Display Alarm Messages, (Log) UO (DisplayMessages)

You can browse t hrough t he st ored syst em alarm m essages ( alarm log) by select ing
“Use r Opt ion > D ispla yM e ssa ge s”, via t he Sm art pack cont roller’s front keys.

The Sm art pack cont roller’s alarm log m ay st ore up t o 1000 chronological event s. Each
log ent ry cont ains event t ext , event act ion, t im e and dat e. When t he log is full, t he oldest
value is overwrit t en. The log is st ored in EEPROM.

22 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 6 Funct ionalit y Descript ion

Display Controller’s Firmware Version UO (SoftwareInfo)

You can display t he Sm art pack cont roller’s firm ware 3 and version num bers by select ing
“Use r Opt ion> Soft w a r e I nfo”, via t he Sm art pack cont roller’s front keys.

The firm ware and version num bers are displayed in t he form at < nnnnnn.yys vv.vv> .
The “ nnnnnn.yys” represent s t he firm ware num ber. The “ s” is a code for t he firm ware
language: 1= Norwegian, 2= Swedish, 3= English, 4= Germ an, 5= French, 6= Spanish,
et c.
The “ vv.vv” represent s t he firm ware’s version num ber.

Display Controllers’ Serial Numbers UO (SerialNumber)

You can display t he Sm art pack cont rollers’ serial num bers by select ing
“Use r Opt ion > Se r ia lN u m be r ”, via t he Sm art pack cont roller’s front keys.

The serial num bers are displayed in t he form at < cc: nnnnnnnnnnnn> .

The “ cc: ” represent s t he I D or CAN bus address of t he Sm art pack cont roller wit h serial
num ber “ nnnnnnnnnnnn” . Press t he or keys t o display t he serial num bers of
ot her cont rollers in t he CAN net work.

Display Rectifier Information UO (Rectifier Info)

You can display inform at ion about t he rect ifiers com m unicat ing in t he Sm art pack- based
DC power syst em , by select ing “Use r Opt ion > Re ct ifie r I nfo”, via t he Sm art pack
cont roller’s front keys.

Following inform at ion m ay be displayed select ing t he Rect ifier I nfo sub opt ions ( level 3) :

Opt ion D e scr ipt ion

N oOfRe ct s. N n Num ber of rect ifiers inst alled in t he syst em .
Re ct Cu r r e n t Rect ifier’s current
Re ct Se r ia lN u m be r Rect ifier’s I D and serial num ber
Re ct .Pr im a r yVolt Rect ifier’s input volt age
Re ct ifie r St a t u s Rect ifier’s st at us
Re ct ifie r Te m p Rect ifier’s t em perat ure
Re ct . Ou t pu t Volt Rect ifier’s out put volt age
Re ct ifie r SW Ve r Rect ifier’s firm ware version

While t he cont roller is accessing inform at ion from a specific rect ifier, t he green LED on
t he rect ifier’s front panel flashes.

The Sm art pack cont roller sends out st at us m essages every 200m s t o all t he rect ifiers
connect ed t o t he CAN bus, such as:
o The Sm art pack cont roller’s st at us
o Current Lim it Reference
o Measured Out put Volt age
o Reference Out put Volt age
o Over- volt age Prot ect ion Reference
o Et c.

3
The m ain program ( firm ware) is st ored in flash m em ory chips.

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 23
6 Funct ionalit y Descript ion

Plug-and-Play Rectifier
When a rect ifier is h ot plugge d in a pow e r sh e lf for t h e fir st t im e , t he Sm art pack
cont roller assigns t he next available I D num ber t o t he rect ifier, st art ing wit h “ 01” . This I D
num ber ( or CAN bus address) and t he rect ifier’s serial num ber are st ored in bot h
m odules.

When a pr e viou sly in st a lle d ( h ot plugge d) rect ifier is insert ed in a power shelf, t he
Sm art pack cont roller “ recognises” t he m odule, and assigns t he sam e I D t o rect ifier.
I n ot her words, t he cont roller and t he rect ifier “ rem em ber” t he assigned I D and serial
num bers, even aft er rem oving and reinsert ing t he rect ifier in t he shelf.

