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EC500 Controller Handbook

General Description

Copyright © 2019 Eaton Corporation. All Rights Reserved.
Issue A March 2019

Page 10 of 107

CONNECTIONS

The following diagram shows a system architecture using EC500 and its peripherals.

The following wiring diagram shows the connections between the EC500, the DC Interface board, the other dc
power system components and external devices for a generic power plant. Please refer to your system wiring
diagram for any system specific changes.



For connector pin-outs see details on page 100. For input and output specifications see details
on page 100.

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Summary of Contents for EC500

Page 1: ...EC500 Controller Operation Handbook Issue A1 Eaton Corporation Telecommunications Power Solutions dcpower eaton com DCinfo eaton com Issue Date March 2019...

Page 2: ...em cost of capital loss of power additional expenses in the use of existing power facilities or claims against the purchaser or user by its customers resulting from the use of the information recommen...

Page 3: ...nd Screen 13 Navigation Keys 13 Main Menu Navigation 14 Changing a Configuration Setting using the Keypad 14 Keypad Access Security 14 Display Settings 15 Display Time out 15 Alarm Indicators 15 EC500...

Page 4: ...Change Indication 47 Alarm Grouping 47 System Alarms 47 Potential Free Inputs DI Alarms 48 Analog Alarms 49 Smart Alarms 51 Potential Free Outputs 52 Common Alarm Parameters 53 Generator Control 53 In...

Page 5: ...er 82 Communication via a Network Management System using SNMP 83 SNMP Access Configurations 83 SNMP trap Configurations 85 Communication via Email 88 Modbus Communications 89 Communications Security...

Page 6: ...d dc powered equipment the relevant local electrical safety regulations and wiring standards Operators and maintenance staff competent in operation of dc power systems safe working practices for ac an...

Page 7: ...des a full suite of communications options including built in Ethernet interface Web server Modbus and SNMP agents Alarm notifications may be by Email SNMP traps SMS text messaging or relay contact cl...

Page 8: ...ns see System Configurations on page 67 For connector pin outs see details on page100 See Troubleshooting on page Error Bookmark not defined for details of EC500 alarm LEDs DC INTERFACE AND IO BOARD T...

Page 9: ...For connector pin outs see details on page 102 POTENTIAL FREE INPUT OUTPUT BOARD A variant of DCIO provides only 8 PFC Inputs and 8 PFC Outputs This board can be used where additional digital monitor...

Page 10: ...re using EC500 and its peripherals The following wiring diagram shows the connections between the EC500 the DC Interface board the other dc power system components and external devices for a generic p...

Page 11: ...Unit Unit Features Remarks EC500 00 Controller EC500 Controller with 10 100Mbps Ethernet USB 1x CAN 1xRS485 and 1xRS232 EC500 01 Controller EC500 Controller with 10 100Mbps Ethernet USB 2x CAN 2xRS48...

Page 12: ...onnector CAN 1 CAN 2 RS485 L RS485 U on rear panel the controller boots up and start up sequence begins Start up Screen At power up Boot loader loads any new firmware and then jumps to application Con...

Page 13: ...RYB voltage Rectifier Current Battery current voltage Load current and bus voltage EC500 OPERATION USING KEYPAD AND SCREEN NAVIGATION KEYS EC500 provides a Joystick for navigation For Navigation towar...

Page 14: ...of a parameter navigate to the parameter and press Enter If not logged in already then a login window will popup else a popup window to change parameter will appear Use Up and Down key to change valu...

Page 15: ...isplay intensity according to ambient light else you may not be able to see the display values DISPLAY TIME OUT If there is no keypad activity for 60 seconds the display will jump back to the Home scr...

Page 16: ...go to Home Main Menu Settings System Settings Buzzer Set Buzzer status to Disable and save Or On Web page go to Home Settings System Settings Buzzer Status Set Buzzer status to Disable and save EC500...

Page 17: ...ATION Parameter Description Where to find Model No Indicates Model number of the controller EC500 Display Home Menu System Status System Info Web Home System Status System Info Controller Serial Numbe...

Page 18: ...amping of log entries and Control Processes The time and date are factory set They can also be set manually using a web browser or can be synchronized to an SNTP reference time server To view the EC50...

Page 19: ...ure access through your network s firewall LANGUAGE OPTIONS The EC500 Controller language default is English and is inbuilt Text on the LCD can be shown in other languages by loading the appropriate T...

Page 20: ...Set Language field to select the Language from drop down Click Save button EC500 language will change to selected language EC500 FIRMWARE UPGRADE If required the embedded software firmware in the EC5...

