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356850.103
Introduction
Eltek Power Supply Systems. . . . . . . . . . . . . . . 3
Overview of Elteks Product Family Ranges . . . . . . . . 4
Micropack System Range . . . . . . . . . . . . . . . . . . 4
Minipack System Range. . . . . . . . . . . . . . . . . . . 4
Flatpack2 System Range . . . . . . . . . . . . . . . . . . 5
FlatpackS System Range . . . . . . . . . . . . . . . . . . 5
Keying Scheme ~ Modules and Power Shelves. . . . . . . 6
Micropack Keying Scheme . . . . . . . . . . . . . . . . . 6
Flatpack2 & FlatpackS Keying Scheme . . . . . . . . . . . 7
Communication
CAN Bus Termination. . . . . . . . . . . . . . . . . . . . 8
CAN Bus Cabling. . . . . . . . . . . . . . . . . . . . . . . . 8
CAN Bus Addressing and Configuration. . . . . . . . . . . . 9
Software Assignment Rectifiers. . . . . . . . . . . . . . . . 9
Hardware Assignment Control Units. . . . . . . . . . . . . . 10
Configuration Control Units. . . . . . . . . . . . . . . . . . 10
AC Mains
External AC Fuses Recommended Rating. . . . . . . 11
Recommended External AC Fuses Micropack Systems . . . 11
Recommended External AC Fuses Minipack Systems. . . . 11
Recommended External AC Fuses Flatpack2 Systems. . . 12
Recommended External AC Fuses Flatpack S Systems. . . 13
Mains Reconfiguration Minipack Systems. . . . . . . 14
Mains Reconfiguration ~AC Terminal Block, 4.8kW-6 Pos. . . 14
Mains Reconfiguration ~AC Terminal Block, 3.2kW-4 Pos. . . 14
Mains Reconfiguration Flatpack2 Systems. . . . . . . 15
Identifying Power Shelves: 4AC, 2AC or 4AC-3kW. . . . . . . 15
Mains Reconfiguration ~Integrated System 1U Distr. . . . . . 15
Mains Reconfiguration ~AC Terminal Block. . . . . . . . . . 16
AC Terminal Block with SPDs ~ NOT Reconfigurable . . . . . 17
About AC, DC Earthing Systems . . . . . . . . . . . . . 18
Telecom Equipment . . . . . . . . . . . . . . . . . . . . . . 18
Industrial Equipment . . . . . . . . . . . . . . . . . . . . . . 19
Mains Phases versus Rectifier ID. . . . . . . . . . . . 20
Phase Balancing . . . . . . . . . . . . . . . . . . . . . 20
Plug-and-Play Rectifiers versus Phase Monitoring. . . . . . 20
Correct Rectifier Positions in Power Shelves. . . . . . . . . 21
Correct Rectifier Positions in Flatpack2 Systems . . . . . . . . . 21
Correct Rectifier Positions in Minipack Systems, 2U . . . . . . . . 22
Battery Monitoring
From Smartpack Controller. . . . . . . . . . . . . . . 23
Smartpacks Battery Symmetry Connections, + 24V . . . . . 23
Smartpacks Battery Symmetry Connections, 48V. . . . . 24
From Battery Monitor CAN node. . . . . . . . . . . . . 25
Battery Monitors Symmetry Connections, 48V, Block . . . 25
Battery Monitors Symmetry Connections, 48V, Mid-Point . 26
Alarms & Monitoring I/O Signals
Connecting Standard Alarm Relays & Digital Inputs. . . . . . 27
About LVD Latching Contactors . . . . . . . . . . . . . . 27
From Smartpack Controller. . . . . . . . . . . . . . . 28
Terminals & Pin-out Location, System Interface Card . . . . . 28
Terminals & Pin-out Location, Battery Interface Card . . . . . 29
Terminals & Pin-out Location, Alarm Interface Card. . . . . . 30
Alarm Interface Card - on Flatpack2 Systems. . . . . . . . . . . 30
Alarm Interface Card - on Minipack 2U Systems. . . . . . . . . . 31
Alarm Interface Card Ext. - on Minipack 2U Systems. . . . . . . . 31
General Precautions
G1
!