To achieve a m ore cont rolled I D assignm ent , you should always insert & hot - plug n e w
rect ifiers in t h e in dica t e d pow e r sh e lf posit ion , on e m odu le a t a t im e , st a r t ing
w it h I D nu m be r 1 , 2, 3 and so on. The sequence is indifferent aft er I D# 6. Read
chapt er “ Mains Phase Assignm ent versus Rect ifier I D” , page 24.

The rect ifiers’ power shelf posit ions vary wit h t he t ype of AC m ains and t he t ype of power
shelves inst alled in your syst em . Refer t o your syst em ’s quick st art guide and specific
docum ent at ion for m ore inform at ion.

D o n ot r e loca t e already pre- inst alled rect ifiers.

Mains Phase Assignment versus Rectifier ID

I n syst em s wit h 3 phase AC feed, t he Sm art pack cont roller can be configured t o report a
warning if one phase fails, and t o report an alarm if t wo phases fail, for exam ple.
The 230V phases of Flat pack2 syst em s’ m ains AC feed are rout ed t o t he rect ifiers’ input s
in a special pat t ern t hat loads t he 3 phases evenly. The rout ing of t he phases is
im plem ent ed via int ernal wiring and t he use of eit her 4 AC Pow e r Sh e lve s 4 or 2 AC
Pow e r She lve s 5 . Refer t o your syst em ’s quick st art guide and specific docum ent at ion
for m ore inform at ion.
To be able t o display correct inform at ion about t he phases, t he Sm art pack cont roller
m ust “ know” which phase is connect ed t o which rect ifier I D num ber.
Flat pack2 DC power syst em s are shipped from fact ory wit h em pt y power shelves. The
rect ifier m odules are shipped in separat e packaging, and you have t o inst all t he m odules
in t h e cor r e ct posit ion in t h e pow e r sh e lve s, wit h respect t o t heir I D num ber ( or CAN
bus address) .
This relat ionship is very im port ant , as t he Sm art pack cont roller always uses rect ifier I D
01, 02 and 03 t o m onit or m ains phase L1, L2 and L3 respect ively. I f t hese rect ifiers
m alfunct ion, rect ifier I D 04, 05 and 06 will aut om at ically t ake over.
For exam ple: accident ally insert ing a rect ifier wit h I D 02 in a power shelf posit ion
int ernally connect ed t o m ains phase L1, will cause t he cont roller t o m onit or L1 “ t hinking“
it m onit ors L2. Then a phase 1 fault will be alarm ed as a phase 2 fault .

Resetting the Number of Rectifiers

When a rect ifier reset is act ivat ed, t he num ber of rect ifiers is recalculat ed, and only t he
num ber of com m unicat ing m odules at t he m om ent will be count ed.
For inst ance: in a Flat pack2 DC power syst em equipped wit h 10 rect ifiers, rect ifier wit h
I D num ber “ 04” m alfunct ions. I f you insert rect ifier I D# 10 in t he posit ion of t he failing
I D# 04, and t hen act ivat e a rect ifier reset , t he Sm art pack cont roller recalculat es t he
num ber of com m unicat ing rect ifiers t o only 9. At t he sam e t im e t he cont roller reassigns
rect ifier wit h I D# 10 t o I D# 04, t hus filling t he gap.

4
4AC Power Shelves ( Single AC feed: 4 AC input s per shelf, each feeding 1 rect ifier) .
5
2AC Power Shelves ( Dual AC feed: 2 AC input s per shelf, each feeding 2 rect ifiers) .