Page 21: ...firmware downgrade is required trial the downgrade and check the configuration before implementing it at a site CONFIGURATION FILE Configuration file for EC500 can be uploaded to Controller through We...

Page 22: ...0 provides CC CV charging and can achieve typical three stage charging of a VRLA battery i e constant current charge topping charge and float The EC500 can also achieve CC CV two stage charging for a...

Page 23: ...s function this limit is not used When mapped and if PFC input is Active Alternate Current Limit is applied Float Voltage Set to the voltage required to maintain optimum charge for battery at referenc...

Page 24: ...set battery current limit If alternate battery current limit is set and engine is running the controller will maintain alternate battery current limit while trying to achieve target voltage Alternate...

Page 25: ...D as per selection of configuration It can be one LVD for all Battery banks or individual LVD for individual Battery bank Configuration 1 Configuration 2 Monitoring The following information is availa...

Page 26: ...on Where to find No of Batt Fuses Set the number of Battery fuse as per Battery bank installed Display Menu System Config DC Config Batt Config Web Menu System Config DC Config Batt Config No of Batt...

Page 27: ...is is recommended by battery manufacturer Compensation Factor This is voltage drop or Increase cell C temperature A factor of 2mv 5mV cell C can be defined Set it as per battery manufacturer recommend...

Page 28: ...o Menu Settings Battery Settings VRLA Charge Profile Equalize Mode Status Enter the appropriate pin then user will be able to see settable parameters Use Web page to go Menu Settings Battery Settings...

Page 29: ...the below conditions becomes true Battery SOC is still greater than 80 but function reaches the duration time i e 1hr Mains Fail set Function disabled High Battery temperature Battery temperature sen...

Page 30: ...talled and we connect the battery in reverse condition then contactor s coil will not triggered due to incomplete path Controller will sense the voltage before battery fuse if sense voltage is less th...

Page 31: ...e time of Manual Charging and after completion it will show Float Display System Status SOLAR CHARGER POWER SHARE Where a DC power system has energy inputs both from AC mains supply or AC generators a...

Page 32: ...r current Alarm Load Priority Diff voltage This voltage defines the difference between Solar charger voltage and AC Rectifier voltage AC rectifiers generate less voltage comparatively solar rectifier...

Page 33: ...erated by Solar charger Display Menu System Status S Charger Web Menu System Status S Charger Output Current Output current generated by Solar charger Status Communication status between Solar charger...

Page 34: ...Single phase Rectifiers cannot operate in this configuration If the system does not have an HVLV card then rectifiers will provide AC phase to phase measurement For Rectifier Type Selection see System...

Page 35: ...er is configured for two CAN buses specify number of rectifiers on CAN Bus number 1 else this setting is not available Installed SMR on CAN2 Bus In case Controller is configured for two CAN buses spec...

Page 36: ...ntroller Rectifier boots up Controller will search ID of rectifier and register it as Rectifier number 1 Check Registration status Rectifier Serial number from Home System Status Rectifier Individual...

Page 37: ...stalled number of rectifiers in the rack s slot and turn them ON one by one from left to right with a time gap of 30 seconds Now check status of rectifier Menu System Status Rectifier Individual Recti...

Page 38: ...less than 10 current share deviation RECTIFIER SLEEP MODE User can manually put some rectifiers in Sleep Mode i e shut down in case load is less or otherwise operation is not required Manual Sleep Mod...

Page 39: ...is enabled rectifiers cannot be put in Sleep Mode manually Any rectifiers already put in Sleep Mode manually will not participate in Economy Mode operation Eco mode will bypass that specific rectifie...

Page 40: ...more than Minimum Load setting or number of active rectifiers is equal to or less than Minimum Active Rectifiers setting In case rectifier current becomes more than Maximum Load per rectifier setting...

Page 41: ...fier fail alarm is generated when Rectifier Fail condition is provided from the rectifier however if all rectifiers communicate Rec Fail alarm to MCM then we get All Rec fail alarm on MCM rather than...

Page 42: ...Mode FS This alarm gets generated in the rectifier by following two conditions 1 Mains voltage 330V upon detection time of 10 ms 2 Input voltage 460V for 32 samples 640 uS Rec Proc Mode Rec IP proc M...

Page 43: ...alarm DC Low Voltage Restore Offset Restore point for clearing DC low voltage alarm DC Overload Set Threshold If system current sum of load and all battery currents exceeds this DC Overload Alarm Thre...

