Blue Sky UCM User Manual

Universal Communication Module

For IPN™ Network compatible charge controllers

INSTALLATION AND OPERATION MANUAL

THIS MANUAL INCLUDES IMPORTANT SAFETY INSTRUCTIONS FOR MODEL:

SAVE THESE INSTRUCTIONS

UCM

Blue Sky Energy – Universal Communication Module

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS ................................................................................................................................ 2

PRODUCT DESCRIPTION ...................................................................................................................................................... 2

Part Numbers ......................................................................................................................................................... 2

UCM CONNECTION TO THE IPN NETWORK ....................................................................................................................... 3

CONNECTING TO THE UCM’S WEB SITE ........................................................................................................................... 3

UCM Direct Computer Connection ......................................................................................................................... 4

UCM Connection Using a Router ........................................................................................................................... 6

UCM Connection Over the Internet ........................................................................................................................ 7

USING THE UCM’S WEB SITE .............................................................................................................................................. 7

Changing Settings and Executing Functions ......................................................................................................... 9

Using the IPN-ProRemote with a UCM .................................................................................................................. 9

TOP Web Page ...................................................................................................................................................... 9

ADVANCED DISPLAY Web Page ......................................................................................................................... 10

SETUP Web Page .................................................................................................................................................. 11

BATTERY CHARGE PARAMETERS Web Page................................................................................................... 12

UCM SETUP Web Page ........................................................................................................................................ 13

DATALOGGING ...................................................................................................................................................................... 13

Datalog Record Time Period .................................................................................................................................. 13

Datalog File Contents ............................................................................................................................................. 14

FTP .......................................................................................................................................................................................... 14

FTP Communication Settings ................................................................................................................................ 15

FTP File Contents .................................................................................................................................................. 15

MODBUS ................................................................................................................................................................................. 15

Electrostatic Handling Precautions ........................................................................................................................ 15

MODBUS Over TCP ............................................................................................................................................... 15

Slave Address / Unit Identifier ................................................................................................................................ 16

Isolated RS-485 ...................................................................................................................................................... 16

RS-485 Serial Communication Settings ................................................................................................................. 15

Supported MODBUS Functions ............................................................................................................................. 16

Read Coils ...................................................................................................................................... 16

Read Input Registers ..................................................................................................................... 17

Preset Single Register ................................................................................................................... 17

Force Coils ..................................................................................................................................... 18

UCM SETUP PARAMETERS .................................................................................................................................................. 19

As Shipped Factory Default Settings ..................................................................................................................... 19

Restoring As Shipped Factory Default Settings ..................................................................................................... 19

MOUNTING ............................................................................................................................................................................. 20

TROUBLESHOOTING GUIDE ................................................................................................................................................ 21

SPECIFICATIONS ................................................................................................................................................................... 22

TWO YEAR LIMITED WARRANTY ........................................................................................................................................ 22

TABLES AND FIGURES

Table 1 Datalog File Data Descriptions ...................................................................................................... 14

Table 2 FTP File Data Descriptions ............................................................................................................ 15

Table 3 RS-485 Baud Rate and Parity Select ............................................................................................. 16

Table 4 Read Coils ...................................................................................................................................... 16

Table 5 MODBUS Registers ..............................................................................................................

Table 6 Force Coils ..................................................................................................................................... 18

Figure 1 UCM Connections and Indicators .................................................................................................. 3

Figure 2 IPN Network & Power Cable Schematic ........................................................................................ 3

Figure 3 Crossover & Straight Thru Ethernet Cables .................................................................................. 4

Figure 4 UCM DIP Switch and Jumper Settings .......................................................................................... 16

Figure 5 Detailed Dimensional Drawing ....................................................................................................... 20

17 & 18

Installation and Operation Manual

IMPORTANT SAFETY INSTRUCTIONS

This manual contains important instructions for Model: UCM

SAVE THESE INSTRUCTIONS

1. Refer installation and servicing to qualified service personnel. Incorrect installation or use may result in risk of electric shock or fire. No user serviceable parts in this unit.

2. To reduce the risk of electric shock, fire or personal injury, the following symbols are placed throughout this manual to indicate dangerous conditions, or important safety or operational instructions.

WARNING CAUTION IMPORTANT

Indicates dangerous conditions or electric

shock potential. Use extreme caution.

Indicates items critical to safe installation or

operation of the unit.

Follow these instructions closely for proper

)

operation of the unit

3. PERSONAL PRECAUTIONS

a) Working in the vicinity of lead-acid batteries is dangerous. Batteries produce explosive gasses during normal operation. b) To reduce risk of battery explosion, follow these instructions and those published by battery manufacturer and manufacturer of any equipment you intend

to use in vicinity of battery. c) Someone should be within range of your voice or close enough to come to your aid when you work near a lead-acid battery. d) Have plenty of fresh water and soap nearby in case battery acid contacts skin, clothing or eyes. e) Wear complete eye protection and clothing protection. Avoid touching eyes while working near battery. f) If battery acid contacts skin or clothing, wash immediately with soap and water. If acid enters eye, immediately flood eye with running cold water for at

least 10 minutes and get medical attention immediately. g) NEVER SMOKE or allow a spark or flame in vicinity of battery. h) Be extra cautious to reduce risk of dropping metal tool onto battery. It might spark or short circuit battery or other electrical part that may cause

explosion. i) Remove personal metal items such as rings, bracelets and watches when working with a lead-acid battery. A lead-acid battery can produce a short

circuit current high enough to weld a ring or the like to metal, causing a severe burn. j) Remove all sources of power, photovoltaic and battery before servicing or installing.