CAUTION: Even though the product incorporates protection circuitry and other safeguards, it can be damaged, perform poorly or
have a reduced lifetime if it is exposed to incorrect treatment during transport, installation or service. Always handle the equip-
Device ment using proper lifting techniques, do not roll, climb or drill hole in the cabinets or enclosures.
Hazard
G2
WARNING: Opening the equipment may cause terminal injury even if the mains AC supply is disconnected. Hazardous voltages
may be present inside, as large capacitors may still be charged.
Electric
Shock
Environmental Precautions
E1
CAUTION: To avoid damage the equipment, keep objects clear of system ventilation inlets, outlets and system fans, if any, ensur-
sss ing the airflow through the units is not obstructed, and that the fans rotate freely. Use caution with rectifiers, as they can reach
Ventilated extreme temperatures under load and normal operation.
Hot Surface
E2
WARNING: The installer/user is responsible for ensuring that the DC power system is not damaged by current surges, over-
voltages, etc. caused by external transients, lightning, electrostatic discharge, etc. To avoid damage and obtain the expected
Current Surge system reliability, it is mandatory to always install SPDs in Elteks power supply systems. Follow the instructions given in
Protection
Guidelines for Lightning and Surge Protection, doc. 2024623.
E3
WARNING: The electronics in the power supply system are designed for indoor, clean environment. When installed in outdoor en-
closures, it is important to keep the door closed during operation, and replace the filters on a regular basis. Indoor installations
Humidity & Dust in dusty or humid areas require appropriate air filtering of the room, or filtering of the air entering the DC power system. Follow
Protection
the instructions given in Generic Guidelines Environmental Protection., doc. 2038879
!
CAUTION: Read the user documentation carefully before installing and using the equipment, as installation and operation is to
be performed as described in it. Always tighten screws and bolts with the torque values recommended in the documentation. For
Qualified safety reasons, the commissioning and configuration of the equipment is only to be performed by Elteks personnel or by author-
Personnel
ized and qualified persons.
I2
!
CAUTION: This product is tested and verified according to international safety, environmental and EMC standards. Any non-Eltek
equipment installed into this product after delivery might influence the performance and could infringe the original approvals. The
EMC, NEC/CEC installer is responsible for ensuring that the environmental properties of this product/ system do not deteriorate during installa-
Regard
tion, and that it is performed in accordance with applying regulations.
Installations in USA and Canada must comply with NEC/CEC requirements.
I3
!
CAUTION: Before you start the electrical installation, you must always disconnect all external AC supply fuses, as well as internal
battery and load fuses/ breakers, if any.
Device
Hazard
I4
WARNING: For safety reasons (high leakage current / high touch current) you must always connect the AC earth wire (PE) to the
terminals, before you connect the AC input cable(s).
Electric
Shock The batteries, if any, represent a major energy hazard. To avoid short-circuit of battery poles, you must always remove metallic
objects uninsulated tools, rings, watches, etc. from the vicinity of the batteries.
I5
WARNING: 60V DC power systems are only to be installed in Restricted Access Locations (RAL). Access must be limited by use
of tool, i.e. lock and key.
Electric
Shock
356850.103, 1v0_2012-12
Internet
WebPower
(Web-based user interface)
Flatpack S
Power System Ethernet
cable (LAN)
Smartpack S
Controller
CAN bus
Internal System Monitoring
and external I/O signals
LVLD
R1
Telecom &
Industrial
R2 Equipment
LVBD
Load Fuses
(Load)
RX & MCBs
AC Fuses, external
(230VAC or 400VAC Battery DC Distribution
or 85-300VDC) Flatpack S Fuses
HE Rectifiers
OR
Internet
Smartpack2
Master Controller Ethernet cable
WebPower
CAN1 (Web-based
user interface)
Smartpack2 Basic
Flatpack2 Flatpack2 Industrial Controller
Power System HE Rectifiers CAN2 From external supply
Max. 75VDC
R1 Max. 75VDC
DC/DC Industrial
Converter Equipment
R2
OR Battery
To suitable Bank
CAN nodes
AC Input DC Output
(Single- or 3-phase) (220VDC or 110VDC)
or DC Input
356850.103, 1v0_2012-12
Figure 2. Example of a typical Flatpack2 DC power supply system for 220 or 110VDC
industrial equipment
Modules in the
Compack
Control Systems
Integrated
Systems
Integrated
Systems
Integrated
Systems
Integrated
Systems
Cabinetized Indoor
and Outdoor Systems
Integrated
Systems
Modules in the
SmartpackS
Control Systems
356850.103, 1v0_2012-12
A B
Micropack
Micropack
power core, 4-pos
module 3
4
C D
When a module and a power core have a key inserted in Module* Power Core
the same corresponding position, the module will not A 1
plug into the power cores socket. B 2
power core.
