EC500 Handbook Issa1 PDF

EC500 Controller
Operation Handbook
Issue A1
Issue Date: March 2019
Eaton Corporation
Telecommunications Power Solutions
dcpower.eaton.com
DCinfo@eaton.com
EC500 Controller Handbook
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Issue A March 2019 Page 2 of 107
EC500 Controller Handbook Contents
CONTENTS
About This Guide.............................................................................................................................. 6
Scope ................................................................................................................................................... 6
Audience ............................................................................................................................................. 6
Reporting Problem With This Guide ................................................................................................... 6
For Further Information and Technical Assistance ............................................................................. 6
Third Party Software ........................................................................................................................... 6
General Description ......................................................................................................................... 7
Overview ............................................................................................................................................. 7
EC500 Controller ................................................................................................................................. 7
DC Interface and IO Board .................................................................................................................. 8
IOB-6V3C ......................................................................................................................................... 8
Potential Free Input / Output Board................................................................................................... 9
Connections ...................................................................................................................................... 10
Board Options ................................................................................................................................... 11
EC500 Operation ............................................................................................................................ 12
Overview ........................................................................................................................................... 12
Starting the EC500 ............................................................................................................................ 12
Home Screen ................................................................................................................................. 13
EC500 Operation Using Keypad and 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 Operation Using a PC/Laptop ................................................................................................ 16
EC500 Identity Information............................................................................................................... 17
Identity Information...................................................................................................................... 17
EC500 Internal Clock ......................................................................................................................... 18
Time Synchronization.................................................................................................................... 19
Language Options ............................................................................................................................. 19
Language Selection ....................................................................................................................... 20
EC500 Firmware Upgrade ................................................................................................................. 20
Software Downgrade .................................................................................................................... 20
Configuration File .............................................................................................................................. 21
System Operation .......................................................................................................................... 22
Overview ........................................................................................................................................... 22
Battery and Voltage Control ............................................................................................................. 22
VRLA Battery Charge Profile ......................................................................................................... 23
Battery Current Limit .................................................................................................................... 24
Multiple Battery Banks.................................................................................................................. 24
Battery Temperature Compensation ............................................................................................ 26
Equalize ......................................................................................................................................... 27
Battery Test ................................................................................................................................... 29
Battery Reverse Detection ............................................................................................................ 30
Manual Charge Mode ................................................................................................................... 30
Solar Charger Power Share ........................................................................................................... 31

Rectifiers ........................................................................................................................................... 34
Rectifier Registration .................................................................................................................... 36
Identify a Rectifier ......................................................................................................................... 37
Force Share Reset ......................................................................................................................... 37
Rectifier Sleep Mode..................................................................................................................... 38
Economy Mode ............................................................................................................................. 38
Rectifier Alarms ............................................................................................................................. 41
Low Voltage Disconnect (LVD) .......................................................................................................... 42
Bus Monitoring ............................................................................................................................. 42
Battery LVD ................................................................................................................................... 43
Load LVD ....................................................................................................................................... 44
Typical LVD Arrangements ............................................................................................................ 44
LVD Operation ............................................................................................................................... 44
DCDB Alarms ................................................................................................................................. 45
Alarms ............................................................................................................................................... 45
Type of Alarms .............................................................................................................................. 45
Active Alarm Indications ............................................................................................................... 46
Alarm 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
Input / Output (I/O) .......................................................................................................................... 55
Identify an I/O Board .................................................................................................................... 55
Analog System Values ................................................................................................................... 55
Analog Inputs ................................................................................................................................ 56
System States ................................................................................................................................ 58
Digital Inputs ................................................................................................................................. 58
Digital Outputs .............................................................................................................................. 59
Energy Metering ............................................................................................................................... 60
Information ................................................................................................................................... 60
Configuration ................................................................................................................................ 61
Data Logging...................................................................................................................................... 62
Event Log ....................................................................................................................................... 62
Data Log ........................................................................................................................................ 63
Energy Log ..................................................................................................................................... 63
Run Hours Log ............................................................................................................................... 64
Status Logs .................................................................................................................................... 64
Change Logs .................................................................................................................................. 65
Performance logs .......................................................................................................................... 65
System Configuration..................................................................................................................... 67
Overview ........................................................................................................................................... 67
System Info ....................................................................................................................................... 67
Battery Configuration ....................................................................................................................... 68
Battery Mid-Point Configuration ...................................................................................................... 70
Load Configuration............................................................................................................................ 72
Current Sensing ................................................................................................................................. 72

Cabinet Configuration ....................................................................................................................... 73

Hardware Channel Mapping ............................................................................................................. 74
Channel Naming Convention ........................................................................................................ 74
Battery Channel Mappings............................................................................................................ 76
Load Channel Mappings ................................................................................................................ 77
Cabinet Channel Mappings ........................................................................................................... 78
Communications ............................................................................................................................ 79
Communications Options ................................................................................................................. 79
Ethernet Communications ................................................................................................................ 79
Ethernet Communication Set-up .................................................................................................. 79
Communication via Web Browser ................................................................................................ 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 ................................................................................................................. 89
Web Access Security ..................................................................................................................... 89
Web User Setup ............................................................................................................................ 90
Specifications ................................................................................................................................. 92
EC500 Controller ............................................................................................................................... 92
Interfaces ...................................................................................................................................... 92
User Input and Display .................................................................................................................. 92
Power, Mechanical & Environmental ........................................................................................... 93
DC Interface Board ............................................................................................................................ 94
Potential Free Input / Output Board................................................................................................. 95
System Maximum Capacities (Software) .......................................................................................... 95
Alarm Descriptions ......................................................................................................................... 97
Connector Pin-outs ...................................................................................................................... 100
System Controller Connector Pin-outs ........................................................................................... 100
DCIF Connector Pin-outs ................................................................................................................. 102
DCIO (IOB-6V3C) Connector Pin-outs ............................................................................................. 103
Support......................................................................................................................................... 107

EC500 Controller Handbook About this guide
ABOUT THIS GUIDE

SCOPE
This guide covers operation of the EC500 Controller.
 See EC500 Identity Information on page 17 to determine the version of the embedded
software.
AUDIENCE
This guide is intended for use by:
• Installers competent in:

• installing and commissioning dc power systems
• safe working practices for ac and 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 and dc powered equipment
REPORTING PROBLEM WITH THIS GUIDE
Please use this email address to report any problem you find in this guide:
dcinfo@eaton.com
FOR FURTHER INFORMATION AND TECHNICAL ASSISTANCE
For further information and technical assistance contact dcinfo@Eaton.com
THIRD PARTY SOFTWARE
This product includes an open source SSL library “mbed TLS” licensed by ARM Limited. Source code of
“mbed TLS” can be downloaded from https://tls.mbed.org/.

EC500 Controller Handbook General Description
GENERAL DESCRIPTION
OVERVIEW
Topic Page
EC500 Controller 7
DC Interface and IO Board 8
Connections 10
EC500 CONTROLLER
The EC500 Controller is an advanced control and monitoring solution which provides 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 closures. Local
notifications are given on Display, Buzzer and LEDs.
EC500 Front View
1 7
2 5 9 6 10
8 11
3 4
ITEM NOMENCLATURE
1 Power LED/normal conditions
2 Major Alarm
3 Info Alarm
4 Display Screen
5 Left Key/ Scroll/Back
6 Right Key/Scroll
7 Up Key/Scroll/Parameter Value Change/ Latch reset
8 Down Key/Scroll/Parameter Value Change

ITEM NOMENCLATURE
9 Enter Key
10 Ethernet Port
11 USB Port
EC500 Rear View
3 4
5 1 2
ITEM NOMENCLATURE
1 CAN Port 1 + Power
2 RS 485 Port (Lower) + Power

3 CAN Port 2 (Optional) + Power
4 RS 485 Port (Upper, Optional) + Power
5 RS232 Port, GSM Modem
The EC500 is supplied pre-configured with either a default configuration file, or with one factory customized
for a particular application. Some configuration file changes can be made with the keypad, or all settings can
be changed via a PC connected to the EC500 through a network. For essential configurations 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
The DC Interface & IO provides the Analogue interfaces, I/O interfaces and connections for system bus.
The DC Interface board includes a range of sense inputs for dc power system control and monitoring. It also
allows real time data collection from building services and other external devices, relay outputs for alarm
signals or control of external devices and drives for DC Contactors.
DCIO board provide Shunt based current sensing. All voltage and current measurements are in reference to
Bus Common (-48V DC).
IOB-6V3C
• Sensors: Current – 3, Bus Voltage – 1, Battery/Mid-point – 5, Temperature – 2
• Input/Outputs: Optically Isolated Inputs – 8, Relays – 8, LVD Contactor Relays – 3

This board provides 8 on board relays for alarm or other control functions.
The IOB-6V3C board provides 3 on board LVD Contactor relays.
 For input and output specifications see details on page 94. 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 monitoring inputs and additional potential free contacts are required, but analogue inputs are not
required. The board communicates with the controller on the system CAN bus. For connector pin outs see
DCIF Connector Pin-outs on Page 102.
This board provides following interfaces:
• Input / Outputs: Optically isolated inputs – 8, Relay (NO / NC) – 8

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.

BOARD OPTIONS
The EC500 system includes a number of options for controller and input / output boards. Contact Eaton for
any new or currently available options.
Unit Unit Features Remarks

EC500-00 EC500 Controller with 10/100Mbps
Controller Ethernet, USB, 1x CAN, 1xRS485 and
1xRS232
EC500-01 EC500 Controller with 10/100Mbps To special order.
Controller Ethernet, USB, 2x CAN, 2xRS485, Contact Eaton.
1xRS232 and 4GB SD card
IOB-6V3C Cased, 6Voltage, 3 Current, 8 PFC inputs, Shunt based current
DC Interface unit 8 PFC outputs, 3 LVD, Bus Powered sensors
IOB-PFCIO-8 Cased, 8 PFC inputs, 8 PFC outputs, Bus To special order.

DC Interface Unit Powered Contact Eaton.

EC500 Controller Handbook EC500 Operation
EC500 OPERATION
OVERVIEW
Topic Page
Starting the EC500 12
EC500 Operation Using Keypad and Screen 13
EC500 Operation Using a PC/Laptop 16
EC500 Identity Information 17
EC500 Internal Clock 18
Language Options 19
EC500 Firmware Upgrade 20
STARTING THE EC500
When dc power is applied to the EC500 (via the connector CAN-1 / CAN-2 / RS485-L / RS485-U on rear panel)
the controller boots up and start-up sequence begins.
Start-up Screen Home Screen Main Menu
At power up, Boot loader Display system values, alarm Option selection displays
loads any new firmware and status, latest alarm and date / Main Menu. See
then jumps to application. time. Colour of particular navigation on page 13. If Logon is
Controller initializes block shows alarm status of required see Keypad Access
hardware, loads system that block. Security on page 14.
settings and starts operation.
 CAN-2 and RS485-U are not part of standard offering and must be purchased as an option
(EC500-01)

HOME SCREEN
The Home screen displays important system parameter values and system block status. Block nomenclature
and colour relations are as given below.
ITEM NOMENCLATURE ITEM NOMENCLATURE

AC Input Alarms
Rectifier Selection Indicator
Solar Input System Status
Battery Bank Menu
Current Flow Load
Home Screen or default screen parameters are read only and are used to show important system parameters
such as Date and Time, Last event, AC phase (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 towards Right push the joystick Rightwards, for Left
push leftwards and similarly, for Up and Down directions. To select an option or Enter, press the joystick
towards the centre.
User can navigate through all enabled screen using the joystick. Joystick functions change according to context.
Important functions are given below.
ITEM Key Operation / Key Direction

To Select an Option (Yes / No) Select using Left / Right and then Enter
To select a sub menu Select using Up / Down and then Enter. On Main menu use
Left / Right and then enter
Previous Menu Item Left
Scroll through sub menus Up / Down

Edit a parameter Up / Down to change value, Enter to select current displayed value
Increase / decrease number of characters When at last location of string, Right press will add one character
location. When at last display location, Left press will reduce string
length.
Fast Scroll push and hold the joystick in the respective direction
Buzzer mute When at Home screen, move joystick in any direction to

turn off Buzzer (if sounding). On new event, Buzzer will
again start to beep, unless Buzzer is permanently disabled
under System settings.
MAIN MENU NAVIGATION
To navigate to Main Menu, from Home screen navigate to the Main Menu icon and press enter.
The following menu items will appear: System Status, Logs, Settings, System Configuration, Maintenance and
Accessories. These can be navigated using left and right navigation keys. To select a particular menu use the
Enter Key. Sub menu items under the selected menu will appear.
CHANGING A CONFIGURATION SETTING USING THE KEYPAD

To change value or configuration of a parameter, the user must have edit access rights and must login. To
change the value 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 value (for changing values rapidly, hold the key in up (increment) or down (decrement) direction. Once
desired value has been set on display, press Enter to save. Valid limits of the parameter are also displayed in
the Edit window. Once the selected value is saved, a “SAVED” message will be displayed. Left press to exit Edit
window.
KEYPAD ACCESS SECURITY

To get Keypad access for changing any setting or configuration, user must first login with the access pin. Login
screen is presented when a user selects a parameter for edit.
➢ To Login
• Select the system parameter that is to be modified.
• If user is already logged in, then the settings can be directly changed, if he/she has required
access rights else a login window will popup.
• Enter the access PIN.
• To enter PIN, move joystick up / down to scroll through numbers 0 -9. To enter next digit
move joystick to right and then up / down to select next digit.
• Selected digit will be displayed for a short duration and then will be hidden using a * symbol.
• Once all required digits are selected, push joystick to Enter.
• Cursor moves to Login button, again push joystick to Enter.
• If PIN is incorrect, user is taken back to Login window.
 User will be auto logged out 5 minutes after last parameter edit.

For example, if a user wants to change Battery Capacity then go to Home  Main Menu  Settings 
Battery Settings  General Settings Battery Capacity and press Enter. If User is not already logged in, a
pop-up window for PIN entry will appear.
Login
Enter Enter
Window
Enter PIN to
Login
Enter Enter
Login Successful and Press Login Button

Change the Value
now the value can
using up/down
be configured. Press
navigation and Press
Enter to Configure.
Enter to save.
DISPLAY SETTINGS
In Display Settings, a user can set brightness level.
➢ To set Brightness level

• Home  Main Menu  Settings  System Settings  Brightness.
• Change level (10% – 100%) using up and down keys.
• Enter to save.
 Adjust display 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 screen.
When the display is at Home screen and there is no user activity for 60 seconds, the display intensity
automatically reduces to half (minimum 10%). If there is no activity for further 180 seconds then the intensity
is reduced to 10%. Display intensity will increase automatically to set value when any key is pressed or any
event occurs.
ALARM INDICATORS

Active alarms are displayed at the bottom left side of the Display. Alarms are categorised as Critical, Major and
Minor. If a Critical or Major Alarm occurs than Status LEDs will glow in Red colour and if a Minor alarm occurs
than Status LEDs glow in Yellow colour.
Visual Indicators
Power on LED (green)
Critical/Major Alarm LED (Red)
Minor Alarm LED (yellow)
Audio Indicators
Whenever any alarm is present, the Buzzer will beep every 2 seconds
➢ To stop the audible indicator

On Home screen move the joystick in any direction (up / down / left / right)
 The audible indicator will restart at the next active alarm or alert message.
➢ To enable / disable the audible alarm indicator
Either:
• Use the keypad to 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 OPERATION USING A PC/LAPTOP
EC500 can be operated using a PC/Laptop through the Ethernet port.

Connect to the EC500 either directly or over a network. Before connecting, ensure you know the IP address,
user id and password to login to EC500. Please obtain your User name and password from your network
administrator.
To see the IP address of EC500 on display go to
For IPv4:
Home  Main Menu  Settings  Communication Settings  Ethernet  IPv4  IP Address
For IPv6 Link Local / Network Address:
Home  Main Menu  Settings  Communication Settings  Ethernet  IPv6  Link Local / IPv6 Address
 Refer section Ethernet Communication Set-up on page 79 for setting static IP address or
enabling DHCP client.

 Refer section Communication via Web Browser on page 82 for establishing communication
using a Web browser.
Open any standard Web Browser, enter IP address of the controller and press enter. Browser will connect to
the controller and a Login page will be presented. Enter your credentials and you will be presented with EC500
data.
By default, the EC500 Controller comes enabled for HTTPS communication. You will need to add "https://"
before the IP Address.
 Recommended web browsers: Microsoft Internet Explorer 10 or later, Mozilla Firefox 3.0 or
later, Chrome V63 or later.
 It is recommended to keep web communication mode to HTTPS to ensure a secure network.
EC500 IDENTITY INFORMATION
The following identity information is available for the EC500:
IDENTITY INFORMATION
Parameter Description Where to find:
Model No. Indicates Model number of the controller, EC500. Display:

Home > Menu > System
Controller Serial EC500 serial number. Factory set. Status > System Info
Number Srl. No.: xxxxxxxxxxxxxxx
Web:
Boot Loader Indicates boot loader version vv.xx format. Factory Home > System Status >
Version loaded. System Info
Firmware Version Indicates currently loaded firmware version in

CC.vv.xx format, where “CC” is hardware group
category of controller. For EC500 category is 34.
Configuration File Indicates currently loaded Configuration file version

Version in vv.xx format. If no configuration file is loaded,
controller can run with default configuration and this
version is shown as 00.00
MAC ID Unique MAC ID of the Ethernet interface. Factory Display:

loaded. Home > Menu > Settings >
Communication Settings >
Ethernet
Web:
Home > Settings >
Communication Settings >
Ethernet
Following additional information can be stored to help system and site location.
Site Name User can store a 12 character Site Name where the Display:
system is installed.

Site ID User can store Site ID where the system is installed. Home > Menu > Settings >
Site ID can be allocated by monitoring servers for System Settings
network wide management. Site ID can be an
alphanumeric string with length 12. Web:
Home > Settings > System
System Part User can store System part number in which this Settings
Number controller has been used. This is to help inventory
management.
System Serial User can store Serial number of the system in which
Number this controller has been used. This is to help
inventory management.
EC500 INTERNAL CLOCK
The EC500 has a battery-backed clock for time stamping 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 EC500 time

Either:
• Use the keypad on controller to go to: Home Screen.
Time is displayed on lower right corner in DD/MM/YY HH:MM:SS format.
Or:
• In Web go to: Home Page
Time is displayed on lower right corner in DD/MM/YY HH:MM:SS format.
➢ To set the time on Web

• Connect to the EC500 via a web browser (See Ethernet Communications on page 79).
• Go to Home  Settings  System Settings.
• Click on Edit button to enable editing
• Click Date and Time field to select the text.
• Select the time or date text to be changed and type the correct time/date.
• Click Save button on Web page.
➢ To set the time from Display

• On EC500 display, go to Home  Main Menu  Settings  System Settings  Date and
Time.
• Enter on Date or Time field, if not logged in then login first and change the date or time.
• Enter to save.

TIME SYNCHRONIZATION
If required, the EC500 time can be synchronized to a reference time server using SNTP protocol (EC500 must
have access to the server).
➢ To synchronize the EC500 time using SNTP

• Go to Home  Settings  System Settings.
• Click Date and Time field to select the text.
• Select Auto under Synchronisation field and click Save button. Web page will refresh and
display NTP server settings.
• Set the following parameters:
Server IP Type IP Type IPv4 or IPv6.