Page 44: ...nd one Load LVD This arrangement allows lower priority loads to be disconnected first contactor controlled by control channel LLVD 1 at a specified battery voltage lower than Battery LVD This prolongs...

Page 45: ...rm Threshold and more than 30V for the duration of 5 seconds These alarm thresholds can have different values for all 4 channels This alarm also triggers the Load Contactor for Load LVD operation with...

Page 46: ...If the audible indicator is enabled it will sound until joystick is operated Audio indicator will sound for a maximum of 1 minute if no keyboard operation is done See details on page 16 Critical Major...

Page 47: ...r mapping Groups to Potential Free outputs SYSTEM ALARMS These are generated by the operating values of dc power system voltages currents temperatures etc operation of power system modules rectifiers...

Page 48: ...that some potential free inputs can be mapped to some pre defined functions also Potential Free Input Configuration Parameter Description Where to find Enable Input Enable it to use the PFC input If...

Page 49: ...ome Settings PFC Settings Input Configuration Sense Map User Alarm Home Settings PFC Settings Input Configuration Map User may have to configure User alarms if not configured already Alarm Name Home S...

Page 50: ...r Deactivation time Alarm Activation Delay Output of comparison function will be de bounced for Alarm Activation Delay before declaring an active alarm Alarm Deactivation Delay Output of comparison fu...

Page 51: ...qual to or higher than Trap receiver s configured alarm severity See page 86 for details Group Map 1 Select alarm group 1 to map Individual alarm can be mapped up to two alarm groups Group Map 2 Selec...

Page 52: ...Alarm Activation Delay Output of comparison function will be de bounced for Alarm Activation Delay before declaring an active alarm Alarm Deactivation Delay Output of comparison function will be de bo...

Page 53: ...ll alarms Parameter Description Where to find Enable Audible Alarm Indication Enable or disable the audible alarm indicator Display Home Settings System Settings Buzzer Web Home Settings System Settin...

Page 54: ...ent limit and enables DG energy and run hour counters Configuration Set the following parameters Parameter Description Where to find DG Control Enable or Disable the Generator control Generator config...

Page 55: ...be turned off both conditions are true INPUT OUTPUT I O The following section describes the input output functions available with a single DCIO and PFCIO board Also see I O Board Mapping on page 77 Ad...

Page 56: ...ttery bank Solar Power The total power produced by the solar chargers controlled by EC500 AC Voltage Single Phase System At the time of polling which rectifier communicates with EC500 first time and p...

Page 57: ...alog input that is Enabled in the Analog Inputs can activate a high and or low alarm The alarm Recognition period applies to analog input alarms Configure the following parameters in the Analog Input...

Page 58: ...input with function set to Battery Fuse Fail is active SPD Fail Indicates if any digital input with function set to SPD Fail is active DG Running status Indicates if any digital input with function se...

Page 59: ...nal equipment or alarm systems Digital outputs are operated by a mapping from a digital input alarm an analog input high or low alarm or a system alarm To configure a digital output Web go to Menu Sys...

Page 60: ...nfigure an Energy Meter In AC configuration set the status of AC energy meter to enabled Select the type of energy meter using in system Internal energy meter or External energy meter The configuratio...

Page 61: ...lative energy Display Menu System Status AC Input Web Menu System Status AC Input CONFIGURATION Set the following parameters Parameter Description Where to find AC Energy Meter Status AC Energy Meter...

Page 62: ...every system event alarm The EC500 can store up to 10 000 event logs All types of alarms i e system alarms analogue alarms user alarms and smart alarms are logged Logging of individual alarms can be d...

Page 63: ...minutes to 1440 minutes Logging will start ENERGY LOG The Energy Log records cumulative and day wise kWh for battery load mains energy diesel generator energy and load energy User can view energy logg...

Page 64: ...ime of mid night Memory for run hours log entries up to 60 days are pre allocated When memory is full the oldest record will be over written Similarly EC500 subtracts the previous month Run Hour from...

Page 65: ...es an option to select the Setting Change logging To download save the Log file in web go to Tab Export it will export the logs in excel sheet and save in the download folder To clear the Change Log I...

Page 66: ...rformance logging options will be available Set following parameters Periodicity This parameter defines the rate of performance logging its value varying in between 1 minute to 1440 minutes End Date M...

Page 67: ...rrect operation of the display screen web pages communication and functionalities Since system hardware does not change in the field these settings are not normally editable from Web SNMP or Display C...

Page 68: ...ed on CAN bus directly Select PFC IO 16 1 2 as Installed or Not Installed as per system configuration Wrong selection will cause non availability or wrong mapping of PFC Inputs and outputs in hardware...