356850.103, 1v0_2012-12
241120.902) and for 12V DC/DC converter systems (Parts: 241120.905 and
241120.907) have the plugs slightly displaced, to avoid mixing rectifiers and
converters.
Shelfs chassis
Modules Key
Shelfs Key
Modules chassis
12xCircuit Breakers
B-Frame
Flatpack2 Flatpack2
module power shelve
Figure 10. Keying scheme for modules and power shelves (keys are black)
When a module and a power shelf have a key inserted in the same position, the
module will not plug into the shelf.
A slot with inserted key may be indicated with 1, and an empty slot with 0.
For example, a power shelf suitable for 24V Flatpack2 solar chargers will be shipped
from factory keyed as <110 001>. Then, only modules keyed as <001 110> can be
plugged into the shelf, e. g. the Flatpack2 24/1500 HE Solar Chargers.
In general, Flatpack2 modules and power shelves for industrial applications are al-
ways keyed at factory. When required, Eltek will also ship keyed Flatpack2 modules
and power shelves for telecom applications.
FlatpackS modules and power shelves are always keyed from factory.
NOTICE:
A keyed power shelf will ONLY allow modules keyed for the specific shelf to be plugged in the shelf.
A non-keyed power shelf will allow both keyed and non-keyed modules to be plugged in the shelf.
WARNING:
Never install modules in power shelves with different output voltage than the modules. The modules output volt- !
age and the power systems output voltage must always be the same. Device
Hazard
356850.103, 1v0_2012-12
CAN bus
Internal System Monitoring
and external I/O signals
01 02 n
cable
120
End-of-Line
AC Mains Monitor Battery Monitor I/O Monitor Load Monitor Resistor (CAN2)
97 33 81 49
ID number CAN1 Shunts Current
Monitoring
Config Inputs Temp, Fan Speed Sense Inputs
Mon & Ctrl
AC Voltage & Current
Sense Inputs Alarm Outputs Fuses
Battery string #1 Fuse
NC-C-NO
Monitoring
Config. Inputs Config. Inputs
Figure 11. Example of CAN bus addressing and termination in a Flatpack2 power sys-
tem using the Smartpack2 Basic Industrial controller
Smartpack2-based DC power systems implemented with the Smartpack2 Basic
Industrial controller have more than one CAN bus, as this industrial controller has
two separated buses: CAN1 and CAN2.
All the CAN buses in the system are to be terminated with two 120 resistors.
Usually, the systems are engineered using CAN1 bus for communication among
controllers and CAN nodes, and CAN2 bus to communicate with rectifiers and
DC/DC converters.
All rectifiers, controllers and other control units connected to the Elteks CAN bus
must have a unique address or ID number.
The control systems master controller assigns automatically the rectifiers ad-
dresses (software assignment).
The power systems control units make use of DIP switches for configuring their
unique CAN bus ID number (hardware assignment). The only exception is the Com-
pack and Smartpack2 Master controllers, which have factory assigned specific ID
numbers <1>and <11> (not changeable).
When a new system 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.
356850.103, 1v0_2012-12
1 Control Area Network. A digital interface architecture that supports a dedicated serial communication
channel utilised for communication between Elteks rectifiers, controllers and control units
*** 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 ID#
Mains Monitor CAN nodes 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 ID#
Table 1. ID numbers formatted in red italics are not available due to software constraints.