24 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 6 Funct ionalit y Descript ion

Ex a m ple : Fla t pa ck 2 D C pow e r syst e m w it h m a lfu n ct ion in g r e ct ifie r ;

3 power shelves wit h 10 rect ifiers ( rect ifier I D # 04 m alfunct ions)
ID “04”
Rect ifier I D 01 Rect ifier I D 02 Rect ifier I D 03 Rect ifier I D 04 SNo.: 04
Serial No. 01 Serial No. 02 Serial No. 03 Serial No. 04 04
Rect ifier I D 05 Rect ifier I D 06 Rect ifier I D 07 Rect ifier I D 08 01 02 03 Flatpack2
Serial No. 05 Serial No. 06 Serial No. 07 Serial No. 08 07 08 rectifier
05 06
Rect ifier I D 09 Rect ifier I D 10
Serial No. 09 Serial No. 10
09 10 ---
---ID “10”
--- --- SNo.: 10

Aft e r r e ct ifie r r e se t :
3 power shelves wit h 9 rect ifiers ID “04”
( rect ifier I D # 10 reassigned t o # 04) SNo.: 10
Rect ifier I D 01 Rect ifier I D 02 Rect ifier I D 03 Rect ifier I D 04 04
Serial No. 01 Serial No. 02 Serial No. 03 Serial No. 10 01 02 03 Flatpack2
07 08 rectifier
Rect ifier I D 05 Rect ifier I D 06 Rect ifier I D 07 Rect ifier I D 08 06
Serial No. 05 Serial No. 06 Serial No. 07 Serial No. 08 05
Rect ifier I D 09 09 ---
Serial No. 09 ---
--- ---

Display System Mains Data UO (Mains Info)

You can display inform at ion about t he power syst em ’s AC feed by select ing
“Use r Opt ion > M a in s I n fo”, via t he Sm art pack cont roller’s front keys.

Following dat a m ay be displayed select ing t he Mains I nfo sub opt ions ( level 3) :

Opt ion D e scr ipt ion

N oOfPh a se s n n Num ber of Mains phases in t he syst em ’s AC feed
M a in s St a t u s The st at us of each of t he phases
M a in s Volt a ge The AC volt age of each of t he phases

Display Battery Temperature Levels UO (TempLevel Info)

You can display how m any hours t he syst em ’s bat t ery bank has been wit hin a cert ain
t em perat ure range ( level) by select ing “Use r Opt ion > Te m pLe ve l I n fo”, via t he
Sm art pack cont roller’s front keys.

• nn:
The inform at ion is displayed in t he form at [ nn: < ddC hhhhhH] , which m eans:
The num ber of t he t em perat ure range or level ( 01 t hrough 10)
• < ddC The range’s upper t em perat ure value, in degrees Celsius
• hhhhhH The num ber of hours t he bat t ery bank has been wit hin t he
t em perat ure range
Using t he PowerSuit e program , you configure t he Bat t ery Lifet im e Tem perat ure m onit or
t o aut om at ically act ivat e an alarm when t he syst em ’s bat t ery bank has been wit hin a
t em perat ure range ( or level) longer t hat a cert ain period of t im e. For each of t he 10
t em perat ure ranges, you can configure t he upper and lower t em perat ure values, and t he
t im e lim it .

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 25
6 Funct ionalit y Descript ion

The t able shows an exam ple of values ent ered in t he Bat t ery Lifet im e Tem perat ure
m onit or.
Tem perat ure Range Tim e wit hin Range
Range # Low Lim it , °C High Lim it , °C Hours
01 00 10 10
02 11 20 20
03 21 30 60
04 31 40 40
05 41 50 05
06 51 60 00
07 61 65 00
08 66 70 00
09 71 75 00
10 76 99 00

You can reset t he values in t he Bat t ery Lifet im e Tem perat ure m onit or eit her by select ing
“ ServiceOpt ion> Bat t LifeTim e Rst ” , via t he Sm art pack cont roller’s front keys, or using
PowerSuit e.

Display Battery Information UO (BatteryInfo)

You can display inform at ion about t he power syst em ’s bat t ery bank by select ing
“Use r Opt ion > Ba t t e r y I n fo”, via t he Sm art pack cont roller’s front keys.