Server IP Address IP address of primary SNTP server.
UDP Port Assigned by the time server
administrator.
Poll Interval The time between synchronizations.
• Click Save button again on Web page.
 For more information on SNTP, including a list of public SNTP servers, visit www.ntp.org
http://www.ntp.org.
 Ensure that your network has an internal SNTP server or allows access to an external server.
It may be necessary to configure 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 Translation File (EC500-xx-Vyyy.lng) into the EC500. Only Menu item
translation is supported. User entered strings and alarm strings are shown in English language only. Only one
language file can be loaded in addition to English.
The controller validates the language file for any corruption at power on / reboot. In case of any corruption the
language file is discarded and controller returns to English language, if another language was selected.
The existing language file will be normally supported in case of a firmware upgrade. In case translation of new
messages is not available, particular messages will be shown in English. In rare instances a firmware upgrade
may require a fresh language file compatible with this firmware.
Contact Eaton for available Translation Files. Current Firmware version does not support language translation
on Web pages.
➢ To add a new EC500 display language:

• Obtain the appropriate Translation File (EC500-xx-Vyyy.lng) from Eaton.
• Save the file on Laptop / PC.
• Connect to the EC500 via an Ethernet connection. See Communications Options on page 79.
• Open a web browser and browse to the EC500 IP address.

• Go to System Config.  File Management. Select Language Download.

• Click on Choose File and select the Translation File (EC500-xx-Vyyy.lng).
• Click on Upload and follow the prompts to add the language.
LANGUAGE SELECTION
EC500 can hold one language file (in addition to inbuilt support for English) and it can be selected from the
Display or Web page.
➢ To select a new language for the EC500 display

Either:
• On the EC500 keypad go to: Home Main Menu Settings  System Settings  Set
Language
• Select Language (English or second loaded language).
• Go back to Home screen. Controller will start showing messages in selected language.
Or:
• Go to Settings  System Settings.
• Click 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 EC500 can be upgraded from a PC/Laptop via a web
browser.
➢ To use a web browser for a Firmware Upgrade

• Obtain the appropriate Firmware File (EC500_nnn_GG.VV.RR.frm) from Eaton.
• Connect to the EC500 via a web browser (For details see Ethernet Communications on page
79).
• Go to System Config.  File Management. Select Firmware Upgrade.
• Click on Choose File and select the firmware File (EC500_nnn_GG.VV.RR.bin).
• Click on Upload and follow the prompts.
• Web page & display will show progress.
• Once full file has been uploaded successfully, EC500 will automatically reboot within 5
Seconds. User will need to login again.
Some configuration settings may be lost when the firmware in the EC500 is upgraded. Refer to the
new firmware Product Release Notes for details of specific configuration settings that may be affected. Check
the configuration after upgrading. Backup any changes to the configuration.
SOFTWARE DOWNGRADE

Some firmware may not be downgraded. Check with Eaton before downgrading the EC500 to an earlier
firmware version. This may not be possible, or downgrade with the wrong file may cause the EC500 to stop
operating, and require factory repair. Eaton may be able to supply a special downgrade file that will work
correctly.
It is likely that configuration settings will be lost if the firmware in the EC500 is downgraded. If a 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 Web Page.
➢ To Upload Configuration File

• Obtain the appropriate Configuration File (EC500_nnn_GG.VV.RR.cnf) from Eaton.
• Connect to the EC500 via a web browser (For details see Ethernet Communications on page
79).
• Go to System Config.  File Management. Select Config File Management.
• Click on Choose File and select the Configuration File (EC500_nnn_GG.VV.RR.cnf).
• Click on Upload and follow the prompts.
• Web page & display will show progress.
• Once full file has been uploaded successfully, EC500 will automatically reboot within 5
Seconds. User will need to login again.

EC500 Controller Handbook System Operation
SYSTEM OPERATION
OVERVIEW
Topic Page
Battery and Voltage Control 22
Rectifiers 34
Low Voltage Disconnect (LVD) 42
Alarms 45
Generator Control 53
Input / Output (I/O) 55
Energy Metering 60
Data Logging 62
BATTERY AND VOLTAGE CONTROL
The output voltage of the rectifiers is controlled by a number of control processes. The EC500 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 Li-ION battery. Note that Li-Ion battery typically
does not require Float mode. The following diagram shows the various control processes, measured values and
operating values that determine the rectifier output voltage.
 If ac fails, then any active control process stops. No control process can start until the ac
supply is restored.
EC500 Supports both VRLA and Li-ION batteries. Monitoring & Configuration for both these batteries is
explained separately.

VRLA BATTERY CHARGE PROFILE

To maximize life and performance of a VRLA battery it should be operated as per the battery manufacturer’s
recommendations.
The EC500 has the following battery charge-related settings:
Configuration
Battery Capacity Set to the rated 10 hour capacity of the installed Display:
battery strings. Set it carefully as some parameters Menu>Settings>Battery
are referenced and dependent upon this value. Settings>General
Settings>Battery Capacity
Web:
Home>Settings>Battery
Settings>General
Settings>Battery Capacity
Battery Current BCL logic maintains the battery charge current Display:
Limit (Normal) below this value, which is a percentage of the Menu>Settings>Battery
installed C10 Battery Capacity. Settings>Charge
Battery Current The Battery Current Limit setting when Engine Run Profile>CC/CV Mode
Limit (Alternate) State is active. Alternate Current Limit is effective Web:
only if a PFC Input is mapped to DG Sense Function. Home>Settings>Battery
If no PFC is mapped to this function, this limit is not Settings>Charge
used. When mapped and if PFC input is Active, Profile>CC/CV Mode
Alternate Current Limit is applied.
Float Voltage Set to the voltage required to maintain optimum
charge for battery at reference ambient
temperature.
Charge Voltage Battery charge voltage as per battery manufacturer
specifications. Charge voltage is typically 55.2V for
48V VRLA battery.
Float to Charge Percentage of Battery Capacity.
Threshold When battery charge current increases above this
threshold, the controller will put the battery in
Charge mode by setting target voltage equal to
“Charge Voltage”. This is typically set to 3% and
should be less than “Charge to Float Threshold”.
Charge to Float Percentage of Battery Capacity.
Threshold When battery charge current falls below this
threshold, the controller will put the battery in Float
mode by setting target voltage equal to “Float
Voltage”. This is typically set to 5% and should be
greater than “Float to Charge Threshold”
Max. Charge If this function is Enabled and Battery temperature
Temperature reaches the Set temperature value, the controller
will abort the battery charging and maintain the
float voltage.
Max. Charge If this function is Enabled and Battery Charging time
Duration reaches the Set time value, the controller will abort
the battery charging and maintain the float voltage.
 Please see additional parameters related to temperature compensation on page 26.

Monitoring
The following information is available about the current state of battery charging.
Charge State Indicates current charging state (Charge / Float / Idle) Home Screen (above date
for the battery. and time)
Battery Voltage Battery terminal voltage. Home Screen (Below

Battery Icon)
Battery Current Battery charging / discharging current. A discharge Home Screen (Adjacent to
current is indicated by a –ve sign. Battery Icon)
Active Battery Battery current limit applied at present.

Current Limit
BATTERY CURRENT LIMIT

Battery Current Limit automatically limits the maximum battery recharge current to:
• Prevent excessive battery charge current in under-loaded systems

• Minimize gas release in VRLA batteries
• Control the load on a standby generator.
Two current limit values can be set (both are percentage of the C10 rating of the battery):
When the rectifier is switched ON, Rectifier voltage rises to below battery voltage and then increases to
achieve target voltage by maintaining 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 Current Limit applies when the EC500 determines that an ac standby generator is
running. EC500 uses a Potential Free Input to determine If Engine is running. For Potential
Free mapping see section Digital Inputs.
 Battery Current Limit (Normal) is always enabled
➢ To activate Alternate Battery Current Limit
• If a Digital Input is required, connect a voltage free relay contact (that will
operate when the standby generator starts) to a Digital Input.
• In Web go to Settings  PFC Settings  Input Configuration.
• Configure the selected Digital Input and set ‘DG Sense’ PFC on required Digital
Input. Input Sense can also be set here.
• In Web go to, Menu  Settings  Battery settings Charge Profiles CC/CV
Mode and set Alternate current limit.
MULTIPLE BATTERY BANKS

The C500 controller supports multiple battery banks. It can monitor battery current for an individual battery
and control charge voltage so that maximum charge current through any battery string is below the set Battery
Current Limit. This avoids over charging of parallel strings in case current sharing among battery strings is not
uniform.
 All Battery strings should be of the same capacity.

➢ To use multiple battery banks

• Install one current monitoring channel for each Battery string
• Set Number of Batt. Fuse equal to number of battery banks. System supports maximum 5
banks in this mode.
• Set Number of Batt. LVD 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 available about Multiple Battery Banks:
Battery n Voltage Battery terminal voltage. Number of batteries is Display:

equal to number of battery fuses configured. Menu>System
Battery n Current Individual Battery current. Number of battery Status>Battery
currents displayed is equal to number of battery
LVDs configured. Web:

Battery n SoC Individual Battery SoC. Number of battery SoC Menu>System

displayed is equal to number of battery LVD’s Status>Battery
configured.
Battery n Charge Individual Battery Charge kWh since last reset.

kWh Number of battery charge energy meters is equal to
number of battery LVDs configured.
Battery n Discharge Individual Battery Discharge kWh since last reset.

kWh Number of battery discharge energy meters is equal
to number of battery LVDs configured.
Battery n Available Individual Battery AH available. Number of battery

Ah AH counters is equal to number of battery LVDs
configured.
 Parameters will be displayed only for the configured number of batteries.

Configuration
Set the following parameters
No of Batt Fuses Set the number of Battery fuse as per Battery bank Display:
installed. Menu>System Config>DC
No of Batt LVD Set minimum one LVD or it can be set as per Config>Batt Config
configuration selection. Number of current sensing
or installed shunt and number of LVD installed are Web:
always same. Menu>System Config>DC
Config>Batt Config
BATTERY TEMPERATURE COMPENSATION

As the ambient temperature of a battery drops (or rises) the voltage required to maintain full charge increases
(or decreases). Temperature Compensation automatically varies the charge voltage to cancel the effects of
changing temperature.
Enable Temperature Compensation for optimum battery life and battery capacity over a wider temperature
range.
 Temperature Compensation does NOT function during a Battery Test.
Temperature compensation function should work when all below conditions are true:
• BCL condition is completed.

• Temperature Compensation function should be enabled, Menu>Settings>Battery Settings>Temp
Comp. Setting.
• Battery charging current is < (BCL Factor% - 1%) of Battery Ah or Battery in float mode.

Monitoring
Status Enables or Disables Battery Temperature Display:

Compensation Menu>Settings>Battery
Settings>Temperature
Compensation Settings
Web:
Battery The temperature measured by the battery Display:

Temperature temperature sensor. Menu>System
Status>Battery>Battery
Temp
Web:
Home>System
Status>Battery>Battery
Temp
Configuration
Status Enables or Disables Battery Temperature Display:

Compensation. Disabled for Li-Ion Battery. Menu>Settings>Battery
Reference The temperature where no voltage adjustment is Settings
Temperature applied. This is recommended by battery Web:
manufacturer. Home>Settings>Battery
Settings
Compensation This is voltage drop or Increase/cell/C temperature.
Factor A factor of 2mv – 5mV / cell/C can be defined. Set it
as per battery manufacturer recommendation.
High Limit While increasing charge voltage due to temperature Display:

compensation, no additional voltage adjustment is Menu>Settings>Battery
made above this voltage limit. Settings>Temperature
Low Limit While decreasing charge voltage due to temperature Compensation Settings
compensation, no additional voltage adjustment is Web:
made below this voltage limit. Home>Settings>Battery
EQUALIZE
Equalize charges batteries at a higher voltage after they have been fully charged to ensure that all individual
cell voltages are the same, that electrolyte is distributed evenly, and that sulphate crystal build-up on the
plates is reduced.
Equalize can be scheduled to occur at regular intervals and/or can be started/stopped manually.
 Refer to the battery manufacturer's instructions before using Equalize.

The Bus voltage should gradually increase to Equalize voltage with Battery current approaching 10% of the
Battery Ah. Equalization Mode-Set Log should be stored in the event log. After the completion of the full
duration, voltage should gradually decrease to float voltage and the display will show Float mode instead of
Equalization mode.
If a system is in float mode and the Start Hour is reached, Equalize should start immediately.
If a system is not in float mode and the Start Hour is reached, then the system will wait for the float mode and
then start the Equalization.
Equalize will stop if either of these conditions is true:
• Equalize is disabled manually.

• Maximum temperature is reached before set duration.
Enable Equalize Mode

• Use the keypad to go 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>VRLA Charge Profile>Equalize Mode>Status.
Monitoring
Status Enables or Disables Equalize Mode Display:

Menu>Settings>Battery
Settings>Charge
Profile>Equalize
Mode>Enable
Web:
Settings>Charge
Profile>Equalize
Mode>Enable
Configuration
Status Enables or Disables Equalize Mode Display:

Menu>Settings>Battery
Settings>Charge Profile>Equalize
Mode
Web:
Settings>Charge Profile>Equalize
Mode
Equalize Voltage The bus voltage maintained during an Equalize cycle. Display:
Use the value recommended by the battery Menu>Settings>Battery
manufacturer. Controller will maintain this Equalize Settings>Charge Profile>Equalize
voltage for battery charging if function is enabled. Mode (Enable)
Start Hour Hour of the day (0 – 23) when Equalization will start Web:
after set interval time.

Duration Once started, equalization will continue for Home>Settings>Battery

“duration” hours unless terminated due to below Settings>Charge Profile>Equalize
reason. Mode (Enable)
Function disabled during charging.
Battery temperature reaches the abort value.
Day Interval Equalization will repeat after “Interval” days.
Max Equalize Temp If this function is enabled, Controller will abort the
Equalize mode if battery temperature reaches this
value.
BATTERY TEST
Battery test is a preventative maintenance tool that monitors the discharge capabilities to ensure that the
condition of the battery has not deteriorated over time.
Battery test starts at the scheduled date and time, when the battery is in float mode or battery SOC is 100%.
Rectifiers stop sharing the load current and the load current is supplied by the battery. The battery will start to
discharge. Battery test-set log is stored in event logs.
Battery test will stop if any of 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 sensor fail
➢ Enable Battery Test

• Use the keypad to go to Menu>Maintenance>Battery>Battery Test>Battery1>Battery Test Status.
Enter the appropriate pin then user will be able to see settable parameters.
• Use Web page to go to Menu> Maintenance>Battery>Battery Test>Battery1>Battery Test Status.
Configuration
Set the following parameters.
Battery Test Function need to set for enable the battery test. Display:
Status Menu>Maintenance>Battery>Battery
Date & Time The Date and Time that the first battery test cycle will Test>Battery1>Battery Test Status
occur. Subsequent test will occur at every Battery Test
Interval after that. Web:
Menu>Maintenance>Battery>Battery
End of Discharge If the Bus voltage drops below this value during a
Test>Battery1>Battery Test Status
Voltage battery test, then the test fails.
Duration The maximum time a Battery Test process will be
active. The Battery test will pass if the Bus Voltage
remains above the Battery Test Termination Voltage
for the duration of the test.
Information
The following information is available about Battery Test:

Periodicity Months between battery tests Display:

Menu>Maintenance>Battery>Battery
Test Voltage Remaining Battery Voltage after Battery Test>Battery1>Battery Test Status
Result Test completion.
Web:
Test Status Final test result of the Battery Test, Menu>Maintenance>Battery>Battery
Pass / Fail. Test>Battery1>Battery Test Status
BATTERY REVERSE DETECTION

If a Battery Reverse Detection alarm is enabled and the battery is connected with reverse polarity, the EC500
will:
• Activate Wrong Battery Polarity alarm, and

• Prevent respective LVD from connecting.
For Battery Reverse condition detection system must install a Normally Open (NO) type contactor between
battery fuse and negative bus bar connection. Battery contactor coil’s one end is connected with relay which is
triggered by controller and provides the positive path to contactor’s coil. The other end of coil is connected
with battery fuse which provides negative path to it.
Battery Reverse detection or Battery reverse alarm can be generated only at the time of system installation.
During run time it is not possible to detect the Battery Reverse condition. When the system is being installed
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 than -20V then EC500 will
declare Battery Reverse alarm and protect the system.
Hazardous condition:
• When the system is running and rectifiers are providing the bus voltage to circuit, the battery
contactor will be ON and EC500 will not turn off the contactor. In this run state of the system, if
reverse battery connected to the system then it can be hazardous for human and system.
• If an N/C (Normally Closed) contactor installed in the system and a reverse polarity battery connected
to it, then before sensing the voltage system will fail.
 If a battery is to be connected while system is in running condition, LVD must be isolated from Home >
Maintenance > Battery isolate.
MANUAL CHARGE MODE

Manual charge automatically increases the Rectifier voltage up to Charge voltage (i.e. 55.2V) to recharge the
batteries as quickly as possible after a prolonged battery discharge.
Rectifiers will charge the battery until its SoC becomes 100%. When battery comes to float mode (i.e. Battery
charging current becomes less than 3% of Battery AH), this function will be disabled.
Manual Charge Mode-Set, is stored in the event log.
Manual charge will stop if any below condition is true:
• Disable the function, Rectifier will fall to float voltage.

• Mains Off, manual charge will stop and will not go Manual mode again, even if Mains becomes OK.

Manual Charge – Clear log will store in event log.
➢ Enable Manual Charge Mode

• Use the keypad to go Menu>Maintenance>Battery>Manual Charge Mode>Status. Enter the
appropriate pin then user will be able to see settable parameters.
• Use Web page to go Menu>Maintenance>Battery>Manual Charge Mode>Status.
Configuration
Status Function need to set for enable the Display:

Manual Charge Mode Menu>Maintenance>Battery>Manual
Start Manual Start / Stop the Manual Charge Mode Charge Mode
Charge Web:
Menu>Maintenance>Battery>Manual
Charge Voltage Rectifier will raise its charge voltage up to
Charge Mode
this limit
Monitoring
Following information is available about Equalization:
Status Display will show the Manual Charge at the time of Display:
Manual Charging and after completion it will show System Status
Float.
SOLAR CHARGER POWER SHARE

Where a DC power system has energy inputs both from AC mains supply (or AC generators) and solar, then the
EC500 must share the load power between these sources. Generally, the preferences are for the load to be
supplied from the alternative energy source first, and take energy from AC only when there is not enough solar
energy. This is done by increasing the solar charger rectifier voltage slightly. Generally 0.5V difference is
maintained between Solar Charger voltage and rectifier output voltage. The following example explains how
this works.
Float mode: Solar charger rectifiers make 54.0V and AC rectifiers make 53.5V.
Charging mode: Solar charger rectifiers make 55.2V and AC rectifiers make 54.7V.
Solar chargers share maximum load by tracking MPPT (Maximum Power Point Tracking) point from solar panel.
Configuration
Installed S- Number of Solar charger installed in the Display:

Charger system. Menu>Settings>S-Charger Settings
Web:
Menu>Settings>S-Charger Settings

Current Limit Maximum current limit for solar charger.

Solar chargers cannot generate current
more than this limit.
Over Voltage Maximum voltage limit for solar charger.