** SP= Smartpack; SP2B= Smartpack2 Basic; SP2BI= Smartpack2 Basic Industrial; SP S= Smartpack S
*** Only 4 of the 8 mounted DIP switches may be used (max. 14 Load Monitors may be connected)
The tables below show examples of the DIP switch position on Battery Monitor
CAN nodes, Table 3, and in **controllers, Table 2.
12 Node
th
44 ON ON OFFON
13th Node 45 OFFOFFON ON
Table 2. Controllers DIP switch addressing
14 Node
th
46 ON OFF ON ON
Note: The Monitors ID# corresponds to the DIP switchs binary value plus 33
Table 3. Battery Monitors DIP switch addressing
or its web interface. Read the WebPower or PowerSuite Online Help for a description
of how to configure and calibrate the CAN Bus Nodes.
For more information regarding External AC IT net () 3 phase 4 15.2 16.8 16A-C 20A-C Th/Mag
fuses and other types of fuses, please read 230VAC 6 15.2 16.8 16A-C 20A-C
the document 2024398
1 phase 4 17.5 19.4 20A-C Th/Mag
230VAC 6 26.3 29.5 32A-C
(Doc 2024398, 1v0)
Notes:
- Use the values in the 150VAC column,
if you are unsure or know that the available AC mains voltage may drop between 230VAC and 150VAC,
or
use the values in the 100VAC column, if the voltage may drop below 150VAC
.
- Each phase feeds two two 800W WIR rectifiers (Wide Input Range)
For more information regarding External AC fuses and other types of fuses, please read the document 2043538.
356850.103, 1v0_2012-12
Notes:
- Use the values in the 185VAC column, if you are unsure or know that the available AC mains voltage may drop below 205VAC.
Notes:
- Use the values in the 176VAC column,
if you are unsure or know that the available AC mains voltage may drop below 205VAC.
- For more information regarding External AC fuses and other types of fuses, please read the document 2052045
- The system is implemented with 4AC-3KW Power Shelves. Systems with more than 3 power shelves require more than 1 AC Mains Feed Input
63 10.00 6
80 16.00 4
100 25.00 2
Notes:
- Use the values in the 185VAC column,
if you are unsure or know that the available AC
mains voltage may drop below 205VAC.
356850.103, 1v0_2012-12
15
Quick Reference Guide Eltek Power Supply Systems
AC Mains
Mains Reconfiguration ~AC Terminal Block
To reconfigure the AC mains feed of Flatpack2 DC power systems that use the AC
Mains terminal block, you have to reconnect the AC mains wires and fishplates on
the terminal block.
1. Switch OFF the AC supply fuses in external fuse boards
2. Check that your system is implemented with 4AC-3kW or 4AC powers
shelves (read Identifying Power Shelves: 4AC, 2AC or 4AC-3kW on page
15).
If your system utilizes 2AC power shelves, you can NOT reconfigure it
as described in this section
3. Connect the AC Mains wires to the AC terminal block, and mount the
fishplates, according to the type of AC mains to be used, as shown in
the actual example in this section
356850.103, 1v0_2012-12
WARNING! Ensure that no excess material sticks out from the fish plates sides after cutting, thus avoiding damaging
short-circuits between them.
1 Surge Protective Device (SPD), also called over-voltage protectors or surge arresters
Telecom Equipment
Also, it is a common practice for telecom power supply equipment to have its com-
mon DC output rail (+ or ) connected to a separate Telecom Earth (TE) or DC
Earth 3.
Usually, TE and PE are kept separated and linked together at only one common
point in the external telecom equipment or someplace in the premises, thus pre-
venting possible noise in the PE cabling to cause interference in sensitive electron-
ics connected to TE.
When applicable, TEs one common connection point can instead be implemented
inside the power system, by connecting the common DC output rail directly to
chassis and PE.
PE (Protective Earth)
AC Mains Input
TE (Telecom Earth)
(L1, L2, L3, N)
EG (Exchange Ground)
AC Mains Flatpack2
Rectifier
Figure 12. Example showing earth connections in generic Telecom power systems with
the common DC rail connected to chassis and PE
At factory, in systems for telecom applications, AC Earth (PE) and DC Earth (TE) are
connected to chassis. Remove Link 2 (floating earth) for compliance with other
local earthing systems.