Page 69: ...ry LVD individual contactors can be operated manually for battery maintenance Maximum 5 drives can be controlled and minimum 1 shall be defined The same number of LVD drives must be mapped in hardware...

Page 70: ...battery is in float mode and after a configurable lockout period since the last battery discharge Fast charge Equalize or Battery Test To enable Battery Mid point Monitoring Connect the mid point mon...

Page 71: ...example Battery String number 2 generates an alarm then display will show Battery String 2 Fail Web Menu Settings Alarm Management Configuration The following parameters are available for configuring...

Page 72: ...sholds refer to section Load LVD on page 44 Equal number of drives shall be mapped in hardware manually 0 0 8 Configurator Main Menu System Config DC Config Load Config Web Home System Config DC Confi...

Page 73: ...illivolt at rated current rating set above Number of Load shunts is equal to Number of Load Paths set above 50mV 30 50 CABINET CONFIGURATION Items related to cabinet configuration like Temperature sen...

Page 74: ...HANNEL NAMING CONVENTION DCIF Voltage channels are referred as DCIFx_VOLT_CHy where x is DCIF board number 1 4 and y is voltage channel 1 4 or 1 6 depending on the particular DCIF board For DCIF 4V2C...

Page 75: ...FC16 IO board Refer DC Interface and IO Board details on page 8 and Potential Free Input Output Board on page 9 Board Type Maximum boards Functionality Number of channels ports Remarks DCIF 4V2C 4 Vol...

Page 76: ...Main Menu System Config Hardware Mapping Battery Battery n Voltage Channel Web Home System Config Hardware Mapping Battery Battery n Voltage Channel Configurator Main Menu System Config Hardware Mappi...

Page 77: ...y n Quarter Point x For battery n quarter point sense required only if respective battery quarter point monitoring is required Requires three channels one for each quarter node None LOAD CHANNEL MAPPI...

Page 78: ...are to be used Any available PFC output can be mapped subject to contact rating required for driving Fan None Configurator Main Menu System Config Cabinet Fan n Relay Channel Web Home System Config C...

Page 79: ...s the most versatile interface for local or remote communications with the controller Refer to Section EC500 Operation Using a PC Laptop on page 16 for how to connect to Ethernet interface Section Sys...

Page 80: ...ettings Communication Settings Ethernet IPv4 Click on IP Configuration and select DHCP If you are not logged in a pin screen will be displayed Enter your pin and press Login Controller will restart an...

Page 81: ...is unique However it can be used within the local LAN network only and cannot cross routers Static IPv6 address is not a common mode of setting and should be used carefully To configure EC500 for IPv6...

Page 82: ...dard web browser to control and monitor the EC500 via an IP network To connect to the EC500 with web browser Set up Ethernet communications and connect the EC500 to the IP network See Ethernet Communi...

Page 83: ...s as SNMP traps to two different SNMP trap receivers Two users for SNMPv2 and Eight for SNMPv3 A MIB file is available for EC500 obtain it from your Eaton representative To setup SNMP Communications S...

Page 84: ...en 30 Home Settings Communication Settings SNMP SNMPv3 USER USERx Username Security Model Select security model NoAuthNoPriv No Authentication and no Privacy AuthNoPriv Authentication no Privacy AuthP...

Page 85: ...Description Range Default Value Where to find SNMP Trap Protocol Select SNMP Trap protocol for sending alarms to SNMP Manager SNMPv2c SNMPv3 Default SNMPv2 Trap Format Select whether a single Trap OID...

Page 86: ...NMP Trap Receiver x IPv4 or IPv6 Trap Receiver Port number Set Port receiver on which respective Trap receiver is listening Contact your NMS manager for correct port number 0 65535 Default 162 Home Se...

Page 87: ...uthPriv Home Settings Communication Settings SNMP SNMPv3 USER USERx Privacy Password Trap Receiver IP Address Type Select IP address type of the Trap receiver IPv4 IPv6 Default IPv4 Home Settings Comm...

Page 88: ...ender s Password Sender s email password for authentication on mail server Total Mail Users Number of Email recipients 0 6 0 Critical Alarm Delay Delay after which mail will be sent to user with Criti...

Page 89: ...uested through each sequential register that follows for the number of register requested The Modbus messages on serial connection are not in broadcast format Devices constructed in such a way that de...

Page 90: ...y security risk WEB USER SETUP The EC500 is shipped with 8 fixed users with different privileges Customers shall change the default Username and Passwords If the passwords for all users are forgotten...