Following dat a m ay be displayed select ing t he Bat t ery I nfo sub opt ions ( level 3) :

Opt ion D e scr ipt ion

N oOfSt r in g N n Num ber of bat t ery st rings
Ba t t St r in gCu r r Each bat t ery st ring’s current
Ba t t St r ingTe m p Tem perat ure of each bat t ery st ring
Ba t t Block Volt Volt age of each bat t ery block

For bat t ery t erm inology, refer t o chapt er “ About Bat t ery Banks, St rings and Blocks” ,
page 26 and t o t he “ Quick St art Guide Flat pack2 PS Syst em ” , Art . 356804.103.

About Battery Banks, Strings and Blocks

Battery Norm ally, bat t ery banks are im plem ent ed by
Block (12V)
connect ing in parallel several bat t ery st rings; each
st ring is form ed by bat t ery blocks connect ed in series.
Battery
String #1
(48V) Figure 20 Exam ple of a 48V bat t ery bank
im plem ent ed wit h t wo 48V bat t ery st rings; each
Battery st ring consist s of four 12V bat t ery blocks
48V Battery Bank String #2
(48V)

26 User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11
 6 Funct ionalit y Descript ion

Battery Symmetry Measurements ⎯ 48V Systems

Sym m et ry m easurem ent is a bat t ery m onit oring m et hod for aut om at ically det ect ing
unbalanced bat t ery blocks.
For inform at ion about 24V syst em s sym m et ry m easurem ent s, read t he “ Quick St art
Guide Flat pack2 PS Syst em ” Art . 356804.103.

Sym m et ry m onit oring of a 48V bat t ery st ring m ay be

perform ed aft er t hree different m et hods:
Battery Symmetry o Block m e a su r e m e n t m e t hod
Block Measurement Measuring each bat t ery block
Card, Art. 200576
Serial Switches Symmetry
1 2 3 4 o M id- poin t m e a su r e m e n t m e t hod
— (-48V)

- + + + + Measuring from t he m id- point of t he bat t ery

+ (0V)

st ring t o one end

o D ou ble m id- poin t m e a su r e m e n t m e t hod
Set all 4 switches
ON (down) Measuring from t he m id- point of t he st ring t o
Four measurement points per string bot h ends
(Serial measurement)

The m id- point m easurem ent m et hod requires 2

sym m et ry wires per bat t ery st ring; t he double m id-
Battery Symmetry point m easurem ent m et hod requires 3 sym m et ry wires
Card, Art. 200576
Mid-point Measurement per bat t ery st ring, while t he block m easurem ent
Serial Switches Symmetry 1 m et hod requires 5 sym m et ry wires per bat t ery st ring.
— (-48V)

Refer t o t he syst em ’s quick st art guide for connect ions.

+ (0V)

- +
Cabinet ized DC power syst em s are norm ally delivered
Set all 4 switches wit h t he sym m et ry m easurem ent m et hod and t he
OFF (up)
One measurement point per string num ber of m easurem ent point s already
preprogram m ed in t he Sm art pack cont roller. Any
deviat ion from fact ory set t ings requires Sym m et ry
Battery Symmetry reconfigurat ion via t he PowerSuit e PC program .
Double Mid-point Measurement
Card, Art. 200576 Symmetry Symmetry
Serial Switches 1 2 Each Sm art pack cont roller is equipped wit h 8 bat t ery
— (-48V)

sym m et ry input s ( on CON4 and CON3) , enabling

+ (0V)

- + +
sym m et ry m easurem ent of:
o 2 bat t ery st rings ( block m eas. m et hod)
Set all 4 switches o 4 bat t ery st rings ( double m id- point m eas. m et hod)
ON (down) Two measurement points per string, o 8 bat t ery st rings ( m id- point m eas. m et hod)
from the middle to the outer terminals

Figure 21 Exam ple of t erm inal connect ion point s for Sym m et ry Block, Mid- point and
Double Mid- point m easurem ent m et hods in 48V syst em s

User’s Guide Sm art pack Monit oring & Ct rl Unit , 350003.013, v5- 2006- 11 27
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