Refer to your systems specific drawings to identify how earth connections are
implemented in your DC power system.
356850.103, 1v0_2012-12
2 AC Earth or Protective Earth (PE) or Safety Earth or Dirty Earth is mostly used for contact protection
3 DC Earth or Telecom Earth (TE) or Technical Earth (TE) or Clean Earth or Output Ground or Signal Earth is
used as the DC outputs voltage reference for telecom equipment
Industrial Equipment
In industrial power supply equipment, it is more usual NOT to connect the DC out-
put poles to AC Earth (PE) or cabinets chassis (often referred to as floating out-
put, floating earth or floating system).
PE (Protective Earth)
AC Mains Input
(L1, L2, L3, N)
AC Mains Flatpack2
Rectifier
DC Load Circuit
PE Link 1
AC Earth
Chassis Cabinet
Ground
Figure 13. Example showing earth connections in generic industrial power systems
with DC output poles not connected to chassis or PE (Floating DC Output)
At factory, in systems for industrial applications, AC Earth (PE) is connected to
chassis, but the DC output poles are NOT connected AC Earth (PE) or cabinets
chassis (floating output system).
Refer to your systems specific drawings to identify how earth connections are
implemented in your DC power system.
356850.103, 1v0_2012-12
Phase Balancing
The distribution of rectifiers among the phases is implemented both via internal
wiring to the power shelves, and how the shelfs back-wiring card routes the phas-
es to each rectifier position.
Figure 14. Example showing distribution of rectifiers among the 3 Mains phases
internally connected to mains phase 1, will cause the controller to monitor phase
1 thinking it monitors phase 2. Then a phase 1 fault will be alarmed as a phase 2
fault.
21
Quick Reference Guide Eltek Power Supply Systems
AC Mains
Correct Rectifier Positions in Minipack Systems, 2U
Minipack 2U systems are fed with 3 One-phase 230VAC Mains input circuits. Each
input circuit is internally connected to feed 2 rectifiers, in such a pattern that loads
the 3 circuits evenly.
If your system is supplied from a 3-phase Mains input circuit, the use of a 3ph AC
Input Connection Kit, part 228898 or 238394, is required. Refer to page 14.
Figure 15. Example showing distribution of Minipack rectifiers among the 3 Mains feeds
To achieve a more controlled ID assignment, you should always insert & hot-plug
new Minipack rectifiers in the power shelf, one module at a time, in following shelf
position order: 1, 3, 5 and 2, 4, 6.
Shelf Position for Minipack Rectifiers
Position # 1 2 3 4 5 6
ID# 01 04 02 05 03 06
This position-versus-ID number relationship is very important for the correct moni-
toring of the mains circuit, as the controller always uses rectifier ID01, 02 and 03
to monitor the Mains Feed 1, 2 and 3 respectively. If these rectifiers malfunction,
rectifier ID 04, 05 and 06 will automatically take over.
For example: accidentally inserting a rectifier with ID02 in a power shelf position
internally connected to mains feed 1, will cause the controller to monitor mains
feed 1 thinking it monitors mains feed 2.
356850.103, 1v0_2012-12
+ + + +
+ +
0V Outer
Terminal
Block 1 Block 2
24V Outer
Intercell Link Terminal +
356850.103, 1v0_2012-12
1 The Mid-Point and the Block Measurement Methods are identical in 24V systems
You can implement any of these methods using one or two Battery Connection
Kits and the appropriate number of Battery Symmetry Kits, which contain a single
wire with suitable cable lugs, etc. Refer to the illustration on chapter Terminals &
Pin-out Location, Battery Interface Card on page 29.