Solar charger cannot generate voltage
more than this limit.
Under Voltage Voltage threshold. If solar rectifiers

generated voltage is less than this limit
then switch to AC from solar.
Low Solar Current threshold. If solar rectifier output

Current Thd. current is less than this limit, then switch
to AC from solar.
Low Solar current When solar current is less than Low Solar
time Current Threshold for this time limit,
generate the Low Solar current Alarm.
Load Priority Diff This voltage defines the difference

voltage between Solar charger voltage and AC
Rectifier voltage. AC rectifiers generate
less voltage comparatively solar rectifier
with keeping this voltage difference.
Input cut-off High Voltage: When Solar charger input

voltage is more than this limit, switch
from solar to AC mode.
Low Voltage: When Solar charger input

voltage is less than this limit, switch from
solar to AC mode.
ID De-Register All: De-register all Solar chargers with

EC500.
Individual: De-register individual Solar

charger with EC500.
Need to use LSS command if again

registration is required.
Redundancy After enabling this function, the first solar

charger will activate, and the second
charger will go into sleep mode. If the first
solar charger fails for any reason, then the
second solar charger will come out of
sleep mode.
Alarm setting Enable Solar charger alarms (S-Charger

Fail, S-Charger Comm Fail, Low Solar
Current) with severity.

Information
The following information is available about all Solar Chargers:
Common Information
Active S-Charger Active Solar chargers count Display:

Count Menu>System Status>S-Charger
Total S-Charger Total current provided by Active Solar Web:
Current chargers. Menu>System Status>S-Charger
Total Solar kWh Total power provided by Active Solar
chargers.
ID ID number of Solar charger provided by
EC500
Individual Charger Information

Output Voltage Output voltage generated by Solar Display:

charger. Menu>System Status>S-Charger
Output Current Output current generated by Solar Web:
charger. Menu>System Status>S-Charger
Status Communication status between Solar
charger and EC500.
DC State The status of DC state of solar charger;
Solar charger is ready to provide output
power. When all working conditions are
normal then DC State of Solar charger
shows ON status.
Input Voltage Input voltage to Solar charger provided by
Solar panel.
Input Current Input current to Solar charger provided by
Solar panel.
Input Power Input power to Solar charger provided by
the Solar panel.
Solar kWh Output power provided by Solar charger
to load.
Solar Runtime Run Hour increments when input current
in single solar charger is greater than
0.1A. In every 6 minutes Run Hour
counter should increment by 0.1.
Temp. Rise The Solar charger’s Mosfet temperature.

RECTIFIERS
The EC500 Controller supports the following Eaton rectifiers:
HPR48-ES 3kW
LPR48-ES 1.2kW
The Controller supports only one series of rectifiers in one system. Please refer to System Configuration for
Rectifier Type selection. Solar Charger is always supported irrespective of the type of rectifier selected.
Configuration 1P-N:
In this configuration all Rectifiers operates on a single phase and neutral. If system does not have any input
measurement unit (ACIF or HVLV) then Rectifiers can provide ac measurement with respect to Neutral.
Configuration 3P-N:
Rectifiers are equally distributed on three different phases, R-phase, Y-phase and B-phase with respect to
neutral. If the system does not have any other input ac measurement unit (ACIF or HVLV) then Rectifiers can
provide AC measurement for R-phase, Y-phase and B-phase with neutral.
Configuration 3P-P
In this configuration, the system uses Rectifiers which operates on phase to phase input. 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 Configurations at page 67

Following information and configurations are available for User.
Monitoring
Active Rectifier Total number of Rectifier installed and Display:

Count communicating. Menu>System Status>
Total Rectifier Total Rectifier Current in Amp. Rectifier>General Status
Web:
Current
Home>System Status>
Current Share Maximum current deviation among rectifiers or Rectifier>General Status
Deviation Share factor stabilize in 1 minute
ECO Mode Status Indicates if Energy Saving Mode is enabled or Display:
disabled Menu>Settings>Rectifier Settings>
Web:
Menu>Settings>Rectifier Settings
Rectifier Slot Slot number allotted to this rectifier. This is allotted Display:
Number as per sequence of registration and not actual Menu>System Status>
physical slot number Rectifier>Individual Rectifier
Status
Rectifier Serial Production Serial Number of rectifier. Can be used Web:
Number for verifying the registered slot number Home>System Status>
Rectifier>Individual Rectifier
ID 15 digit Identification number of rectifier provided Status
by EC500

Output Voltage DC output voltage as measured by rectifier Display: NA

Web:
Output Current DC output current as measured by rectifier Home>System
Status>Rectifier>Individual
Rectifier Status
Status Communication Status
DC State Internal DC / DC stage status
Share Factor Current percentage deviation
Input Voltage Input AC voltage as measured by rectifier
Input Current Input AC current as measured by rectifier
Temperature Rise Heat Sink temperature rise (C)
 All parameters may not be available for every type of rectifier

Configuration
Installed SMR Defines maximum number of Rectifier installed in Display:

system. Controller will register only these many Menu>Settings>Rectifier
rectifiers. Settings
Installed SMR on In case Controller is configured for two CAN buses, Web:
CAN1 Bus specify number of rectifiers on CAN Bus number 1, Home>Settings>Rectifier
else this setting is not available. Settings
Installed SMR on In case Controller is configured for two CAN buses,
CAN2 Bus specify number of rectifiers on CAN Bus number 2,
else this setting is not available.
Current Limit Defines maximum current limit of individual
rectifier.
Over Voltage Indicates set value for DC High Voltage alarm
threshold of rectifier.
Ext Over Voltage Extended over voltage to extend the Over Voltage to
the Maximum of 67V.
Under Voltage Indicates set value for DC Low Voltage alarm
threshold of rectifier.
ID De-Register To De-register the rectifier Individually or All.
ECO Mode Refer to Section Economy Mode on Page 38.
Start Voltage Minimum Voltage to start the rectifier.
Rectifier Default In case controller communication is lost, rectifiers
Voltage will target this voltage. For this setting to be present,
the rectifier should communicate at least once with
the controller. This happens at factory level.
Rectifier Default In case controller communication is lost, rectifier
Current Limit current limit will fall back to this limit. For this
setting to be present, the rectifier should

communicate at least once with the controller. This

happens at factory level.
 If more rectifiers are installed than Install Rectifier Count, the rectifiers will work but no
alarms will be reported.
RECTIFIER REGISTRATION
All the rectifier slots in the DC Power system are identical. The Controller automatically registers all rectifier
modules and solar chargers as they are inserted into the dc power system. Rectifiers are assigned a sequence
number in the order these are registered. All further reference to rectifiers / solar chargers is with this
sequence number. To have one to one correspondence between the Rack Slot numbers and rectifiers, the
following procedure shall be followed.
➢ New System Installation

• Remove or Switch Off all the Rectifiers. Keep Rectifier in Slot 1 in switched on condition.
• Go to Home  Settings  Rectifiers Settings ID De-Register and select ALL. This will de-
register all rectifiers.
• Switch Off Rectifier in Slot 1 also and Switch it on again after a few seconds.
• Once Controller / 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 Rectifier Status
• Now switch on rectifier in slot 2. Controller will register it for rectifier number 2. Registration
status can be checked as above.
• Similarly register all rectifiers one by one in correct sequence.
• Controller will register rectifiers install count set at Home  Settings  Rectifier Settings 
Installed SMR.
• Controller will not register rectifiers more than “Rectifier Install Count” set above.
• If the number of Rectifiers installed is less than “Rectifier Install Count”, the Rectifier
Communication Fail alarm will keep generating. In such a case whenever a new rectifier is
inserted, it will automatically get registered at next slot location.
 It takes about 2-3 seconds for registration of one rectifier.

 A normal blinking of Green LED of Rectifier shows correct registration of individual rectifier.
➢ Rectifier LEDs
Three LEDs located to the centre of the front panel of rectifier indicate the following status:
1st LED (Green): OFF - AC fails
ON - AC OK
Flashing - Blink at rate of 500ms when rectifier identified by controller.
Flash when EC500 poll rectifier for command.
2nd LED (Yellow): OFF - Normal

ON - Alarms present
AC abnormal, Frequency abnormal, I/P AC de-rating,

Temp de-rating, O/P de-rating, current limit

Flashing - Blink at rate of 500ms when Rectifier comm. Fail is present
3rd LED (Red): OFF - Normal

ON - Alarms present
High temp shutdown, O/P over voltage shut down,
O/P under voltage, High mains, Low mains, Fan Fail
Blink - Rectifier in sleep mode
➢ Replacing / Manual Registration / De-registration of a Rectifier

Follow the De-registration and Registration process to replace an installed rectifier.
The EC500 sends a LSS command to rectifier. In response, the rectifier sends it data. The EC500
checks, and if the rectifier is already registered then it will skip the registration process. Else it starts
the registration process.
• First De Register the ID of specific rectifier from display “Menu>Settings>Rectifier Settings>ID

De-Register>All / Individuals”. One pop message will appear on the screen while
deregistering and ask for YES.
• Insert installed 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 Rectifier Status”. All rectifiers’ green LEDs will blink. The EC500
should show rectifier ID in individual rectifier status.
• If a registered rectifier is replaced with an unregistered rectifier then EC500 will not
communicate with the unregistered rectifier.
• Now remove the unregistered rectifier from rack and replace with registered rectifier, EC500
will starts to communicate with registered rectifier.
IDENTIFY A RECTIFIER
The rectifier’s registration number does not correspond to a physical position in the DC power system.
➢ To Identify a Rectifier
Either:
• In EC500 keypad go to: Menu>System Status> Rectifier>Individual Rectifier Status. Press
Enter.
 For identification Green LED on corresponding rectifier will start blinking fast when a User
selects this rectifier on LCD.
• Rectifier detail screen will appear and show rectifier’s identification number and
communication status.
Or:
• In Web page go to: Menu>System Status>Rectifier, appear screen will show rectifiers
identification number.
FORCE SHARE RESET

The controller automatically adjusts rectifier target voltage so that each rectifier equally shares DC load. To
achieve this, the controller periodically updates a share factor in each rectifier for a faster current sharing after
a power restore. The user can manually reset this current share factor to restart current share factor
calculation again.
Note that sharing is effective only when rectifier load is more than 25% of its capacity.
➢ To force Share Factor Reset

To force reset of current share factor
Either:
• On the EC500 keypad select: Home  Settings  Rectifier Settings  Force Share Reset
• Confirm the action to reset current share factor.
Or:
• Go to Settings  Rectifier Settings  Force Share Reset.
• Click on “Force Share Factor” action field to reset current share factor.
 On Current Share Factor Reset, controller will restart current sharing adjustment. It may take
2 – 5 minutes to achieve 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 Mode operation is not available when Economy Mode Operation is
enabled. In Sleep Mode, the rectifier does not produce any output voltage, though it keeps on communicating
with the controller.
➢ To force rectifier to Sleep Mode

To force any rectifier to sleep mode or to make it active
Either:
• On the EC500 keypad Enable: Home  Settings  Rectifier Settings  Force SMR to Sleep
• Then Select or Deselect individual rectifier to put it in sleep mode or to activate it.
Or:
• Go to Settings  Rectifier Settings  Force SMR to Sleep.
• Select individual rectifier Sleep status from drop down.
• Click Save button.
 Rectifiers can be put in Sleep mode manually only of Economy Mode Operation is disabled.
ECONOMY MODE
If Economy Mode operation is enabled, the Controller can automatically put the rectifiers in sleep mode when
the total load current is less than the total rectifier capacity.
This raises the average load on the remaining rectifiers which will then operate in higher efficiency range and
results decrease in system power consumption.

Controller will progressively enable rectifiers when load increases. User can select minimum number of
rectifiers which will always run.
 Carefully select minimum number of rectifiers to run in Economy Mode taking care of battery
backup conditions and input power conditions.
➢ Enabling Economy Mode Operation

To enable Economy Mode operation
Either:
• On the EC500 keypad Enable: Home  Settings  Rectifier Settings  Eco Mode
Or:
• Go to Settings  System Settings  Rectifier Settings.
• Click ECO Mode / Status field to select Enable / Disable drop down.
• Select Enable and Click Save button.
• On successful change, more options will appear.
 When Economy Mode Operation 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 rectifier.
Monitoring
Economy Mode Indicates if Economy Mode is enabled or disabled. Display:

Menu>System Status>
Rectifier > General Status
Web:
Home>System Status>
Rectifier > General Status
Rectifier Status If rectifier is in Sleep mode, it will be indicated. Display:

Menu>System Status>
Rectifier
Web:
Home> System Status>
Rectifier
LED Indication If a rectifier is in Sleep Mode, Red LED starts flashing Rectifier front panel LED
at high rate on rectifier front panel.
Configuration
Economy Mode Enable to activate Economy Mode operation. Display:

Status Menu>Settings>Rectifier
Minimum Active Set minimum number of rectifiers which shall Settings>Eco Mode
Rectifiers remain active irrespective of Economy mode logic. Web:
Minimum Load Load percentage (of rectifier capacity). If rectifier
load is below this threshold the Economy mode logic

will start forcing rectifiers to sleep mode till rectifier Home> Settings >Rectifier
load increases to “Maximum Load threshold”. Settings >Eco Mode
Maximum Load Load percentage (of rectifier capacity). If rectifier
load is above this threshold the Economy mode logic
will start enabling rectifiers from sleep mode.
Sleep Sequence Two sleep sequences are supported, Linear & Cyclic.
Cyclic Period Duration after which a rectifier in sleep mode will be
made active and next rectifier put in sleep mode.
Operational only if cyclic sleep sequence is selected.
Operation
Economy mode logic, when enabled, monitors per rectifier current and if it is less than the Minimum Load
setting and number of active rectifiers is more than Minimum Active Rectifiers setting, then it will put one
rectifier in sleep mode. This cycle is continuously repeated and next rectifier put in sleep mode till either load
current per active rectifier is 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 or number of active rectifiers
becomes less than Minimum Active Rectifiers setting, logic will start enabling rectifiers one by one, till per
rectifier current is less than Maximum Load setting or all rectifiers have been enabled. Each cycle takes
approximately 1 minute.
The following two types of sleep and wake up sequences are provided:
Linear Sleep Sequence

If Linear Sleep Sequence is selected, the rectifiers are put in sleep in right to left direction i.e. the last rectifier
is put in sleep mode and then second to last and so on. Conversely the rectifiers are woken up in left to right
order. A rectifier in sleep mode remains in this mode unless changed by wake-up logic.
Cyclic Sleep Sequence

In this sequence, rectifiers sleep and wake-up in cyclic order in a clockwise direction. In diagram below, six
rectifiers are present; three rectifiers are active and the other three rectifiers are in sleep mode.
Cyclic process uses these variables:
• cyclic index number
• cyclic period.
At time t = 0, the cyclic index is one. Assume rectifier 4, 5 and 6 are active and rest are in sleep mode.

When the cyclic period is over (i.e. 60min), the cyclic index increments by one, so that the index becomes 2
and time t = 1. When the index is incremented by one, then ON/OFF status of rectifier is shifted by one
position in clock wise direction as shown in fig below.
Similarly, at every cyclic period completion, the cyclic index is incremented by one and reaches its maximum
value that is equal to installed number of active rectifiers.
When cyclic index reach at its maximum value (6 in this example), the cyclic index rolls back to value one at its
next completion of cyclic period.
The advantage of the cyclic sleep sequence over linear sleep sequence is that in cyclic sleep sequence each
rectifier goes to sleep mode for their dedicated time period. This gives equal running time for all rectifiers.
For the Linear sleep sequence, the Min Active Rectifier count of rectifiers from left to right direction are always
ON.
RECTIFIER ALARMS
Alarm Description Where to find:
Rectifier Fail The rectifier fail alarm is generated when Rectifier Display:
Fail condition is provided from the rectifier Menu>Setting>Rectifier
(however, if all rectifiers communicate “Rec Fail” Settings>Alarm Settings
alarm to MCM then we get “All Rec fail” alarm on Web:
MCM rather than “Rec Fail”). Home>Settings>Rectifier
Multiple Rectifier Multiple Rectifier Fail alarm is generated when one Settings>Alarm Settings
Fail more than one but not all rectifiers have Rectifier
Fail alarm.
All Rectifier Fail The “Rec Current Limit” alarm is generated by the
rectifier when the control loop switches from
constant voltage to constant current mode and
output voltage drops by 1V compared to previously
measured voltage.
Rectifier Comm. The “Rec CAN COMM Fail” alarm is generated inside
Fail the rectifier when the rectifier communication with
MCM is interrupted for continuous delay of 10
seconds. Whenever “Rec CAN Comm Fail” occurs,
rectifier re stores its default settings – a) Output
Voltage of 54.0V, Rectifier Current Limit of 63A,
Battery Temp Comp Factors and Values, Re-set of
previously disabled commands issued to the
rectifier.
All Rectifier Comm. In case, if 1) Rectifier Fail condition is provided from
Fail the individual rectifier (however, if all rectifiers
communicate “Rec Fail” alarm to MCM then we get
“All Rec fail” alarm on MCM rather than “Rec Fail”)

or 2) while scanning all rectifier’s on a phase, even if

1 or more rectifiers has communication established
with MCM, the remaining rectifiers on that phase
are declared “Fail”, provided they are not
communicating
Rec Comm Fail is generated whenever rectifier does
not respond to MCM request to communicate
within 60ms then “Rec Comm Fail” is generated and
when this happens to all the installed rectifiers then
“All Rec Comm Fail” is generated.
All Rec Current The “Rec Curr Limit” alarm is generated by the
Limit rectifier when the control loop switches from
constant voltage to constant current mode and
output voltage drops by 1V compared to previously
measured voltage.
Rectifier Internal This alarm contains the rectifier’s internal alarms i.e.
Alarm SMR Fan fail, SMR EEPPROM fail etc.
Rec Proc Mode (FA) This alarm is generated by the rectifier when the
input frequency is <44 Hz and greater than 66 Hz for
10 ms.
Rec Proc 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 Mode (Set)” alarm is generated by the
rectifier when the input voltage fluctuates more
than 3 times within the time period of 90 seconds.
LOW VOLTAGE DISCONNECT (LVD)
The controller continuously monitors system bus and battery voltages. It can generate system alarms and Low
Voltage Disconnect signals for protecting battery and loads.
 The system can also generate pre-disconnect warnings.