Page 91: ...EC500 Controller Handbook Copyright 2019 Eaton Corporation All Rights Reserved Issue A March 2019 Page 91 of 107...

Page 92: ...ations Interface CAN 2 0b Baud Rate 250kbps Connector RJ 45 rear panel Number of interfaces 2 Proprietary RS 485 Serial Interface RS485 4 wire Connectors RJ45 rear panel Number of interfaces 2 Protoco...

Page 93: ...led default Enabled Language Language standard English Language options One additional language supported available to special request POWER MECHANICAL ENVIRONMENTAL Power Input Rated Voltage 48V DC n...

Page 94: ...Sensor Type Proprietary supplied with the system Range 20 C to 100 C 1 C Resolution 1 C LVD Relays 3 on board LVD Contact rating 10A 60VDC NO NC header selectable PFC Inputs 8 Input Circuit 2KV Opto I...

Page 95: ...48V dc System Interface CAN Bus RJ45 Power Input Rated Voltage 48V DC nominal Operational Range 36V to 60V DC Power input connector RJ 45 part of CAN bus Input current 0 1A 48V SYSTEM MAXIMUM CAPACITI...

Page 96: ...application Web SNMP Mail Users Web Users http https 6 fixed rights SNMP V2c Read Write Communities One each SNMPv3 Users 8 SNPv2c Trap Receivers 2 SNMPv3 Trap Receivers 8 Mail users 6 Logs Event Log...

Page 97: ...ifier then Rec Fail alarm will be activated This alarm is declared by both rectifier and EC500 Multi Rec Fail When EC500 receives more than one rectifier fail alarm Rec Fail from individual rectifiers...

Page 98: ...thresholds can be different value for all n channels BLVD Disconnect This alarm is generated by EC500 when Bus voltage becomes lower than Battery Low Voltage Disconnect BLVD Alarm threshold and more t...

Page 99: ...xceeds than Rack Temperature 2 High Alarm Threshold for the duration of 10 seconds Rack Fan Fail This alarm is generated when the Fan Fail Alarm is continuously detected for 10 seconds provided Fan is...

Page 100: ...ce 1 Rx 2 Rx 3 Tx 4 5 6 Tx 7 8 USB USB Type A USB Serial Interface 1 VCC 5V dc max 100mA 2 Data 3 Data 4 Ground common with controller CAN 1 Rear Panel RJ45 System primary isolated CAN bus 1 CAN H 2 C...

Page 101: ...ial Bus 2 Rx IN 3 Tx Out 4 Ground common with CAN Bus 5 6 Tx Out 7 0V Reference 8 48V DC power input RS485 U Rear Panel RJ45 RS 485 2 Upper 4W Serial Bus 1 Rx IN 2 Rx IN 3 Tx Out 4 Ground common with...

Page 102: ...CAN H 2 CAN L 3 4 CAN Ground Isolated from controller 5 6 7 0V Reference 8 48V DC protected power output X2 Upper DB9F Relay drives for Potential Free outputs Use a 1 1 cable for connecting to PFC 8 I...

Page 103: ...ched LVD Contactor 2 Coil 8 Contactor Supply Ve common for both Contactor drives X3 6 Pin M Molex Current Sensor inputs 1 Bus Ve reference for Measurements Must be connected 2 Bus Ve reference for Mea...

Page 104: ...AN 5 ISO5V1 Isolated 5V for CAN 6 TX1 7 0V Reference 8 48V DC power output X7D RJ45 Isolated 5V CAN supply Power output External RS485 Interface 1 CANH RX2 2 CANL RX2 3 TX2 4 ISOGND_EXT 5 ISO5V1 Isola...

Page 105: ...ole NC NO 14 16 18 6th Relay Pole NC NO 19 21 23 7th Relay Pole NC NO 20 22 24 8th Relay Pole NC NO TB2 16 Pin Male Dual Row 8 User defined optically isolated PFC input 2 1 0V D1 Input 4 3 0V D2 Input...

Page 106: ...9 Eaton Corporation All Rights Reserved Issue A March 2019 Page 106 of 107 X3 8 Pin Male Dual Row Differential Current Sensing Inputs 1 2 Shunt Common 3 Current Input 3 4 Current Input 3 5 Current Inp...

Page 107: ...rt Copyright 2019 Eaton Corporation All Rights Reserved Issue A March 2019 Page 107 of 107 SUPPORT For product information and a complete listing of sales offices visit Eaton s website at dcpower eato...

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