Battery Symmetry ~ Mid-point Measurement Battery Symmetry ~ Block Measurement
Smartpack Controller, -48V Systems Smartpack Controller, -48V Systems
Symmetry 1.1
Symmetry 1.2
Symmetry 1.3
Symmetry 1.4
Set all 4 switches Set all 4 switches
OFF (up) ON (down)
+ + + + +
+ + + + + + + +
-48V Outer -48V Outer
Terminal Terminal
Block 1 Block 3 Block 4 Block 1 Block 3 Block 4
Symmetry 1.2
+ + + +
-48V Outer
356850.103, 1v0_2012-12
Terminal
Block 1 Block 3 Block 4
Symmetry 1.2
Symmetry 1.3
Symmetry 1.4
Symmetry 2.1
Symmetry 2.2
Symmetry 2.3
Symmetry 2.4
+ + + + + + + +
Battery Battery
String 1 String 2
+ + + + + + + +
-48V Outer -48V Outer
Terminal Terminal
Block 1 Block 3 Block 4 Block 1 Block 3 Block 4
Battery Symmetry ~ Block Measurement, String 3 Battery Symmetry ~ Block Measurement, String 4
Battery Monitor -48V Systems Battery Monitor -48V Systems
Symmetry 3.2
Symmetry 3.3
Symmetry 3.4
Symmetry 4.1
Symmetry 4.2
Symmetry 4.3
Symmetry 4.4
+ + + + + + + +
Battery Battery
String 3 String 4
+ + + + + + + +
-48V Outer -48V Outer
Terminal Terminal
Block 1 Block 3 Block 4 Block 1 Block 3 Block 4
Notice
Always connect Battery Monitor with ID#<33> to bat- Figure 19. 48V Battery Symmetry Connections
tery string 1 (lowest), with ID#<34> to string 2, and so
on. PowerSuite will then refer to the correct battery
string.
on the Battery Monitor unit (Block M.)
Battery
Symmetry 1.2
String 2
Latching Contactors
ON OFF
+Pulse Pulse
1 LVBD, Low Voltage Battery Disconnect; LVLD, Low Voltage Load Disconnect
2 Smartpack S- and Smartpack2-based systems may be configured with latching and with non-latching
contactors
Notice
JP1 and JP2 are used to configure the system for Nega-
tive DC distribution (48 and 60V systems) or Positive
DC distribution (24V systems).
Figure 23. System Interface Card, Art 200625
356850.103, 1v0_2012-12
29
Quick Reference Guide Eltek Power Supply Systems
Alarms & Monitoring I/O Signals
Terminals & Pin-out Location, Alarm Interface Card
The Smartpack controllers alarm and digital input monitoring signals can be ac-
cessed via an alarm interface card, on Flatpack2 systems, and via two types of
interface cards on Minipack 2U systems, as described below.
31
Quick Reference Guide Eltek Power Supply Systems
CAN Bus Nodes
The CAN Bus Nodes are control units connected to the power systems CAN bus.
They have a rugged sealed-plastic design, with DIN-rail or Velcro tabs as standard
mounting options.
When the CAN bus address is configured and the unit connected to the bus, it will
automatically communicate with the power systems controller (plug and play).
Configure then the CAN node functionality from the controllers front or its web-
based interface or via PowerSuite.
Read also the Installation Guide Battery Monitor CAN Node, document 351507.033.
356850.103, 1v0_2012-12
33
Quick Reference Guide Eltek Power Supply Systems
CAN Bus Nodes
I/O Monitor and I/O Monitor2 CAN Nodes
NOTICE! The figure shows the location of terminals and LEDs in the I/OMonitor node. The I/OMonitor2 node imple-
ments the same inputs and outputs as the I/OMonitor node (X:*, X:**), except for the Fan Control signals (X:***)
The I/OMonitor and the I/OMonitor2 CAN Bus Nodes enable you to decentralize
and increase the number of input monitoring and output controlling signals in your
DC power supply system.
Also, the I/OMonitor node monitors and controls the compartment temperature
inside fan-cooled outdoor cabinets.
Read also the installation guides for I/OMonitor CAN Node (document 351503.033)
and for I/OMonitor2 CAN Node (document 351509.033).
356850.103, 1v0_2012-12
35
Quick Reference Guide Eltek Power Supply Systems
356850.103, 1v0-2012-12, Published 2013-03-22
www.eltek.com
Headquarters: Eltek
Visitor address: Grterudveien 8, 3036 Drammen, Norway
Phone: +47 32 20 32 00 Fax: +47 32 20 32 10