The controller supports one Battery Low Voltage Disconnect and up to four Load Low Voltage Disconnects.
Low Voltage Disconnect has two purposes:
• to protect a VRLA battery from deep discharge and premature failure, and/or
• to reduce the load on a battery under discharge so that high priority equipment operates for
a longer time after an AC supply failure.
In case multiple battery contactor drives are required same can be mapped. Please see Configuration on page
43Error! Bookmark not defined.. All battery contactors use the same disconnect and reconnect thresholds.
BUS MONITORING
The following thresholds can be set to generate alarms whenever the system bus is lower / higher than these
thresholds:-

Monitoring
Bus Voltage System Bus voltage. Home Screen (Below load

Icon)
System Current System Current, sum of load and all battery currents. Home Screen (Below
rectifier Icon)
Configuration
DC High Voltage Set Whenever Bus voltage is higher than this set Display:
Threshold threshold, system generates a DC high Voltage Home>Settings>DC
alarm. This alarm can be latched. Settings>DC Alarm Settings
DC High Voltage Restore point for clearing DC High Voltage alarm.
Restore Offset Web:
Home>Settings>DC
DC Over Voltage If Enabled DC High Voltage alarm will be latched,
Settings>DC Alarm Settings
Latch requiring a manual clearing of alarm.
DC Low Voltage Set Whenever Bus voltage is lower than this set
Threshold threshold, system generates a DC Low Voltage
alarm.
DC Low Voltage Restore point for clearing DC low voltage alarm.
Restore Offset
DC Overload Set If system current (sum of load and all battery
Threshold currents) exceeds this DC Overload Alarm Threshold
(Normally 105% of System Capacity) system
generates DC Overload alarm. This alarm can be
latched.
DC Overload Offset Restore point for clearing DC Overload alarm.
Threshold
DC Over Current If Enabled DC Over Current alarm will be latched,
Latch requiring a manual clearing of alarm.
When the DC High Voltage alarm condition becomes true, the system generates the DC High Voltage alarm.
The rectifier stops providing current for battery charging , but Loads are connected to system and remain
powered.
BATTERY LVD
The user can define Disconnect & Reconnect thresholds. These apply to all battery LVDs.
Configuration
Battery Low Indicates “disconnect voltage threshold” for battery Display:

Voltage Disconnect contactor. Home>Settings> Battery
Threshold Settings>BLVD Settings
Battery Low Indicates “re-connect voltage threshold” for battery
Voltage Disconnect contactor. Web:
Restore Home> Settings> Battery
Settings>BLVD Settings

LOAD LVD
The user can define up to 4 Load connect & disconnect thresholds.
Configuration
Load x Low Voltage Indicates “disconnect voltage threshold” for Load x Display:
Disconnect contactor. Menu>Settings>DC Settings
Threshold > LLVD Settings
Load x Low Voltage Indicates “re-connect voltage offset” for Load x Web:
Re-connect Offset contactor. Home>Settings>DC Settings
>LLVD Settings
 Refer Hardware Channel Mapping on page 74 for LVD physical channel mapping.
TYPICAL LVD ARRANGEMENTS
The simplest use of an LVD is as a single battery disconnect contactor.
The following diagram shows a typical arrangement of one battery and 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 battery availability for the higher priority loads
(contactor controlled by control channel BLVD). The battery will be disconnected when the battery voltage
reaches its BLVD set threshold.
LVD OPERATION
The battery LVD operates (opens) if the bus voltage is below the BLVD Set Threshold. Battery LVD will
reconnect if Battery voltage is higher than BLVD Restore Threshold. A fixed delay of 15 seconds is provided
before operating (activating / de activating) the LVD when voltage conditions are met.
The load LVD operates (drops) if Bus voltage falls below the respective LLVD Set Threshold. Load LVD will
reconnect when Bus voltage rises above respective LLVD Restore point. A fix delay of 15 seconds is provided
before operating (activating / de activating) LVD when voltage conditions are met.

DCDB ALARMS
DC Overload This alarm is generated when System Current Display:

(Summation of load and all battery current) exceeds Menu>Setting>DC Settings>
the System Overload Alarm Threshold (Normally Alarm Settings
105% of System Capacity) for the duration of 10 Web:
seconds. Home>Setting>DC Settings>
This Alarm will be latched if System Overload Alarm Alarm Settings
Latch Enable is “Set”.
DC Over Voltage This alarm is generated when Bus Voltage exceeds
the DC Over Voltage Alarm Threshold for duration of
10 seconds.
This Alarm will be latched if DC Over Voltage Alarm
Latch Enable is set.
DC Low Voltage This alarm is generated when Bus Voltage becomes
lower than DC Voltage Low Alarm Threshold and
more than 30V for the duration of 5 seconds.
LLVD Disconnect This alarm is generated when Bus Voltage becomes
lower than DC Under Voltage Alarm 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 no delay.
ALARMS
EC500 provides a number of alarms to indicate any abnormal system condition to the user. The EC500 is
supplied with a standard configuration file has a default set of alarms configured and enabled. This will be
sufficient for standard dc power system operation.
For specific alarm arrangements all EC500 alarms can be individually enabled or disabled and are configurable.
TYPE OF ALARMS
EC500 provides following four type of alarms:
Alarm Type Description Configuration:
System Alarms Generated by the operating values of dc power See details on page 47.
system (voltages, currents, temperatures, and so
on), operation of power system modules (rectifiers,
circuit breakers, fuses, and so on) and
communication alarms. The EC500 system alarms
are listed in Alarm Descriptions on page 97.
Analog Alarms Activated when the result of Analog compare logic is See details on page 49.
active.
Potential Free / Activated when mapped PFC / DI is in its active See details on page 48.
Digital Input Alarms state.

Alarm Type Description Configuration:
Smart Alarms Software simulation of logic gates to allow the See details on page 51.
logical combination of multiple alarms.
ACTIVE ALARM INDICATIONS

All alarms can be assigned a Severity:
• Critical
• Major
• Minor
The Severity determines how an active alarm is indicated:
Alarm Severity Indications Details
Critical Major LED (RED) on front panel will turn ON. See details on page 16.
Major Major LED (RED) on front panel will blink. See details on page 15.
Minor Minor LED (Amber) on front panel will turn ON. See details on page 15.
Critical If the audible indicator is enabled, it will sound until See details on page 16.
Major joystick is operated. Audio indicator will sound for a
Minor maximum of 1 minute if no keyboard operation is
done.
Critical The alarm name and severity icon will be displayed

Major on the EC500 main screen.
Minor
The Event Log will record the alarm activation /
deactivation.
If configured, an Email message will be sent to one

or more Email addresses.
If configured and Modem is installed, an SMS text

message will be sent to one or more cell phones.
In Web (if connected), the alarm name and severity

icon will be displayed in the Alarms list on the
System page.
If configured, SNMP Trap will be sent to a configured

Trap Receivers.
Critical If configured, one or two digital outputs (relays) will

Major be operated via Group alarms.
Minor
➢ To view a list of active alarms

• Use the EC500 keypad to go to: Alarms.
• Or, Web go to Home or System Alarms page.

ALARM CHANGE INDICATION

The time and date of the last alarm state change is shown in the Alarms menu on Web page and Display. The
last alarm change is also shown on the display Home page.
ALARM GROUPING
EC500 has provision for grouping of individual alarms. A maximum of 64 alarm groups can be configured. The
user can map individual alarm to up to two alarm groups. Grouping provides an OR function. User can edit
group names to match the requirement. Some of the group names may not be editable. Only Groups can be
mapped to operate output relays. Alarms cannot be mapped directly to relays. In case alarm grouping is not
required, users can map individual alarms to independent group.
 If a Potential Free alarm output is required, the alarm should be mapped to at least one
alarm group.
Group Alarm Configurations

Number of Groups Number of Groups available to user can be set.
Group Name Group can be given a meaningful name to represent

the alarms grouped.
 Refer section Digital Outputs on 59 for 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, circuit breakers, fuses etc.) and communication alarms. The
EC500 system alarms are listed in Alarm Descriptions on page 97. The user can define alarm severity, Trap
operation and output mappings for System alarms. The user cannot change alarm names from Web page
though these can be changed in Configurator.
Configuration
The following system alarm parameters can be configured for individual system alarm.
Enable Alarm If set to Disabled then the alarm will not activate. These settings are available
Note that for some alarms enable / disable may not under respective resource
be available. settings e.g. alarm settings
for Battery will be available
Alarm Severity Alarm Severity (Critical / Major / Minor) of individual under Battery Settings.
alarm.
Display:
Enable Audible Enable or disable the audible alarm indicator for Menu>Settings> xxx
Alarm Indication particular alarm. Settings>Alarm Settings
Enable SNMP If Enabled, SNMP Trap will be sent for this alarm. For Web:
SNMPv3, alarm severity should be equal to or higher Home>Settings>> xxx
than Trap receiver’s configured alarm severity. See Settings>Alarm Settings
page 86 for details.

Group Map 1 Individual alarm can be mapped to one of the 64

alarm groups.
Group Map 2 Individual alarm can be mapped to one of the 64

alarm groups.
 Refer Alarm Descriptions on page 97 for System alarms.

 System alarm names can be modified in Configurator. Carefully modify System alarm name
so that it reflects the actual condition, else the end user may not be able to identify the alarm.
POTENTIAL FREE INPUTS / DI ALARMS

EC500 supports up to 64 Potential Free inputs for external alarm reporting. For using the same, up to 64 user
alarms are provided. Potential Free inputs are de-bounced before being taken as alarm. The user can directly
map the PFC inputs to user alarms. Alarm names can be set. Note that some potential free inputs can be
mapped to some pre-defined functions also.
Potential Free Input Configuration

Enable Input Enable it to use the PFC input. If set to Disabled then
the input will not be polled.
Input Sense Open / Close, determines Active state of input. If set

to Open, an open input will raise alarm.
User Alarm Map Map input PFC to one of the User alarms. Some of
the user alarms may be pre-defined and not
configurable.
Input Hardware Hardware input mapping for corresponding pfc

map input.
User Alarm Configuration

User can do following settings for User Alarms.
Enable Alarm If set to Disabled then the alarm will not activate.
Note that for some alarms enable / disable may not
be available.
Alarm Name Set Alarm name for respective user alarm. This name
will appear in alarm windows and reported on
SNMP.
Alarm Severity Alarm Severity (Critical / Major / Minor) of individual

alarm.
Enable Audible Enable or disable the audible alarm indicator for

Alarm Indication particular alarm.

Enable SNMP If Enabled, SNMP Trap will be sent for this alarm. For
SNMPv3, alarm severity should be equal to or higher
than Trap receiver’s configured alarm severity. See
Activation Delay Input will be de-bounced for Alarm Activation Delay

before declaring alarm active.
Deactivation Delay Input will be de-bounced for Alarm De-activation

Delay before declaring alarm de-active.
Group Map 1 Select alarm group 1 to map. Individual alarm can be

mapped up to two alarm groups.
Group Map 2 Select alarm group 2 to map, optional. Individual

alarm can be mapped up to two alarm groups.
➢ Using Potential Free input for alarm

Follow below steps to enable and map PFC input for alarms
• Map PFC hardware: Home  System Configuration  Hardware Mapping  PFC Input
• Enable PFC: Home  Settings  PFC Settings  Input Configuration  Status
• Enable Sense: Home  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  System Configuration  Alarm Management  User Alarms (on
web only)
• Enable Alarm: Home  Settings  PFC Settings  Alarm Settings  Status
• Set Severity: Home  Settings  PFC Settings  Alarm Settings  Severity
• Group Map 1& 2: Home  Settings  PFC Settings  Alarm Settings  Map 1 / 2
• Enable Trap : Home  Settings  PFC Settings  Alarm Settings  Trap
ANALOG ALARMS
EC500 provides 16 analogue compare engines. Predefined parameters can be compared against fixed values or
other parameters. High / low compare to absolute value or analogue parameters, offset and hysteresis are
provided. Following configurations can be done. User can set names of Analog Alarms as given in Analog Alarm
Configuration.
Analog Engine Configuration

Enable Engine If set to Disabled then the analogue alarm will be Web (only view):
disabled and engine will not execute the Home>Settings> Analog
comparison. Alarm Configuration.
Input Parameter Select parameter to compare. System variable and Configurator:

analogue user inputs can be selected.

Reference Reference parameter against which Input Parameter Home>Settings> Analog

Parameter will be compared. Alarm Configuration
Function Select High or Low function for comparison. E.g. If

High function is selected and Input parameter is
higher than Reference parameter + Offset for
Activation time, an alarm will be generated. Alarm
will clear when Input parameter is lower than
Reference Parameter + Offset + Hysteresis for
Deactivation time.
Alarm Activation Output of comparison function will be de-bounced

Delay for Alarm Activation Delay before declaring an active
alarm.
Alarm Deactivation Output of comparison function will be de-bounced

Delay for Alarm Deactivation Delay before declaring an
inactive alarm. At start up all alarms are inactive.
 Additional configurations may be required for enabling analogue user inputs.

Analogue Alarm engine can be configured only with help of Configuration Generator “ConfGen”. For easy
configuration a GUI is provided.
Analog Alarm Configuration

User can do following settings for Analog Alarms.
Enable Alarm If set to Disabled then the alarm will not activate. Display:
Note that for some alarms enable / disable may not
be available.

Alarm Name Set Alarm name for respective analogue engine Menu>Settings> Alarm
alarm output. This name will appear in alarm Management > Analog
windows and reported on SNMP. Alarms
Alarm Severity Alarm Severity (Critical / Major / Minor) of individual Web :

alarm. Home>Settings> Alarm
Management > Analog
Enable Audible Enable or disable the audible alarm indicator for Alarms
Alarm Indication particular alarm.
Configurator:
Home>Settings> Alarm
Management > Analog
Alarms
Enable SNMP If Enabled, SNMP Trap will be sent for this alarm. For
SNMPv3, alarm severity should be equal to or higher
than Trap receiver’s configured alarm severity. See
Group Map 1 Select alarm group 1 to map. Individual alarm can be

mapped up to two alarm groups.
Group Map 2 Select alarm group 2 to map, optional. Individual

alarm can be mapped up to two alarm groups.
SMART ALARMS
EC500 provides 16 user configurable logic block. Each combinational logic block provides three inputs and two
function blocks. Each function block provides three logic functions i.e. AND, OR & XOR and two inputs. Each of
the two inputs can be inverted before presentation to function blocks. A graphical interface is provided for
selecting the inputs and functions. Alarm activation and de activation delays can be set. The output of each
logic alarm generator can be mapped to any available User alarm so that all functions available with User
alarms can be used seamlessly. A truth table for alarm helps in verifying the logic.

Following configurations can be done:
Smart Alarm Logic Configurations

Enable Engine If set to Disabled then the smart alarm will be Web (only view):
disabled and engine will not execute the function. Home>Settings> Smart
Alarm Configuration.
Input Alarm 1/2 Select Alarm input 1 / 2 for function block 1.
Configurator:
Function Block 1 Select AND / OR / XOR function for function block 1.
Home>Settings> Smart
Invert Input 1 / 2 Invert input 1 / 2 of function Block 1 Alarm Configuration
FB1
Input Alarm 3 Select Alarm input for function block 2
Function Block 2 Select AND / OR / XOR function for function block 2
Invert Input 1 / 2 Invert input 1 / 2 of function Block 2

FB2
Alarm Activation Output of comparison function will be de-bounced

Delay for Alarm Activation Delay before declaring an active
alarm.
Alarm Deactivation Output of comparison function will be de-bounced

Delay for Alarm Deactivation Delay before declaring an
inactive alarm. At start up all alarms are inactive.
Alarm Map Select User Alarm to which output of Logic block is

to be mapped.
User Alarm to be used shall also be configured as detailed in
User Alarm Configuration on page 48.
 Note that Smart Alarms inputs can be System Alarms, User alarms and Analog alarms. Since
output of Smart alarm is mapped to User alarms, care should be taken not to loop the
alarms.
POTENTIAL FREE OUTPUTS

The EC500 supports up to 64 Potential Free outputs for alarm reporting to other equipment or control
purpose. Potential free outputs are controlled via mapping from Alarm Groups detailed on page 47 or direct
function mapping. For using the same, up to 64 user alarms are provided. Please refer Digital Outputs on page
59 for configuration.

Alarm Flow
The following diagram indicates various alarms types available and their input / output paths.
Hardware Attributes PFC Alarm Logic: Alarm Attributes 40 Groups

Hardware Attributes
{enable / disable, map, 1. Predefined functions {name, delays, severity, snmp {each alarm can be
{enable / disable, map}
sense} 2. Pass through trap} mapped to any 2 groups}
PFC input hardware

PFC Input Alarms
mapping
User Alarms
User Alarms PFC output

Analog Alarms Dynamic Alarms Map to Group PFC Outputs hardware
System Alarms One alarm can mapping
be mapped to
2 groups
Compare Parameter,
Analog Inputs (V/I/T)
Analog Alarms
Reference Parameter
System Alarms
Alarm Attributes
{severity, snmp trap}
COMMON ALARM PARAMETERS

The following parameters are common to all alarms.
Enable Audible Enable or disable the audible alarm indicator. Display:

Alarm Indication Home>Settings>System
Settings>Buzzer
Web:
Home>Settings>System
Settings>Buzzer
GENERATOR CONTROL
Generator control function is used to delay the start of a standby ac generator until the batteries are partially
discharged (rather than immediately after the ac supply fails). This can save fuel by preventing the generator
running during short ac supply failures.
Generator logic provides control for two digital outputs (relays) which can be used to control running and load
control of generator. EC500 provides option to start / stop generator based on Bus voltage and / or Battery
SOC. Once generator start condition is met it activates Relay 1 and after a user configured delay (Ton) activates
Relay 2. Relay 2 can be used to transfer load to generator. Once generator stop conditions are met, it de-
activates Relay 2 first and then deactivates Relay 1 after user configured delay (Toff). Below timing diagram
demonstrates the relay operation.

Ton Toff
Relay 1
Relay 2
Generator ON Generator OFF

Condition met Condition met
In any case, if stop conditions is not met i.e. Battery SOC does not reach at its Stop SOC Threshold or Battery
Voltage does not reach at its Stop Voltage Threshold, but DG Run Timeout (4 hours by default) is over, then
EC500 will start Generator off sequence.
EC500 can also monitor one potential free input to sense generator run condition provided by generator. A
generator fail alarm is activated if EC500 does not detect ac supply (rectifiers have turned on) or does not
sense the digital input, once generator Relays have been activated.
 A digital input can be mapped to monitor generator run status. On activation of this input,
controller applies alternate battery current limit and enables DG energy and run hour
counters.
Configuration
Set the following parameters:
DG Control Enable or Disable the Generator control. Generator Display:

configuration parameters are visible only when DG Menu>System Config
control is set to enable. This is a configuration >System Info>DG Control
setting.
Web:
Menu>System config
>System Info>DG Control
Drive ON Delay Time delay between Relay 1 activation and Relay 2 Display:
activation at the time of generator ON condition. Menu>Settings>DG Settings
Drive OFF Delay Time delay between Relay 2 de-activation and Relay
1 de-activation at the time of generator OFF Web:
condition. Menu>Settings>DG Settings
DG Max Run The maximum run time of generator, whatever is the
Timeout status of battery SOC and battery voltage, if this
timeout expires then generator will be turned off.
DG Function SOC If enabled, controls generator On or Off as per the
Based battery SOC threshold.
Start SOC Generators is turned On if Battery SOC falls below
this threshold limit; default 40% of battery capacity.

Stop SOC Generator is turned off if battery SOC equals or

crosses this threshold limit; default 95% of battery
capacity.
DG Function If enabled, controls generator On or Off as per the
Voltage Based bus voltage threshold.
Start Voltage Generator is turned On if bus voltage falls below this
threshold limit; default 47.0V.
Stop Voltage Generator is turned Off if bus voltage rises above this
threshold limit; default 54.0V.
DG Control Drive 1 Map output PFC relay of DCIO card for generator Web:
relay 1. Menu>System
DG Control Drive 1 Map output PFC relay of DCIO card for generator Config>Hardware
relay 2. Mapping>DG
DG Feedback Input Map isolated input of DCIO card for generator run
status sense.
 If both SOC and Voltage based control are enabled, then generator will start if any start
condition is true and generator will 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

Additional Input / Output boards can be connected to EC500 to provide additional input/output to monitor
and control external devices.
IDENTIFY AN I/O BOARD

Input / output boards are referenced by their serial numbers; EC500 supports 4 DCIO cards and 2 PFCIO cards
➢ To identify a particular I/O board

• At the time of system installation, set different jumper settings on each DCIO and PFCIO boards.
• On board controller sense digital inputs of these jumpers and provide a unique Node ID.
• EC500 communicate with these boards and use their allocated Node IDs for further
communication.
• Identification of boards occurs only at power on time.
ANALOG SYSTEM VALUES

The EC500 provides access to the following system analogue values.
Bus Voltage Each card’s first channel is allocated for Bus voltage;
EC500 reads the Bus voltage from each card. The
card which provides the Bus voltage greater than or
equal to 30V determined that card and channel for
system Bus voltage.

Load Current Total Load current is the sum of any analogue input
configured as Load current. Otherwise, if Battery
Current is available, the Load current is calculated as
Rectifier Current – Battery Current. Otherwise it is
unavailable.
Battery Current Total Battery current is the sum of any analogue
inputs configured as Battery current. If positive
battery is being charged.
Solar Current Total current produced by the Solar chargers
controlled by EC500.
Sum of Reported The sum of the currents reported by all rectifiers.
Rectifier Currents Where there is no analogue input configuration as
Rectifier current. This will be the same value as
Rectifier current.
Load Power The power being supplied to the load. Load current x
Bus voltage.
System Power Calculated as Bus voltage x Rectifier current if system
operating at Mains supply or DG.
Calculated as Bus voltage x Load current if system

operating at Battery 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
provides the data of AC voltage that rectifier is
determined for voltage measurement.
Three Phase System: Similarly, at polling time which

rectifier communicates with EC500 and provide
specific phase data (R,Y or B) that rectifier is
considered for AC measurement for respective
phase.
Rectifier Delta Each Rectifier provides its delta, subtraction of
Temperature Rectifier Ambient temperature – Max Heat Sink
temperature.
Battery Each Battery module provided itself through
Temperature communication.
ANALOG INPUTS
The analog inputs (AI) monitor variable dc voltages (bus voltage sense, general purpose analog inputs, current
sensors or temperature sensors).
Generally, the system analog inputs are configured at the factory and do not need to be changed.
➢ To configure an analog input

• Web go to Menu>System Config>Hardware Mapping, select Tab for analog inputs Battery,
Load, Cabinet, String Monitoring and User Analog Channels.
 The table shows the available number of analog inputs. The actual number of analog inputs
available depends on the number of I/O boards or modules connected.

• Select an analog input. The analog inputs are mapped to specific I/O connectors and are of
three types (voltage/general purpose, current or temperature). See mapping table on page
77.
• Configure the following parameters to suit the application.
 To change a setting, select from drop down list or edit the text.
Parameter Setting
Channel Enable Set to Enabled
Name Type the name of the input or use the default value.
I/O Board Number Select the Analog input number with DCIO board
+ number for respective predefined function.
Analog Input
Number
Shunt Value Select the shunt value with respective mV output
voltage for sensing current.
Analog Input High and Low Alarms

Any analog 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 High Alarms and/or Analog Input Low Alarms tables to
suit the application.
Parameter Setting
Severity Set the required alarm polarity. This determines how

the alarm is indicated.
If set to Disabled then the alarm will not activate.
Threshold An analog input high/low alarm is activated if the

scaled input is greater than/less than or equal to this
value.
Hysteresis The amount of hysteresis applied to the input before

an active alarm is deactivated.
Digital Output If required, select a relay that will be operated when

Mapping A the alarm is active.
Digital Output If required, select a second relay that will be

Mapping B operated when the alarm is active.
Send Trap An SNMP Trap will be sent for this alarm, if Send
Trap is True and the alarm’s severity matches the
setting of the SNMP Trap Level.

SYSTEM STATES
The EC500 monitors the following system states to provide an overview of the DC power system’s operation.
States displayed will depend upon the dc power system model. Some states will only be displayed if there is a
digital input configured for this function.
Name Description
Fan Fail Indicates if any digital input with function set to “Fan
Fail” is active.
Door Open Indicates if any digital input with function set to

“Door Open” is active.
Temperature fail Indicates if temperature probe gets disconnected or

break down.
Load Fuse Fail Indicates if any digital input with function set to
(DCCB Trip) “DCCB Trip” is active.
Battery Fuse Fail Indicates if any digital 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 set to “DG
Running status” is active.
DIGITAL INPUTS
The input / output board is fitted with a number of configurable digital inputs (DI) which can monitor external
voltage-free relay contacts or switches.
➢ To configure a digital input

• On Web go to Menu>System Config>Hardware Mapping>PFC Input, expand the digital input
table.
• Select a configurable Digital Input and select the input from drop down list.
➢ Digital Input Alarms

• Any digital input that is enabled in the digital input table can activate an alarm.
Configure the following parameters in the Digital Input Alarms table to suit the application.
 To change a setting, select the input from drop down list.

Parameter Setting
Severity Set the required alarm polarity. This determines how

the alarm is indicated.
If set to disabled, then the alarm will not activate.

Parameter Setting
Recognition Period This alarm will activate only after the digital input is
active for this period.
Deactivation The alarm will deactivate only after the digital input
Recognition Period is inactive for this period.
Digital Output If required, select a relay that will be operated when

Mapping A the alarm is active.
Digital Output If required, select a second relay that will be

Mapping B operated when the alarm is active.
Send Trap An SNMP Trap will be send for this alarm, if send
trap is true and the alarm’s severity matches the
setting of the SNMP trap level.
DIGITAL OUTPUTS
The input / output (I/O) board is fitted with a number of digital outputs (relays) which can control external
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>System Config>Hardware Mapping>PFC Output, expand the table.
• Select a configurable Digital output and select the output from drop down list.
• Configure the following parameters to suit the application.
Parameter Setting
Control State Set to Automatic
Status Set to Enabled
I/O Board Number Select the Analog input number with DCIO board
+ number for respective predefined function.
Analog Input
Number
Active State Select the state of output when the Digital Output is
active
Group With Alarm Management select alarm with different

group, then map these groups to PFC output number
with Output configuration and at last map this PFC
output number to DCIO/PFCIO output relay with
hardware mapping.
Send Trap An SNMP Trap will be send for this alarm, if send
trap is true and the alarm’s severity matches the
setting of the SNMP trap level.

ENERGY METERING
EC500 provides following built-in energy meters.
• 1x for Total Battery (Bus Voltage & battery discharge current)

• 5 x for individual Battery, if individual current monitoring is configured
• 4x for Load (Bus Voltage & load current)
• 1x for AC Mains (AC voltage & current from Rectifiers)
• 1x for DG (AC voltage & current from Rectifiers, DG running)
• 1x for Solar (Energy from Solar Charger)
The Energy Logger records the energy readings for energy meters, cumulative at a specific interval and once in
a full day at midnight. The user can also view per day energy consumption.
DC voltage and current for energy meters are read from respective mapped analogue channels i.e. bus voltage,
battery current, load currents etc. and no additional mapping is required. AC voltage and ac currents are
measured by rectifiers. Solar energy is measured by respective solar chargers.
The EC500 supports internal and external energy meter option.
The EC500 also supports predefined external Modbus based energy meters. Contact Eaton for more details
and availability.
➢ To configure 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 configuration set for AC that must be same for generator configuration.
• For Battery Energy metering, enable the status of Battery energy meter, set battery LVD as
per requirement.
• For load energy meter, enable the status of Load energy meter. Set number of load paths
and number of load LVDs, number of load path and LVD must be same.
• Load current computation, set it enable if EC500 computing load current from the difference
of rectifier current and battery current. This can be used for the last load channel.
• Select the shunt configuration from current sensing.
• For solar energy metering, power is read from the solar charger directly.
INFORMATION
The following information is available about energy metering.
Load Voltage Voltage used in calculating an individual load path Display:

energy meter power. Menu>System Status>Load
Load Current Current used in calculating an individual load path

energy meter power.
Web:
Load kWh Energy in kWh measured by this meter. It is Menu>System Status>Load
continuously calculated and increased individually as
per load path.
Battery Voltage Voltage used in calculating an individual load path Display:
energy meter power.

Battery Current Current used in calculating an individual battery path Menu>System

energy meter power. Status>Battery
Charge kWh Battery charge energy measured.
Discharge kWh Battery discharge energy measured.
kAh Capacity of battery bank.

Web:
kWh Energy measured as per battery bank. Menu>System
Status>Battery
AC Voltage R, Y and B phase voltage of AC Source Type (EB or Display

DG) calculating its individual energy meter power. Menu>System Status>AC
Input
AC Current R, Y and B phase current of AC Source Type (EB or
DG) calculating its individual energy meter power.
Web:
AC kWh Calculate cumulative energy Menu>System Status>AC
Input
CONFIGURATION
Set the following parameters.
AC Energy Meter Enable the status of AC Energy Meter Display:

Status Menu>System Config>AC
Config>
AC Energy Meter Select the type of AC Energy Meter, Internal or
Type External Web:
Menu>System Config>AC
Config
Battery Energy Enable the status of Battery Energy Meter Display:

Meter Status Menu>System Config>DC
Config>Batt Config
No. of Battery LVD Select the number battery LVD.
Web:
Menu>System Config>DC
Config>Batt Config
Load Energy Meter Enable the status of Load Energy Meter Display:
Status Menu>System Config>DC
Config>Load Config
Load Energy Meter Select the load energy meter type, Internal or
Type External.
No of Load Paths Select the number of Load paths as per load strings.
No of Load LVD Select number of load LVDs as per system

configuration.

Web:
Load Current Compute the load current with difference of Rectifier Menu>System Config>DC
Computation current and Battery current instead of using load Config>Load Config
shunt.
Battery Shunt Amps Set the battery shunt rating in ampere. Display:
Menu>System Config>DC
Battery Shunt mV Set the battery shunt output voltage proportional to Config>Current
current passing through it. Sensing>Shunt
Load Shunt Amps Set the load shunt rating in ampere.

Web:
Load Shunt mV Set the load shunt output voltage proportional to Menu>System Config>DC
current passing through it. Config>Current Sensing
DATA LOGGING
The EC500 has the following event and data logging functions. All log data can be downloaded as csv file
through web interface or directly to USB drive and can be read using any standard spreadsheet program.
 All kind of data log have their own settings. Some logging needs to be enabled, such as
Performance logging and Data logging.
EVENT LOG
The Event Log records 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 disabled under the alarm management section.
Each alarm is logged with its status (Set or Clear), severity and date-time of event.
The 10,000 log store is used in a circular fashion. The oldest logs are over written.
➢ To view and save the Event Log

• In LCD Display, go to: Menu>Logs>Alarm Logs. Display will show following options of entries
like Today, Last 7 Days, Last 30 days and all entries.
• In Web page go to: Menu>Logs>Alarm Logs. Web page will show following options of entries
like Today, Last 7 days, Last 30 days, Filtered and All entries. Tab “All Alarms” provides an
option to select the alarms for logging.
• To download/save the Log file in Web, go to Tab “Export”. It will export the logs in Excel
format and save in the browser download folder.
• To download logs in USB, attach a USB drive to the USB connector on front panel, go to
Home > Settings > USB Settings > CopyToExtDrive and select required logs to download. Logs
will be downloaded to USB.
➢ To Clear the Event Log

• In the LCD display, go to: Menu>Logs>Erase Logs>Alarm Logs. Enter the appropriate pin, a
popup window will appear and ask for Are you sure? Press the enter key to erase the Event
Log.

• In Web page go to: Menu>Logs>Erase Logs>. Click on Edit tab and press “Yes Confirm” of
Alarm Logs and press Yes to erase Event Logs.
DATA LOG
The Data log records several system parameters like AC Voltage, Bus Voltage, Load Current, Rectifier Current,
Battery Current, Battery Temperature and Discharge Ah at specified intervals. The rate of Data recording is
settable from Web page. Memory for 10000 Data Log entries is pre-allocated. When this memory is full the
oldest record will be overwritten.
➢ To view and save the Data Log

• In Web page, go to: Menu>Logs>Data Logs. Web page will show following options of entries
like Today, Last 7 days, Last 30 days, Filtered and All entries.
• To download/save the log file in web, go to Tab “Export” it will export the Logs in excel sheet
and save in download folder of your system.
• To download logs in USB, attach a USB drive to USB connector on front panel, go to Home >
Settings > USB Settings > CopyToExtDrive and select required logs to download. Logs will be
downloaded to USB.
➢ To configure the Data Log

• In Web page go to: Menu>Settings>System Settings. Edit the parameter Data Logs Status and
set it for Enable.
• Set the Data Logs Periodicity range in between 5 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 logging “Day Wise” and “Month Wise”.
➢ To view and save the Energy Log

• In LCD display, go to: Menu>Logs>Energy Logs. Display will show the following parameters :e
AC, Battery, Load and Solar kWh.
• Select any parameter with the help of Up and Down key, now press enter key. Display will
show following options: Daily, Last 7 days, This Month and previous Month.
• In Web page, go to: Menu>Logs>Energy Logs. The web page will show the following options :
“Daily Wise Log” or “Monthly Wise Log”.
• To download/save the log file in web, go to Tab “Export”. It will export the logs as csv file and
stored in download folder of your system.
• EC500 subtracts previous day Energy Logs from Current Day Energy Logs and logs the result
at the time of mid night. Memory for Energy Logs entries up to 60 days are pre-allocated.
When memory is full the oldest record will be over written.
• Similarly, the EC500 subtracts the previous month Energy Logs from Current Month Energy
Logs and logs the result at the mid night of last date of current month. Memory for Energy
Logs entries up to 60 months is pre-allocated. When memory is full the oldest record will be
over written.
downloaded to USB.

➢ To clear the Energy Log

• In the LCD display, go to: Menu>Logs>Erase Logs>Cumulative Logs. Press the Enter key, enter
appropriate pin, a pop window will appear and ask for Are you sure? Press the enter key to
erase cumulative logs.
• In Web page, go to: Menu>Logs>Erase Logs. Click on Edit Tab and then press “Yes Confirm”
of Cumulative Logs. Erase of cumulative logs will erase both Energy Logs and Run Hour Logs.
RUN HOURS LOG

The Run Hour Log records run hours for mains, generator, battery and solar. The rate of Run Hour logging is
“Daily Wise” and “Monthly Wise”.
➢ To view and save the Energy Log

• In LCD display, go to: Menu>Logs>Run Hour Logs. The display will show the following
parameters like AC, Battery, Load and Solar run hours.
• Select any parameter with the help of Up and Down key, now press enter key. Display will
show following options like Daily, Last 7 days, This Month and previous Month.
• In Web page, go to: Menu>Logs>Run Hour Logs. Web page will show the following options
like “Daily Wise Log” or “Monthly Wise Log”.
• 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.
• EC500 subtracts previous day Run Hour from Current Day Run Hour and logged the result at
the time 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 Current Month Run Hour and
logged the result at the mid night of last date of current month. Memory for run hours log
entries up to 60 months are pre-allocated. When memory is full the oldest record will be
over written.
downloaded to USB.
➢ To clear the Energy Log

• In LCD display, go to: Menu>Logs>Erase Logs>Cumulative Logs. Press the Enter key, enter
appropriate pin, a pop window will appear and ask for Are you sure? Press the enter key to
erase cumulative logs.
• In Web page, go to: Menu>Logs>Erase Logs. Click on Edit Tab and then press “Yes Confirm”
of Cumulative Logs. Erase of cumulative logs will erase both Energy Logs and Run Hour Logs.
STATUS LOGS
The Status Log records battery status of the system. Memory for 1000 Status Log entries is pre-allocated.
When this memory is full the oldest record will be overwritten.
➢ To view and save the Status Log

• In LCD display, go to: Menu>Logs>Status Logs. Display will show the transition from previous
status to current status with date and time.
• In Web page, go to: Menu>Logs>Status Logs. Web page will show the following options like
Today, Last 7 days, Last 30 days, Filtered and all entries. Tab “ALL” provides an option to
select the status logging.

• To download/save the Log file in web, go to Tab “Export”. The EC500 will export the logs in
excel sheet and save in the download folder.
downloaded to USB.
➢ To clear the Status Log

• In LCD display, go to: Menu>Logs>Erase Logs>Status Change Logs. Enter the appropriate pin,
a pop window will appear and ask for Are you sure? Pressed enter key for erase Status
Change Logs.
• In Web page go to: Menu>Logs>Erase Logs. Click on Edit Tab and press “Yes Confirm” of
Status Change Logs and press yes to erase Status Change Logs.
CHANGE LOGS
Any changes to system configuration are logged along with old value, new value, date-time and user. Memory
for 1000 Change Log entries is pre-allocated. When this memory is full the oldest record will be overwritten.
➢ To view and save the Change Log

• In Web page, go to: Menu>Logs>Change Logs. Web page will show the following options like
Today, Last 7 days, Last 30 days, Filtered and all entries. Tab “User” and “Item” provides 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

• In LCD display, go to: Menu>Logs>Erase Logs>Setting Change Logs. Enter the appropriate pin,
a pop window will appear and ask for Are you sure? Pressed enter key for erase Status
Change Logs.
• In Web page go to: Menu>Logs>Erase Logs. Click on Edit Tab and press “Yes Confirm” of
Setting Change Logs and press yes to erase Setting Change Logs.
PERFORMANCE LOGS
The Performance Log records the user selected parameters of system. Settings need to be done before starting
the performance log. Controller with SD card provides this option. Refer Controller options on page 11.
Performance data will be logged at user set periodicity and for user set duration.
➢ To view and the save Performance Log

• In Web page, go to: Menu>Logs>Performance Logs. Web page will show the following option
of entries like folder name or module serial number formed in SD Card, duration of logged
performance log with date wise, Tab “Get Log” for retrieve performance log and progress
bar.
• To download/save the log file in web, go to Tab “Get Logs” it will export the log in text file,
progress bar will show the progress. After log download completion in download folder of
windows operating system, a pop up window will appear “Logs Download Complete”. Press
OK to complete this process.

➢ To configure the Data log

• In Web page, go to: Menu>Settings>Performance Logs. If system is configured with SD card,
Performance 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/Month/Year: when this date arrives, the EC500 will stop performance logging.
• SD Perf Logs Folder: EC500 will create the folder in SD card with same name as written in this
text box.
• Select parameters to be logged out of the list given on the web page.

EC500 Controller Handbook System Configuration
SYSTEM CONFIGURATION
OVERVIEW
The EC500 Controller supports a number of functions which are dependent upon availability of specific
hardware in the system. Some critical parameters are also controlled under this section. EC500 configuration
should be set accordingly before commissioning. Most of these configuration settings are not available on
display or Web pages, as these are related to system hardware and should not be changed at run time.
To generate a suitable configuration use the Configuration Tool “Configurator”. This tool generates a
configuration file which can be downloaded to the controller.
For specific requirements, this configuration file can be preloaded in the factory for quick installation &
commissioning.
The next sections describe the important System Configuration parameters.
SYSTEM INFO
The following settings relate to system hardware. These are required for correct 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.
 Change of these settings may require a restart of controller.

Parameter Description Default Value Where to find:
Rectifier Type Select the rectifier type which will be HPR48-ES Configurator:
used in the system. This will result in Main Menu>System
proper communication with rectifier, Config>System Info
rectifier parameters and alarm Web:
reporting. Currently supported Home>System Config>
rectifiers are: System Info
• HPR48-ES (3kW)
• LPR48-ES (1.1kW)
Refer section Rectifiers on page 34 for
more details.
System Type Select whether it is a Single Phase (1P-
N), Three Phase (3P-N) or Phase –
Phase (3P-P) system. Refer section
Rectifiers on page 34 for more details.
DC Interface The EC500 supports following options DCIF 6V3C Shunt
Type depending upon hardware Sensor
requirements:
• DCIF 4V2C Shunt Sensor
• DCIF 6V7C Shunt Sensor
• DCIO 6V3C Shunt Sensor
Refer section DC Interface Boards on
page 8 for more details.
DCIF n Install The EC500 supports up to four DCIF DCIF 1: Installed
status boards. Depending upon the number of DCIF 2: Not Installed

DCIF to be installed (1 – 4), configure DCIF 3: Not Installed

install status. DCIF 4: Not Installed
DCIF n: Installed / Not Installed
Please note that DCIF 1 must always be
installed as Bus Voltage is read from
DCIF 1. Refer section DC Interface
Boards on page 8 for more wiring
details.
PFC IO 8 DCIF 4V2C, DCIF 6V7C and DCIO 6V3C Installed
support 8 PFC Input & Output Board.
Select PFC IO 8 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.
PFC IO 16 – 1 EC500 supports 2 number of PFC IO 16 Not Installed
PFC IO 16 – 2 boards in addition to PFC IO8. These
boards are installed 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.
Refer section PFC Boards on page 8 for
more details.
Solar Chargers If Solar chargers are to be installed, Not Installed
enable Solar Functionality. Select
Installed or Not Installed.
Solar alarms, solar charger control &
monitoring will be done only when this
parameter is set to Installed. More
settings will be enabled when set to
Installed.
Modem EC500 supports GSM / GPRS modem Not Installed
board. Modem functionality is enabled
when Modem is Installed. When Not
Installed all settings and alarms are
suppressed / hidden.
DG Control If control for external DG start / stop is Disabled
required, Enable this control.
 The maximum number of PFC Inputs & Outputs supported is 40.

 Refer section Generator Control on page 53 for more settings and details on DG Control.
BATTERY CONFIGURATION
The following battery settings must be configured.

Detailed battery parameter settings should be done as given under section Battery and Voltage Control on
page 22.
Battery Type Select the Battery Type to be used in VRLA Configurator:

system. Following options are available: Main Menu>System
• VRLA Config>DC Config>Batt.
• VRLA + Li-ION Config
• Li- ION Web:
Home>System
Number of Number of battery fuses to be 1, (0-5) Config>DC Config>Batt.
Config
Battery Fuses monitored. Maximum 5 battery fuses
can be monitored. Refer to Multiple
Battery Banks on page 24 for more
details. Battery Fuse sensing
is based on voltage monitoring and
requires voltage channel mapping as
given below.
Number of Systems can provide individual battery 1, (1 – 5)
Battery LVD LVD contactor drive. Though these LVD
are driven from a single Logical Battery
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.
Refer section Multiple Battery Banks on
page 24. Also refer to parameter
“Minimum Battery Connected” below.
Minimum In case of individual LVD for each 1
Battery battery string, a user can accidently
Connected disconnect all BLVD. In such a case site
availability will be at risk. To override
this, define the minimum number of
battery strings which need to remain
connected under all test / maintenance
operations. Minimum 0 and maximum
equal to Number of Battery LVD can be
defined.
Battery If the Battery requires Temperature Enabled
Temperature Compensation, it should be Enabled.
Compensation Additional parameters are defined as
given in section Battery Temperature
Compensation on page 26.
Battery Energy Enable or Disable Battery Energy Enabled Configurator:
Meter Status Metering. If disabled, no metering will Main Menu>System
be done and the corresponding menu Config>DC Config>Batt.
items will be hidden. Config>Batt. Energy
Meter
Web:

Home>System Config>
DC Config>Batt. Config
>Batt. Energy Meter
Li-Ion Battery The number of Li-ION modules to be 8, (1 – 16)

Modules supported, if enabled. All modules
should be of the same make & capacity.
Refer section VRLA Battery Charge
Profile on page 23.
 For Li-Ion Batteries, Temperature Compensation will be automatically disabled, as Li-Ion

batteries do not require temperature compensation.
BATTERY MID-POINT CONFIGURATION
Battery Mid-point Monitoring provides a cost effective method for the early detection of internal battery
faults. The voltage of the two halves of the battery strings are measured and the system controller generates
an alarm signal if voltage imbalance is detected.
A voltage imbalance is an indication that one or more cells have an internal fault. Further investigation can
then isolate the faulty cell(s) and action can be taken to correct the problem and prevent a total battery
failure.
To ensure reliable operation Mid-point Monitoring operates only when the 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 monitoring sense wires to the batteries. Refer the System Installation
Guide.
 There are two mid-point monitoring Analog inputs on DCIO board (for two battery strings).
Up to 10 additional battery strings can be monitored if additional DCIO input/output boards
are connected. Refer to the System Installation Guide for details on how to connect additional
DCIO input/output boards to the EC500.
• In the LCD Display, go to: Menu>System Config>DC Config>String Monitoring>Monitoring.

Enter the appropriate pin and select the Battery monitoring type.
• Go to parameter Max String for MPM/QPM and enable the Mid-point monitoring Analog
inputs (one per battery string) as required.
• In Web page, go to: Menu>System Config>DC Config>String Monitoring. Press Tab “Edit” and
select the Battery monitoring type. Similarly, select the number of Battery strings.
• Go to Menu>Settings>Alarm Management. Enable and configure the “Battery String x Fail”
alarm, x defines the number of Battery string.
 Battery strings 1-2 will be connected to DCIO Number 1, DCIO Analog Input number 2-5.
Battery strings 3-4 will be connected to DCIO number 2, DCIO Analog Input numbers 2-5. And
so on, as required up to string 10.

Monitoring
The following information is available about Battery Mid-point Monitoring.
Upper Half String This shows the voltage of Battery string from mid- LCD: Menu>System
point of the string to top of the string. For example, Status>String
if 24 cells consider for 48V Battery bank, then it Monitoring>Mid String
shows the voltage between 13th cells to 24th cell. Voltage.
Lower Half String This shows the voltage of Battery string from ground
point of the string to mid-point of the string. It
shows the voltage between 1st cells to 12th cell.
String Status Calculate the difference between Upper Half String
voltage and Lower Half String voltage, if this Web: Menu>System
difference is less than MPM Threshold Voltage then Status>String Monitoring
status shows OK.
Battery String x When string status is not OK, EC500 generates an Web:
Alarm alarm if “Battery String x Fail” is enabled, x defines Menu>Settings>Alarm
the number of battery string. For example, Battery Management
String number 2 generates an alarm then display will
show “Battery String 2 Fail”.
Configuration
The following parameters are available for configuring Battery Mid-point Monitoring.
Monitoring If set for disabled, then Battery Mid-point LCD: Menu>System

monitoring will not active and respective parameters Config>DC Config>String
are not visible to user. So, to activate and configure Monitoring
the Battery Mid-point monitoring first select it for
Mid-point monitoring (MPM) or Quarter point
monitoring (QPM).
Max Strings for Select the number of Battery strings available in Web: Menu>System
MPM system. As per the selection of Strings for MPM, Config>DC Config>String
string parameters are visible in system status monitoring
MPM Volt This setting is used to calculate the final status of LCD:
Threshold Battery string. Each string compares its difference of Menu>Settings>Battery
Upper half voltage and Lower half voltage with this Settings>General
threshold. If difference is beyond this limit then Settings>String Monitoring
status is not OK. Same value is applicable to all
available Battery strings.
Mid-point monitoring operates only when Battery is

in float mode. Every time when Battery rests in Float

MPM Lockout mode more than MPM Lockout period then EC500 Web:
Period will starts the Mid-point operation. Menu>Settings>Battery
Settings
String x Mid Mapping of DCIO voltage channel with Battery Mid- Web: Menu>System
Voltage Channel point sensing signals. For detailed description refer Config>Hardware
the System Installation guide. Mapping>String Monitoring
LOAD CONFIGURATION
EC500 controller provides support for settable individual LVD and Energy metering for each load. It supports
up to 8 Loads. Following settings should be done as part of system configuration.
Number of Load Select number of Load LVDs to control. 0, (0 – 8) Configurator:

LVD For LVD operate & restore thresholds Main Menu>System
refer to section Load LVD on page 44. Config>DC Config>Load
Equal number of drives shall be Config
mapped in hardware manually. Web:
Number of Load Select number of Load sensors to use. 1, (0 – 8) Home>System Config>
Paths Normally only 1 sensor or number DC Config>Load Config
equal to Load LVDs is used. Equal
number of Load Energy meters are
enabled, if Load Energy metering is
enabled below.
Last Load To save one Load shunt sensor (and Disable
Calculation channel) current of last load channel
can be calculated from Total Rectifier,
Battery Current and other Load
channels. Set to Enabled to use this
function. Note that measurement
inaccuracies of all channels may make
this calculation have wider error (up to
3%).
Load Energy Enable to measure Load channel Enabled
Meter Status energy. One energy meter for each
load path is enabled.
Load Energy In some specific installations, a Internal
Meter Type predefined External DC Energy Meter
(on RS485 bus, Modbus protocol) can
be used. Select Internal or External
load energy meter.
CURRENT SENSING

The system should be configured for the shunt ratings used in the system. Shunt rating and millivolts full scale
can be configured for each of the selected battery & load current channels. The shunt rating is passed on to
the DCIF card by EC500 and the DCIF scales the measurement as per the settings. These settings are not
intended for channel calibration. All DCIF channels come calibrated from factory. Refer to DCIF specifications
for accuracy.
Battery n Shunt Current rating of respective shunt in 150A, (50 – 5000) Configurator:
current rating Amp. To be defined for individual Main Menu>System
shunt. Setting range is from 50 – Config>DC Config>
5000A. The number battery shunts is Current Sensing
equal to “Number of Battery LVD” set Web:
above. Home>System Config >
Battery n Shunt Shunt millivolt at rated current rating, 50mV, (30 – 50) DC Config>Current
millivolt set above. Number of Load shunts is Sensing
equal to “Number of Load Paths” set
above.
CABINET CONFIGURATION
Items related to cabinet configuration like Temperature sensor, Door sensor and cabinet Fans etc. are
configured as part of System Configuration.
The following settings are available.
Cabinet Type For enabling fan control, the system Indoor Configurator:
can be defined as Outdoor. Main Menu>System
Config>Cabinet Config
Web:
Home>System Config
>Cabinet Config
Smoke Sensor Define if Smoke Sensor is installed Not Installed

or not. Consequent actions in case
of Fire sense are enabled if Smoke
Sensor is enabled.
Door Sensor Define if Door Sensor is installed or Not Installed
not. Consequent actions in case of
Door Open, like Image clicking (if
Camera is installed) are enabled if
Door Sensor is installed.
Temperature Sensor Configure if temperature sensors Sensor 1: Main Menu>System
n are Installed or Not Installed. Two Installed Config>Cabinet
temperature sensors can be Sensor 2: Not Config>Temp Sensing
installed per DCIF. Installed
Number of fans Configure if fans are Installed or Min: 0 Max: 4 Web:
Not Installed.

Main Menu>System
Config>Cabinet
Config>Fan Config
Fan Sensing Enable or disable the fan sensing. Disable, Enable Main Menu>System
Config>Cabinet
Config>Fan
Config>Fan Sensing
HARDWARE CHANNEL MAPPING
For using system functions, all the required logical channels need to be mapped to respective channels in
hardware. The mapping must match the system wiring and needs to be done carefully.
 A wrong hardware mapping may result in malfunctioning of system.
Following mappings shall be defined:
• Voltage Channels on DCIF boards

• Current Channels on DCIF boards
• LVD Drive Channels on DCIF or PFC boards
• Potential Free Input Ports on DCIF or PFC boards
• Potential Free Output Ports on DCIF or PFC boards
 The first voltage channel on each DCIF shall be wired to Bus Voltage. First channel of first
DCIF shall be mapped to Bus Voltage.
CHANNEL 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 Shunt board y varies from 1 – 4,
for DCIF 6V7C Shunt board it varies from 1 – 6 and for DCIO 6V3C Shunt board it varies 1 – 6.
DCIF Current channels are referred as DCIFx_CURR_CHy, where x is DCIF board number (1 -4) and y is current
channel (1- 2 or 1 – 7) depending on particular DCIF board. For DCIF 4V2C Shunt board y varies from 1 – 2, for
DCIF 6V7C Shunt board it varies from 1 – 7 and for DCIO 6V3C Shunt board it varies from 1 – 3.
DCIF Temperature channels are referred as DCIFx_TEMP_CHy, where x is DCIF board number (1 -4) and y is
temperature channel (1- 2 or 1 – 3) depending on particular DCIF board. For DCIF 4V2C Shunt board y varies
from 1 – 2,for DCIF 6V7C Shunt board it varies from 1 – 3 and for DCIO 6V3C Shunt board it varies from 1 - 2.
DCIF LVD channels are referred as DCIFx_LVD_CHy, where x is DCIF board number (1 -4) and y is drive (1- 2 or
1 – 5 or 1 - 3) depending on the particular DCIF board.
DCIF PFC inputs are referred as DCIFx_PFC_INy, where x is DCIF board number (1 -4) and y is PFC input (1- 8) of
the particular DCIF board.

DCIF PFC outputs are referred as DCIFx_PFC_OUTy, where x is DCIF board number (1 -4) and y is PFC output
(1- 8) of the particular DCIF board.
PFC IO 16 inputs are referred as PFC16_x_INy, where x is PFC board number (1 - 2) and y is PFC input (1- 16) of
the particular PFC board.
PFC IO 16 outputs are referred as PFC16_x_OUTy, where x is PFC board number (1 - 2) and y is PFC output (1-
16) of the particular PFC board.
 LVD relays of DCIF 6V7C are physically mounted on Relay Board or PFC16 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 Remarks

channels / ports
DCIF 4V2C 4 Voltage Channels 4 Channel 1 is always Bus
voltage
Current Channels 2
Temperature 2
Channels
LVD Drives 2
PFC Input 8 Requires additional

relay boards
PFC Output 8 Requires additional

relay boards
DCIF 6V7C 4 Voltage Channels 6 Channel 1 is always Bus

voltage
Current Channels 7
Temperature 3
Channels
LVD Drives 5 Requires additional
relay boards or PFC
IO16 board
PFC Input 8 Requires additional

relay boards
PFC Output 8 Requires additional

relay boards
DCIO 6V3C 4 Voltage Channels 6 Channel – 1 always bus

voltage
Current Channels 3
Temperature 2
Channels
LVD Drives 3
PFC Inputs 8
PFC Outputs 8

Board Type Maximum boards Functionality Number of Remarks

channels / ports
PFC IO 16 2 PFC Input 16 Also provides up to 5
LVD relays
PFC Output 16
Following section defines object wise hardware mappings required.
BATTERY CHANNEL MAPPINGS

Voltage channels, current channels and LVD drives shall be defined for each battery string, if configured.
Battery n For battery n sense, required only DCIF1_VOLT_CH2 Configurator:

Voltage if respective battery LVD is used. Main Menu>System
Config>Hardware
Mapping>Battery>Battery
n Voltage Channel
Web:
Home>System
Config>Hardware
Mapping>Battery>
Battery n Voltage
Channel
Battery n Fuse For battery n Fuse fail sense, DCIF1_VOLT_CH3 Configurator:

Voltage required only if battery Fuse is Main Menu>System
used. Config>Hardware
Mapping>Battery>Batt
Fuse n Voltage Channel
Web:
Home>System
Config>Hardware
Fuse n Voltage Channel
Battery n For battery n current DCIF1_CURR_CH2 Configurator:

Current measurement, required only if Main Menu>System
respective battery LVD is used. Config>Hardware
Mapping>Battery>
Battery n Current
Channel
Web:
Home>System
Config>Hardware
Mapping>Battery>
Battery n Current
Channel
Battery n LVD For battery n LVD, required only if DCIF1_LVD_CH1 Configurator:

respective battery LVD is used. Main Menu>System
Config>Hardware

Mapping>Battery>
Battery n LVD Channel
Web:
Home>System
Config>Hardware
Mapping>Battery>
Battery n LVD Channel
Battery For battery temperature DCIF1_TEMP_CH1 Configurator:

Temperature measurement, required only if Main Menu>System
Temperature compensation is Config>Hardware
enabled. Only one temperature Mapping>Battery> Batt
measurement is used for all Temperature Channel
batteries. Web:
Home>System
Config>Hardware
Temperature Channel
Battery n Mid- For battery n mid-point sense, None

Point required only if respective battery
mid-point monitoring is required.
Battery n For battery n quarter point sense, None
Quarter Point x required only if respective battery
quarter point monitoring is
required. Requires three channels
one for each quarter node.
LOAD CHANNEL MAPPINGS

Voltage channels, current channels and LVD drives shall be defined for each battery string, if configured.
Load Voltage Voltage channel 1 of DCIF 1 is used as DCIF1_VOLT_CH1 Configurator:

fixed Bus voltage channel. Channel 1 of Main Menu>System
all other DCIF boards shall be wired to Config>Load>Load n
Bus Voltage and cannot be mapped. Voltage Channel
Web:
Home>System
Config>Load>Load n
Voltage Channel
Load MCB Trip Single Load MCB trip using diode string None
Sense is sensed on PFC input. Any available
PFC input can be mapped.
Load n Current For load n current measurement, DCIF1_CURR_CH1 Configurator:

required only if respective load current Main Menu>System
path is enabled. Config>Load>Load n
Current Channel
Web:

Home>System
Config>Load>Load n
Current Channel
Load n LVD For Load n LVD, required only if None Configurator:

respective Load LVD is used. Main Menu>System
Config>Load>Load n
LVD Channel
Web:
Home>System
Config>Load>Load n
LVD Channel
CABINET CHANNEL MAPPINGS

Following hardware shall be mapped for Cabinet functions.
Fan n drive For Fan n drive, required only if Cabinet None Configurator:
is set as Outdoor & Fans are to be used. Main Menu>System
Any available PFC output can be Config>Cabinet>Fan n
mapped, subject to contact rating Relay Channel
required for driving Fan. Web:
Home>System
Config>Cabinet>Fan n
Relay Channel
Fan n Fail Sense For Fan n fail sense PFC input, required None
only if Cabinet is set as Outdoor & Configurator:
individual Fan fail sense is to be used. Main Menu>System
Any available PFC input can be mapped Config>Cabinet>Fan n
Sense Channel
Web:
Home>System
Config>Cabinet>Fan n
Sense Channel
Rack For rack temperature sensing, required DCIF1_TEMP_CH2 Configurator:

Temperature n only if Cabinet is set as Outdoor & Fans DCIF1_TEMP_CH3 Main Menu>System
channel are to be used. Up to 2 rack Config>Cabinet>Rack
temperatures can be mapped. Temp n Channel
Web:
Home>System
Config>Cabinet>Rack
Temp n Channel

EC500 Controller Handbook Communications
COMMUNICATIONS
COMMUNICATIONS OPTIONS
The EC500 controller provides multiple methods for local and remote communications. A user can
communicate with the controller using 100BaseT Ethernet interface, serial RS485 (Modbus RTU) interface or
GSM modem on RS232 interface. These interfaces provide different level of communication capabilities.
The USB interface is not used for controller communication; it is used for file transfers (to controller) in Host
mode.
ETHERNET COMMUNICATIONS
Ethernet provides 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 System Controller Connector Pin-outs on page 100 for pin outs.
A typical connection diagram is as shown below. Multiple devices can communicate simultaneously over the
Ethernet connection.
PC
Laptop
Ethernet Communication Network
(LAN / WAN)
EC500
NMS Server
ETHERNET COMMUNICATION SET-UP

For using Ethernet Interface IP Address, Subnet Mask and Gateway Address must be set. The EC500 can be set-
up for using a static IP address pre-assigned by Network Administrator, or it can be automatically assigned
using a DHCP server.
 The network administrator may assign a unique IP address to each EC500 to be connected to
the TCP/IP network.

 Alternatively, use DHCP (Ipv4 or IPv6) to automatically assign an IP address. Network shall
have a DHCP server.
 IPv4 address mode is always available in EC500 and IPv6 must be enabled if IPV6 is required.
➢ To configure the EC500 for Static IPv4 Address using the keypad
• Using EC500 Joystick go to: Home  Settings  System Settings  Communication
Settings  Ethernet  IPv4
• Click on IP Configuration and select Static
• If you are not logged in, a pin screen will be displayed. Enter your pin and press Login.
• Click on IP Address and enter required IPv4 address. Static IP addresses are typically pre-
assigned by network administrators / network planner.
• Similarly enter the pre-assigned Subnet Mask and Gateway Address. If not assigned,
Gateway Address can be left blank.
• Click Apply IP Settings to apply the entered IP settings.
• The Ethernet interface will now start communicating at selected IP address.
➢ To configure EC500 for IPv4 Address allocation from DHCP server using the keypad
Settings  Ethernet  IPv4
• Click on IP Configuration and select DHCP
• Controller will restart and obtain an IP address from DHCP server.
• The Ethernet interface will now start communicating at assigned IP address.
• Assigned IP Address can be viewed from Home  Settings  System Settings 
Communication Settings  Ethernet  IPv4  IP Address.
 Ensure that a DCHP Server is available in the network. Otherwise no IP address will be
assigned to the controller and no communication is possible on Ethernet interface.
The controller will not communicate on Ethernet until a DHCP server is available or IP configuration is changed
to static.
By default, the controller is configured in Static mode with IP Address 172.16.66.50. This can be used for
starting direct communication with laptop / PC. You will have to set Laptop / PC IP address in static mode with
same subnet mask as the Controller. The controller Ethernet interface supports MDI / MDI-X so regular
Ethernet cable can be used.
Direct Ethernet Connection
M1000 Controller
Laptop
(Set Laptop to static IP)
➢ To configure EC500 for Static IPv6 Address using the keypad

Settings  Ethernet  IPv6 Status
• Enable IPV6 by selecting the check box.

• Click on IP Configuration and select Static
• Click on IP Address and enter required IPv6 address. Static IP addresses are typically pre-
assigned by network administrators / network planner. If an assigned IPv6 address is already
in use, it will be rejected by the controller upon connection to network.
• Click Apply IP Settings to apply the entered IP settings.
• Ethernet interface will now start communicating at selected IPv6 address.
 IPv6 address requires entry of 8 octets in comparison to 4 for IPv4.

 Alternatively IPv6 Link Local address can be used for local LAN network or direct connection
to Laptop / PC. IPv6 Link Local address is based on MAC address of Ethernet interface and 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 Address allocation from DHCP server using the keypad
Settings  Ethernet  IPv6 Status
• Enable IPV6 by selecting the check box.
• Click on IP Configuration and select DHCP
• The controller will restart and obtain an IP address from DHCP server.
• The Ethernet interface will get IPv6 address from DHCP server and start communicating at
assigned IP address.
• The assigned IP Address can be viewed from Home  Settings  System Settings 
Communication Settings  Ethernet  IPv6  IP Address.
 The EC500 supports DHCP (stateful) IPv6 allocation.

➢ To change EC500 IP Address or mode from Web
• After Login, go to Home  Settings  Communications  Ethernet
• Modify IPv4 or IPv6 address settings as required.
• Click on Apply IP Settings button, to activate the modified settings.

➢ To view the MAC Address of the EC500

Either:
• On the EC500 keypad select: Home  Menu  Settings  Communication Settings 

Ethernet  MAC
• Confirm the action to reset current share factor.
Or:
• Go to Home  Settings  Communication Settings  Ethernet  MAC
The following methods can be used for communications over the Ethernet interface:
COMMUNICATION VIA WEB BROWSER

The EC500 controller has an in-built web server. This allows a PC/laptop with a standard 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
Communications on page 79.
• Open a web browser window.
 Recommended web browsers: Microsoft Internet Explorer 10 or later, Mozilla Firefox 3.0 or
later, Chrome V63 or later.
 Internet Explorer 10/11: Ensure that Compatibility Mode is turned off. Go to Tools >
Compatibility View Settings.
• Type the IP Address of the EC500 into the address bar of the browser.
 If HTTPS Access has been enabled and you wish to use secure web communication then type
"https://" before the IP Address.
• The EC500 web server Log On page will appear.

• Type your Username and Password. Click Sign In. The EC500 web system page will be
displayed.
 EC500 in-built Web server uses default port 80.

• Click on the appropriate menu item on the left.

• Or click on a block (Input / Rectifier / Battery / Load) to view status of that block.
• To change a setting click the “Edit” link on top right of display pane. This will enable editing.
• Now click on required text field, type the new value, then click Save in the top right of display
window. You can change multiple items before clicking on Save button.
• Click Logout (top right of window) to log out.
COMMUNICATION VIA A NETWORK MANAGEMENT SYSTEM USING SNMP

The EC500 Controller can be configured to allow access by a Network Management System (NMS), and/or to
send alarms 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
• Set up Ethernet Communications (see details on page 79).
• On the web, go to Home  Settings  Communication Settings  SNMP.
• Set the SNMP Access and specific protocol parameters
SNMP ACCESS CONFIGURATIONS

User shall set SNMP access protocol and related access parameters before SNMP manager can access EC500
over SNMP. Some parameters depend upon type of access selected.
SNMP Access
Parameter Description Range, Default Where to find:
Value
SNMP Port Port for access by SNMP Manager 161, not settable
SNMP Access Select SNMP protocol for access by SNMPv2c Home> Settings>
Type SNMP Manager SNMPv3 Communication
Settings>SNMP>SNMP
Default: SNMPv3 Type
SNMPv2 Access Configuration

Set following parameters when SNMP Access Type is set to SNMPv2


Value
Write Password for write access. Do not private, (string, Home> Settings>
Community change the default settings unless len 15) Communication
requested by the network Settings>SNMP>SNMP
administrator. Write Community
Read Community Password for read access. Do not public, (string, len Home> Settings>
change the default settings unless 15) Communication
requested by the network Settings>SNMP>SNMP
administrator. Read Community
SNMPv3 Access Configuration

EC500 supports up to 4 different users for SNMPv3 access. Set following parameters for each of the four users,
when SNMP Access Type is set to SNMPv3.

Value
User Name Security Model name for Manager eaton, (string, len Home> Settings>
access. A blank user name disables 30) Communication
the user. Only one user with Read Settings>SNMP>SNMPv3
only access is defined by default. USER>USERx>Username
Security Model Select security model. NoAuthNoPriv Home> Settings>

NoAuthNoPriv: No Authentication AuthNoPriv Communication
and no Privacy AuthPriv Settings>SNMP>SNMPv3
AuthNoPriv: Authentication, no USER>USERx>Security
Privacy Default: AuthPriv Type
AuthPriv: Authentication and Privacy
Authentication Select one of the two Authentication MD5 Home> Settings>
Protocol protocols. Required if Security model SHA-1 Communication
is set to either AuthNoPriv or Default: SHA-1 Settings>SNMP>SNMPv3
AuthPriv USER>USERx >
Authentication Protocol
Authentication Set a complex authentication ******** Home> Settings>

Password password. Required if Security model Communication
is set to either AuthNoPriv or Settings>SNMP>SNMPv3
AuthPriv USER>USERx >
Authentication
Password
Privacy Protocol Select one of the two Privacy DES Home> Settings>
protocols. Required if Security model AES Communication
is set to AuthPriv Default: DES Settings>SNMP>SNMPv3
USER>USERx > Privacy
Protocol
Privacy Set a complex privacy password. ******** Home> Settings>

Password Required if Security model is set to Communication
AuthPriv Settings>SNMP>SNMPv3
USER>USERx > Privacy
Password


Value
Parameter Select whether this user has Read only Read Only Home> Settings>
Access Type or Read / Write access. Read Write Communication
Settings>SNMP>SNMPv3
Default: Read USER>USERx >Access
Only
 For SNMP V3 security, the default user should be disabled or have its rights restricted.
 By default SNMP access type is set to SNMPv3. It is recommended to use SNMPv3 for
SNMP access by a NMS Manager else your network may be at security risk.
SNMP TRAP CONFIGURATIONS

SNMP Traps can be used for sending system alarms to SNMP managers. SNMP Trap protocol can be selected
independently of SNMP Access Type.

Value
SNMP Trap Select SNMP Trap protocol for sending SNMPv2c
Protocol alarms to SNMP Manager SNMPv3
Default: SNMPv2
Trap Format Select whether a single Trap OID is Group
sued for sending trap or individual OID Individual
is used for sending Trap Default: Individual
Trap Repeat Enable trap repeat if the network is not Enable
reliable Disable
Default: Disable
Trap Repeat Rate Set Trap repeat period, if enabled. 1 – 1440 Minute
Optimize between quality of network
and network load. It should be Default: 10 minute
repeated more often if network is not
reliable, but this increases network
load.
 Individual alarm shall be enabled for sending SNMP Traps, by default all alarms are enabled.
Based on SNMP Trap protocol selected, user needs to configure below mentioned different parameters.
SNMPv2 Trap Configuration

EC500 supports up to 2 Trap receivers in SNMPv2 format. Set following parameters when SNMP Trap Protocol
is set to SNMPv2 for both receivers.

Parameter Description Range, Default Value Where to find:
Trap Receiver Configure if the Enable Home> Settings>

Status respective Trap receiver Disable Communication
is Enabled or Disabled. Default: Enable Settings>SNMP>Trap Receiver
x>Status
Trap Community Set Trap community *****, (string, len 15) Home> Settings>
accepted by respective Communication
Trap receiver. Contact Settings>SNMP>Trap Receiver
your NMS manager for x>Community
correct Trap Community.
Trap Receiver IP Select IP address type of IPv4 Home> Settings>
Address Type the Trap receiver. IPv6 Communication
Default: IPv4 Settings>SNMP>Trap Receiver
x>IP Address Type
Trap Receiver IP Set IP address of the Trap Valid IPv4 or IPv6 Home> Settings>
Address Receiver. Contact your address Communication
NMS manager for correct Settings>SNMP>Trap Receiver
IP address. x>IPv4 or IPv6
Trap Receiver Set Port receiver on 0 -65535, Home> Settings>

Port number which respective Trap Communication
receiver is listening. Default: 162 Settings>SNMP>Trap Receiver
Contact your NMS x>Port
manager for correct port
number.
All Traps will be sent to both Trap receivers, if enabled.
SNMPv3 Trap Configuration

EC500 supports up to 8 Trap Receivers for SNMPv3 Traps. Set following parameters for each of these Trap
receivers, when SNMP Access Type is set to SNMPv3. Following three security models are supported.
NoAuthNoPriv: No Authentication and no Privacy
AuthNoPriv: Authentication, no Privacy
AuthPriv: Authentication and Privacy both are applied

Value
User Name Security Model name for ******, (string, Home> Settings>
Manager access. A blank user len 31) Communication
name disables the user. Only Settings>SNMP>SNMPv3
one user with Read only access USER>USERx>Username
is defined by default.
Security Model Select security model. NOAUTHNOPRIV Home> Settings>
AUTHNOPRIV Communication
AUTHPRIV Settings>SNMP>SNMPv3
USER>USERx>Security Type
Default:
AUTHPRIV


Value
Authentication Select one of the two MD5 Home>Settings>Communication
Protocol Authentication protocols. SHA-1 Settings>SNMP>SNMPv3
Required if Security model is set Default: SHA-1 USER>USERx>Authentication
to either AuthNoPriv or Protocol
AuthPriv
Authentication Set a complex authentication ******** Home>Settings>Communication
Password password. Required if Security Settings>SNMP>SNMPv3
model is set to either USER>USERx>Authentication
AuthNoPriv or AuthPriv Password
Privacy Protocol Select one of the two Privacy DES Home>Settings>Communication

protocols. Required if Security AES Settings>SNMP>SNMPv3
model is set to AuthPriv Default: DES USER>USERx>Privacy Protocol
Privacy Set a complex privacy ******** Home>Settings>Communication

Password password. Required if Security Settings>SNMP>SNMPv3
model is set to AuthPriv USER>USERx>Privacy Password
Trap Receiver IP Select IP address type of the IPv4 Home> Settings>

Address Type Trap receiver. IPv6 Communication
Default: IPv4 Settings>SNMP>Trap Receiver
x>IP Address Type
Trap Receiver IP Set IP address of the Trap Valid IPv4 or IPv6 Home> Settings>
Address Receiver. Contact your NMS address Communication
manager for correct IP address. Settings>SNMP>Trap Receiver
x>IPv4 or IPv6
Trap Receiver Set Port receiver on which 0 -65535, Home> Settings>

Port number respective Trap receiver is Communication
listening. Contact your NMS Default: 162 Settings>SNMP>Trap Receiver
manager for correct port x>Port
number.
Severity Level Select Alarm Severity Level for Default: All
which this User will get SNMP
Trap.
All: Alarms And Warnings to
receive Critical, Major and
Minor alarms, and Warnings.
Minor And Above: to receive
Critical, Major and Minor
alarms Major & above
Minor & above.
Major And Above: to receive
only Critical and Major alarms.
Critical: to receive only Critical
alarms.
 For SNMP V3 security, the default user should be disabled or have its rights restricted.

COMMUNICATION VIA EMAIL

The EC500 Controller can be configured to send Email alarm messages when an alarm of configured severity is
SET or CLEAR.
➢ To set up Email communications:

1. Set up Ethernet communications and connect the EC500 to the IP network. See Ethernet
Communications on page 79 .
2. On the web, go to Home  Settings  Communication Settings  Email Settings..
3. Set the following parameters:

Value
Email Server IP The mail server IP that will be used to -
Address: send the Emails.
Email Port: The mail server port that will be used 25
to send the Emails.
Sender’s Mail: Sender’s email address for -
authentication on mail server.
Sender’s Sender’s email password for -
Password: authentication on mail server.
Total Mail Users: Number of Email recipients. 0-6,0
Critical Alarm Delay after which mail will be sent to 1-1440 min,10
Delay user with Critical alarm severity
Major and Above Delay after which mail will be sent to 1-1440 min,10
Alarm Delay user with Major alarm severity
Minor and Above Delay after which mail will be sent to 1-1440 min,10
Alarm Delay user with Minor alarm severity
4. For each Email recipient (up to 6), set the following parameters:

Value
User Mail: The recipient's Email address. -
Severity: The severity of alarms that are to be All

reported to this recipient.
• Select None to send no Emails.
• Select Minor to send an Email when
an alarm with a severity of Minor or
above changes state.
• Select Major to send an Email when
an alarm with a severity of Major or
above changes state.
• Select Critical to send an Email when
an alarm with a severity of Critical
changes state.

MODBUS COMMUNICATIONS
The Modbus protocol is an industry standard that allows a master station to interrogate devices for its publicly
available data and set supported control and configuration parameters. Modbus is an open protocol and
transmitted over serial lines between devices.
 For details of the Modbus registers supported by the EC500, please refer the document
“EC500_Modbus_Register_Details.pdf”.
Modbus supports two serial transmission modes, ASCII and RTU (Remote Terminal Unit). Eaton products
support the RTU mode of operation, which is more prevalent. The EC500 supports RS485, 2 wire interface for
Modbus communications. Serial communication parameters are set to 19200B, 8 data bits, No parity and 1
stop bit.
The response message contains the data read from registers on the slave. The registers occur in order from the
first register requested 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 detect the beginning and end of messages. Framing constructed by measuring gaps of silence on the
communication line. Before each message, there must be a minimum gap of 3.5 characters. O prepare for new
messages, the receiver clears the buffer when gap of 1.5 characters is detected.
The EC500 only employs the Modbus Input Register and Holding Registers. By definition all Input Registers are
read only and Holding Registers are read-write. Depending upon the operation, the device may restrict access
to certain registers to read-only
 For detailed description of Parameter Register mapping and Alarm Registers refer document
“AN0157 EC500 Modbus Server”.
COMMUNICATIONS SECURITY
WEB ACCESS SECURITY

Access to the EC500 web server is provided as HTTP or HTTPS. By default EC500 is set for HTTPS web access.
HTTPS uses Transport Layer Security (TLS1.2) protocol for providing a secure access over the network. Data
transfer (including login exchange information) is end to end encrypted.

 TLS is a protocol for transmitting encrypted data over the Internet. URLs that require a TLS
connection start with https: instead of http. If the network is insecure, Eaton recommends
that you use HTTPS access only.
 HTTPS access will be slower than HTTP because of the encryption process.
➢ To change access to the web server

Set the following parameters as required.

Value
Enable HTTPS Select Enable / Disable for HTTPS. If Enable
HTTPS is disabled, HTTP is Disable
automatically enabled. Default: Enable
 By default Web access type is set to HTTPS. It is recommended to keep using HTTPS to
avoid any 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 then the EC500 will not be
accessible from the web. It will continue system control as normal in this condition. Please contact
your Eaton representative in such a case.
➢ To set up Web Users

Set the following parameters as required.

Value
User Name Username of the User Enable
Disable
Default: Enable
User Password Password of the User. Only a complex
password is accepted
User Login Delay Admin can set this variable to 0 to

unblock a blocked user instantly.
 Three successive wrong password entries will block the specific user id for 30 seconds. User
must wait for the blocking period to login again. For every successive wrong password entry
the blocking delay will increase by 1 minute. Maximum delay will be 15 minute.

EC500 Controller Handbook

EC500 Controller Handbook Specifications
SPECIFICATIONS
EC500 CONTROLLER
INTERFACES
Ethernet
Interface: 10/100baseT, MDI / MDI-X, Auto Negotiation
Connector: RJ-45, front panel
Protocols: IPv4, IPv6, TCP/IP, UDP, SNMPv2c, SNMPv3, http (Web), https
(secure Web), SNTP, SMTP, DHCP Client
Static IP Settings: IP Address, Subnet mask, Gateway address
USB
Connector: USB Type A, front panel
Version: 2.0
Speed: Full Speed (12Mbits/s)
Function: File Transfers from controller
System Communications
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
Protocols: Modbus RTU (Master / Slave), Proprietary
RS-232 Serial
Interface: RS-232 (DTE)
Connectors: DB9F, rear panel
Protocols: Modem interface, Proprietary
External modem options
GSM Modem: Modem Unit HE315xxx
SMS (Text) system status and alarm messages (EC500-V2)
Optional SD Card
Maximum Capacity: 8GB, usable 4GB
USER INPUT AND DISPLAY

Display
Display type: 320 x 240 back-lit TFT, 65k color
Viewable area: 45.12mm x 33.84mm
Display Intensity: Adjustable Intensity, auto intensity reduction in case of no
activity
Orientation: Orientation Horizontal, Vertical (EC500-V2)

Home Screen: System Block Diagram with key system values, latest alarm,
Status and RTC date and time.
Entry
Input: Joystick
(Up / Down / Left / Right / Enter)
Access Security: Read Only,
Write Access with PIN Protection
User interface functions: View system values
View and change alarms
View status messages
Start / Stop control functions
Change operating settings
Audio & LED Indicators
Power On: Green
Critical / Major Alarm: Red
Minor Alarm: Yellow
Audible Alarm Indicator: Enabled/Disabled (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, nominal
Operational Range: -36V to -60V DC
Power input connector: RJ-45 (part of CAN bus)
Input current: 0.1A (48V)
Mechanical
Dimensions H, W, D: 43mm, 112mm, 130mm. Horizontal Mounting
Weight: TBD
Mounting options: Slot mount with Lock
Orientation: Horizontal, Vertical (EC500 V2)
Environmental Specifications
Rated Operating Temp. Range: -10°C to +50°C (14°F to 122°F)
Extended Operating Temp. Range: -20°C to +60°C ( -4°F to 140°F)
May affect product lifetime, metering accuracy and display
contrast.
Altitude: <3000m (9800 feet)
Humidity: <95%RH (Non-condensing)
Location: This unit must be installed in a restricted access location.

DC INTERFACE BOARD
DC Interface Units
Number of DC Interface units supported 4, default 1
Types IOB-6V3C
Channels per IOB-6V3C
Voltage: Bus / Load Voltage + 4
Maximum range: +/- 72V
Resolution: 0.01V
Current: 3
Current Sensor Type: Shunt, 50mV
Current Range: Max. + 3000A
Current Resolution: + 0.1A for shunts less than 1000A, + 1A for shunts > 1000A
Temperature: 2
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 Isolated
PFC Outputs: 8
Contact Form: NO / NC, 1 Form C
Contact Rating: 1A @ 48V dc
Voltage: Bus / Load Voltage + 5 battery Voltage
Maximum Range: +/- 72V
Resolution: 0.01V
Current: 3
Current Sensor Type: Shunt, +/- 50mV
Current Range: Max. +/- 3000A
Current Resolution: +/- 0.1A for shunts less than 1000 A, +/- 1A for shunts > 1000A
Temperature: 2
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, requires external termination unit
Input Circuit: 2KV, Opto Isolated
PFC Outputs: 8 on board relays
POTENTIAL FREE INPUT / OUTPUT BOARD
Potential Free Input / Output Units

Number of PFC Interface units supported: 2, in addition to PFC I/Os of DCIF units
PFC Inputs per unit: 16
Input Circuit 2KV, Opto Isolated
PFC Outputs per unit: 16
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 CAPACITIES (SOFTWARE)
Voltage, Current & Temperature

Bus Voltage Channels 1
Battery Voltage / Fuse Monitoring 5
Battery Current Monitoring 5
Load Current Monitoring 4
System Temperature Monitoring 1x Battery + 1x System
Mid-Point monitoring 10
Quarter-point monitoring 5
User Voltage Channels 16
User Current Channels 16
User Temperature channels 12
AC Monitoring 3 phase, using Rectifiers
Rectifiers and Chargers
Rectifiers Controlled, only one type in a HPR48-ES (3kW)
system LPR48-ES (1.1kW)
Number of rectifiers supported: 120
LVD and Potential Free I/O
Battery LVD Drives, Physical 5

Battery LVD, Logical 1

Load LVD Drives 4
Load LVD, Logical 4
Potential Free Inputs 40
Potential Free Outputs 40
Alarms
Analog Alarms 16
Smart Alarms 16
Alarm Groups 30
System Alarms As per 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 Logs 10000
Data Logs 10000
Energy Logs 1x Battery, 1x AC Mains, 1x DG, 1x Solar, 4x Load, 60 day reading
Change Logs 1000
User Logs 64 user selected system values, 6 month, 2GB
 These are maximum software capacities. Full capacity may not be utilizable sue to usage of
common resources and will depend upon hardware installed.

EC500 Controller Handbook Alarm Descriptions
ALARM DESCRIPTIONS
Alarm Description
Mains Fail All three phases R, Y and B are less than 90V or greater than 300V and
communication between EC500 and Rectifiers is not OK. If these two
conditions are found on any complete set of rectifiers per phase for 7 seconds
continuously then “Mains Fail” alarm will be activated.
Phase Fail (R/Y/B) Individual phase is less than 90V or greater than 300V and communication
between EC500 and respective phase rectifiers is not OK. If these two
conditions are found on any complete set of rectifiers per phase for 10
second continuously then “R/Y/B Phase fail” alarm will activated.
Mains High All Rectifiers which are mapped on to different phases are scanned
continuously. If AC voltage range on all rectifiers are found less than 300V
and greater than 270V for 15 seconds continuously then “Mains High” alarm
will activated.
Mains Low All rectifiers which are mapped on to different phases are scanned
continuously. If AC voltage range on all rectifiers are found less than 150V
and greater than 90V for 15 seconds continuously then “Mains Low” alarm
will activate.
Rec Fail EC500 continuously scans the rectifier on different phases if actual rectifier
fail condition is generated from the individual rectifier 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 then multiple fail alarm will be activated. This alarm is
generated by the EC500, not the rectifier.
Rec Comm. Fail The EC500 continuously communicates with each rectifier. When a rectifier
does not respond to an EC500 request within 60ms then rectifier
communication fail (“Rec Comm. Fail) alarm will be activated. This alarm is
generated by the EC500, not the rectifier.
All Rec Comm. Fail The EC500 continuously communicates with all rectifiers. When EC500
receives “Rec Comm. Fail” alarm from all individual rectifiers then all rectifier
communication fail (“All Rec Comm. Fail”) alarm will be activated. This alarm
is generated by the EC500.
Rec Temperature High If any rectifier has ambient temperature is less than -40°C and greater than
75°C or PFC heat sink temperature is greater than 93°C or DC heat sink
temperature is greater than 115°C, then rectifiers send rectifier temperature
fail (“Rec Temp Fail”) alarm to EC500 and EC500 activates rectifier
temperature high (“Rec Temperature High”).
Rec Over Voltage This alarm is generated in rectifier when below conditions are satisfied:
✓ EC500 gives output voltage command greater than (Set Overvoltage
limit – 1.0V)
✓ When actual output voltage of any rectifier is greater than Set
Overvoltage limit and present average output current of that
rectifier exceeds the previous measured averaged current by 1A.
Rectifiers send this alarm to EC500.

Rack Fan Fail The fan tacho signal is sampled at the rate of 20us and averaged for 65536
samples. If averaged value is less than 0.3V and greater than 2.57V for 13
seconds continuously, then fan fail will be activated. EC500 activates this
after receiving it from rectifier for 17 seconds.
Rec Proc Mode This alarm is generated in the rectifier with a delay of 10ms (one AC cycle)
when input Mains frequency of rectifier less than 44Hz and greater than
66Hz. EC500 receives this and wait for 60 seconds to activate this alarm.
System Overload This alarm is generated when system current (summation of load and all
battery current) exceed the system overload alarm threshold (Normally 105%
of system capacity) for the duration of 10 seconds. This alarm will be latched
if System Overload alarm latch enable is “Set”.
DC Over Voltage This alarm is generated when bus voltage exceed the DC Overvoltage Alarm
Threshold for the duration of 10 seconds.
This alarm will be latched if DC Overvoltage alarm Latch Enable is set.
DC Low Voltage This alarm is generated when Bus voltages becomes lower than the DC
Voltage Low Alarm Threshold and more than 30V for the duration of 5
seconds.
LLVD-n Disconnect The alarm is generated by EC500 when Bus Voltage becomes lower than DC
Under Voltage Alarm Threshold and more than 30V for the duration of 5
seconds. These alarm 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 than 30V
for the duration of 5 seconds.
This alarm also triggers the battery contactors for battery LVD operation with
no delay.
Batt Bank Dischg. This alarm is generated when any battery current becomes lower than the
Battery Discharge Current Threshold (1%) in percentage of Battery Capacity
and Bus Voltage also becomes lower than Battery Discharge Voltage Alarm
Threshold (52V) for the duration of 15 seconds.
MBD (Mains ON Batt This alarm is generated when Battery Bank Discharge Alarm present and
Dischg.) Mains Fail alarm is not present or in other words if at-least one phase is OK
for duration of 120 seconds.
Temp Comp CBL Fail Temperature Compensation Cable Fail alarm is generated when Battery
Temperature becomes less than -25°C for the duration of 10 seconds.
Batt n Reverse This alarm is generated when the Battery Voltage becomes lower than
-20V for the duration of 10 seconds.
Batt n Fuse Fail This alarm is generated when any of the below mentioned condition is
present for the duration of 10 seconds:
1. Bus Voltage is more than the addition value of Battery Voltage and
Battery Fuse Fail Alarm Threshold.
2. Bus Voltage is less than the subtraction value of Battery Voltage and
Battery Fuse Fail Alarm Threshold.
Batt n Not Present This alarm is generated when Bus Voltage is less than 20V for the duration of
10 seconds.
Rack Temp1 Low This alarm is generated when Rack Temperature 1 becomes lower than Rack
Temperature 1 Low Alarm Threshold for the duration of 10 seconds.

Rack Temp2 Low This alarm is generated when Rack Temperature 2 becomes lower than Rack
Temperature 2 Low Alarm Threshold for the duration of 10 seconds.
Rack Temp1 High This alarm is generated when Rack Temperature 1 exceeds than Rack
Temperature 1 High Alarm Threshold for the duration of 10 seconds.
Rack Temp2 High This alarm generates when Rack Temperature 2 exceeds 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 in running condition.
DCIF Comm. Fail This alarm is generated when no communication packet from DCIF is received
by EC500 for continuously 5 seconds. This alarm clear all the parameters
related to DCIF.
S-Chg. Comm. Fail Solar charger communication fail is generated whenever any solar charger
does not respond to EC500 request for communication for the duration of 15
seconds.
RTC Fail When the Real Time Clock’s second does not change for the duration of 10
seconds then RTC fail alarm is declared.

EC500 Controller Handbook Connector Pin-outs
CONNECTOR PIN-OUTS
SYSTEM CONTROLLER CONNECTOR PIN-OUTS
Connector Type Pin

Purpose Description
ETH, Front RJ45 Ethernet Interface 1 Rx

Panel
2 Rx
3 Tx
4 -
5 -
6 Tx
7 -
8 -
USB USB USB Serial Interface 1 VCC (+5V dc), max 100mA
Type A
2 Data -
3 Data +
4 Ground, common with controller
CAN -1, RJ45 System primary isolated CAN 1 CAN-H

Rear Panel bus
2 CAN-L
3 -
4 CAN Ground, Isolated from

controller
5 -
6 -
7 0V, Reference
8 -48V DC, power input
CAN -2, RJ45 Additional isolated CAN bus, 1 CAN-H

Rear Panel for rectifiers from 61 - 120
2 CAN-L
3 -
4 CAN Ground, common with CAN Bus
5 -
6 -
7 0V, Reference
RJ45 1 Rx- / (IN)

Connector Type Pin

Purpose Description
RS485-L, RS-485 #1 (Lower) 4W Serial 2 Rx+ (IN)

Rear Panel Bus
3 Tx+ (Out)
4 Ground, common with CAN Bus
5 -
6 Tx- (Out)
7 0V, Reference
RS485-U, RJ45 RS-485 #2 (Upper) 4W Serial 1 Rx- / (IN)

Rear Panel Bus
2 Rx+ (IN)
3 Tx+ (Out)
4 Ground, common with CAN Bus
5 -
6 Tx- (Out)
7 0V, Reference
RS232, Rear DB9F RS-232 Serial Interface, 1 TxD (Out)

Panel modem specific pin out
2 -
3 -
4 CTS
5 Ground, common with controller
6 RTS
7 Modem PWR Disable
8 RxD (In)
9 -

DCIF CONNECTOR PIN-OUTS
Note: pinouts to be updated
Connector Type Purpose Pin Description
P1, P2 RJ45 System primary isolated CAN 1 CAN-H

bus + Power Output. Both
connectors are in parallel for 2 CAN-L
cable extension. 3 -

controller
5 -
6 -
7 0V, Reference
8 -48V DC, protected power output
X2, Upper DB9F Relay drives for Potential Free 1 +15V DC, protected power output
outputs.
2 Relay Drive 2
Use a 1:1 cable for connecting
to PFC 8 IO Board 3 Relay Drive 4
4 Relay Drive 6
5 Relay Drive 8
6 Relay Drive 1
7 Relay Drive 3
8 Relay Drive 5
9 Relay Drive 7
X2, Lower DB9M Potential Free inputs. Use a 1 0V, Common for PFC input
1:1 cable for connecting to PFC (Protected)
8 IO Board
2 PFC IN 2
3 PFC IN 4
4 PFC IN 6
5 PFC IN 8

6 PFC IN 1
7 PFC IN 3
8 PFC IN 5
9 PFC IN 7
X1 8 Pin, M Contactor drive and Voltage 1 Bus –Ve, reference for

Molex sense inputs. Shunt Common Measurements. Must be connected.
must always be connected
2 Bus +Ve / Load Voltage
3 Battery 2 Fuse / Mid / Quarter point
6 Switched LVD Contactor 1 Coil +
7 Switched LVD Contactor 2 Coil +
8 Contactor Supply +Ve, common for

both Contactor drives
X3 6 Pin, M Current Sensor inputs. 1 Bus –Ve, reference for

Molex Measurements. Must be connected.
2 Bus –Ve, reference for

Measurements. Must be connected.
3 Shunt 2 Sense +Ve
4 Shunt 2 Sense -Ve
5 Shunt 1 Sense +Ve
6 Shunt 1 Sense -Ve
J14 2 Pin, M Temperature Sensor 1 Input 1 Temperature Sensor 1 +Ve,

Molex Protected Supply
2 Temperature Sensor 1 -Ve
J15 2 Pin, M Temperature Sensor 2 Input 1 Temperature Sensor 2 +Ve,

Molex Protected Supply
2 Temperature Sensor 2 -Ve
DCIO (IOB-6V3C) CONNECTOR PIN-OUTS
X7A, X7B RJ45 System Primary isolated CAN 1 CAN-H

bus + Power Output. Both
connectors are in parallel for 2 CAN-L
cable extension. 3 -


controller
5 Isolated 5V
6 -
7 0V, Reference
8 -48V DC, protected power output
X7C RJ45 Isolated 5V CAN supply + 1 CANH RX1+

Power output. External
RS485 Interface. 2 CANL RX1-
3 TX1+
4 ISOGND_EXT, Isolated GND for

CAN
5 ISO5V1, Isolated 5V for CAN
6 TX1-
7 0V, Reference
8 -48V DC, power output
X7D RJ45 Isolated 5V CAN supply + 1 CANH RX2+

Power output. External
RS485 Interface. 2 CANL RX2-
3 TX2+
4 ISOGND_EXT
5 ISO5V1, Isolated 5V for CAN
6 TX2-
7 0V, Reference
8 -48V DC, Power output
X12 2-Pin Male Isolated CAN Bus 1 CANH
Dual Row 2 CANL
X11 6-Pin Male, System LVD Contactor Drives 1 Contactor1+,
Single Row 2 Contactor2+
3 Contactor3+
4 Common1
5 -
6 -
X1 4-Pin Male, Bus voltage + Individual 1 Battery Negative or Shunt

Battery voltage Common
Dual Row measurement
2 Bus Voltage
3 Battery Voltage – 2

X6 4-Pin Male, Individual Battery voltage 1 Battery Negative or Shunt

Dual Row measurement Common
TB1 24-Pin Male, PFC Output 1,3,5 1st Relay – Pole, NC, NO
Dual Row 2,4,6 2nd Relay – Pole, NC, NO
7,9,11 3rd Relay – Pole, NC, NO
8,10,12 4th Relay – Pole, NC, NO
TB2 16-Pin Male, 8 User defined optically 2,1 0V – D1 Input

Dual Row isolated PFC input
4,3 0V – D2 Input
6,5 0V – D3 Input
8,7 0V – D4 Input
10,9 0V – D5 Input
12,11 0V – D6 Input
14,13 0V – D7 Input
16,15 0V – D8 Input
TB3 4-Pin Male, Battery Temperature sensing 1 3.3V Protected

Dual Row
2 Temperature – 1 Input
3 3.3V Protected
4 Temperature – 2 Input
TB4 10-Pin Male, External RS485 Interface 1,2 Isolated Ground

Dual Row
3 Transmit Data 1, Tx1+
4 Transmit Data 2, Tx2+
5 Transmit Data 1, Tx1-
6 Transmit Data 2, Tx2-
7 Receive Data 1, Rx1+
8 Receive Data 2, Rx2+
9 Receive Data 1, Rx1-
10 Receive Data 2, Rx2-

X3 8-Pin Male, Differential Current Sensing 1,2 Shunt Common

Dual Row Inputs
3 Current Input 3+
4 Current Input 3-
5 Current Input 2+
6 Current Input 2-
7 Current Input 1+
8 Current Input 1-

EC500 Controller Handbook Support
SUPPORT
For product information and a complete listing of sales offices, visit Eaton’s website at: dcpower.eaton.com, or
email dcinfo@eaton.com


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EC500 Controller

Issue Date: March 2019

Copyright © 2007-2019 Eaton Corporation. All Rights Reserved.

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Cabinet Configuration ....................................................................................................................... 73

Copyright © 2019 Eaton Corporation. All Rights Reserved.

ABOUT THIS GUIDE

This guide covers operation of the EC500 Controller.

This guide is intended for use by:

• Installers competent in:

REPORTING PROBLEM WITH THIS GUIDE

FOR FURTHER INFORMATION AND TECHNICAL ASSISTANCE

For further information and technical assistance contact dcinfo@Eaton.com

THIRD PARTY SOFTWARE

Copyright © 2019 Eaton Corporation. All Rights Reserved.

DC Interface and IO Board 8

EC500 Front View

Copyright © 2019 Eaton Corporation. All Rights Reserved.

2 RS 485 Port (Lower) + Power

DC INTERFACE AND IO BOARD

• Input/Outputs: Optically Isolated Inputs – 8, Relays – 8, LVD Contactor Relays – 3

Copyright © 2019 Eaton Corporation. All Rights Reserved.

The IOB-6V3C board provides 3 on board LVD Contactor relays.

POTENTIAL FREE INPUT / OUTPUT BOARD

This board provides following interfaces:

• Input / Outputs: Optically isolated inputs – 8, Relay (NO / NC) – 8

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Unit Unit Features Remarks

IOB-PFCIO-8 Cased, 8 PFC inputs, 8 PFC outputs, Bus To special order.

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Starting the EC500 12

EC500 Operation Using Keypad and Screen 13

EC500 Operation Using a PC/Laptop 16

EC500 Identity Information 17

EC500 Internal Clock 18

EC500 Firmware Upgrade 20

STARTING THE EC500

Start-up Screen Home Screen Main Menu

Copyright © 2019 Eaton Corporation. All Rights Reserved.

ITEM NOMENCLATURE ITEM NOMENCLATURE

Rectifier Selection Indicator

Solar Input System Status

Battery Bank Menu

Current Flow Load

EC500 OPERATION USING KEYPAD AND SCREEN

ITEM Key Operation / Key Direction

Previous Menu Item Left

Scroll through sub menus Up / Down

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Buzzer mute When at Home screen, move joystick in any direction to

MAIN MENU NAVIGATION

CHANGING A CONFIGURATION SETTING USING THE KEYPAD

KEYPAD ACCESS SECURITY

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Login Successful and Press Login Button

➢ To set Brightness level

Copyright © 2019 Eaton Corporation. All Rights Reserved.

Power on LED (green)

Critical/Major Alarm LED (Red)

Minor Alarm LED (yellow)