4. UCM LOCATION & INSTALLATION

a) Unit is not water tight. Do not expose to rain, snow or excessive moisture. b) Unit is designed to be used only with Blue Sky Energy Integrated Power Net™ (IPN™) compatible charge controllers and accompanying displays. Do

not attach IPN NETWORK connector to anything other than an IPN compatible communications port.

c) Ethernet connector is designed for use with Ethernet TCP/IP communication only. Do not attach ETHERNET connector to anything other than a

10baseT Ethernet compatible computer or router or similar device via standard RJ-45 connector and wiring.

d) MODBUS RS-485 communication port is designed to communicate with other RS-485 communication ports only. Do not attach terminal block to

anything other than a standard RS-485 communication port, or to an RS-485 communication port with a common mode voltage differential of

PRODUCT DESCRIPTION

greater that ±100V Peak with respect to charge controller battery negative. MODBUS terminals are to be tightened to 2.1 in-lb (0.24 nm).

The Universal Communication Module (UCM™) provides a full featured communication bridge or gateway between Blue Sky Energy’s Integrated Power Net (IPN™) based charge controllers and external systems The UCM may be used with any IPN compatible charge controller (lower case “i” in the part number, e.g., SB3024iL) and receives both power and IPN network communication from the charge controller. The UCM then provides multiple standard communication interfaces which may be used simultaneously. These standard communication interfaces allow easy access to data and setup parameters for all charge controllers on the IPN network. If an IPN-ProRemote display is present its full featured battery system monitoring functionality and associated setup become available as well.

Ethernet connectivity includes a built in HTTP web site server allowing data view and parameter setup with a standard web browser either locally or globally over the Internet without a subscription. The ability to provide periodic real time FTP data upload to a remote server is also provided. A standard MODBUS RTU interface is included as well and provided as both isolated RS-485 and Ethernet TCP/IP based MODBUS/TCP. In addition the UCM also provides 128 days (or shorter periods) of datalogging of key performance parameters available as downloadable Microsoft nonvolatile memory.

PART NUMBERS

Excel® compatible file stored in

• UCM ..................... Universal Communication Module, supplied with one each of the following

• 910-0003-03 ............. 3 foot (0.9m) red Ethernet crossover cable

• 910-0002-07 ............. 7 foot (2.1m) IPN network cable

• 430-0030 ................... UCM Operators Manual

Blue Sky Energy – Universal Communication Module

UCM CONNECTIONS AND INDICATORS

UCM CONNECTION TO THE IPN NETWORK

Connect the UCM’s IPN NETWORK jack to the charge controller’s IPN DISPLAY jack using the supplied 4-pin telephone cable. If more than one charge controller is present the UCM may plug into any charge controller on the network. The charge controller must have proper battery power attached for the UCM to receive power and operate. The UCM’s Power/Heartbeat indicator will blink when properly connected to and powered by the accompanying charge controller.

¾ Standard 4-pin telephone cables swap pin numbers end-to-end. If cables are custom terminated or cable couplers are used

)

be certain the proper pin swap is maintained. If a telephone splitter is required to attached both a display and a UCM to the same charge controller use a 1-male to 2-female splitter plugged into the charge controller to maintain proper pin swap.

IPN NETWORK & POWER CABLE SCHEMATIC

FIGURE 1

Ethernet connector:

Connects to router with Cat-5 patch cable, or

directly to computer with supplied crossover type Ethernet cable. LINK LED indicates communication link established. ACT LED indicates communication

activity occurring.

IPN Network connector: UCM power & IPN network communication. MUST be connected to properly powered IPN compatible charge controller for UCM to operate.

Power / Heartbeat indicator: Green LED indicates the UCM is powered by an accompanying charge controller. LED blinks when UCM is alive and operating.

MODBUS RS-485 terminal block: Electrically isolated Full or Half Duplex RS-485 serial port for connection to MODBUS master. RX and TX LED’s indicate Transmit or Receive is occurring.

Standard 4-pin telephone cable pin swap

¾ CAUTION: Only one UCM may be present on the IPN network. Do not plug the UCM’s IPN network connector into anything other than an IPN-compatible charge controller or damage may result which will void the limited warranty. The UCM may consume up to 1W of power from the charge controller with Ethernet communication operating. Total maximum cable length

FIGURE 2

should be limited to approximately 75 feet (22.3m) with 28 awg cable or 300ft with 22 awg cable.

CONNECTING TO THE UCM’S WEB SITE

The primary means of communicating with the UCM is through its built in web site server which provides access to all data and setup parameters for both the UCM and charge controller(s), and provides access to the datalog file. The UCM may connect directly to a computer without a router, be accessed from computers on your LAN using a standard router, or be accessed over the Internet by configuring your router for port forwarding. The UCM web site server can support 2 users simultaneously.

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direct conn ection between the UCM and a computer using the supplied crossover

configure UCM communication settings. A direct connection to a computer without a router is the easiest method confirm UCM operation and communicate with the UCM to configure communication settings while eliminating possible communication issues

type cable will likely be necessary to

relating to UCM or router setup. The supplied crossover cable is RED in color and the word XOVER is present on both cable connectors to make this special cable readily identifiable from other non-crossover type cables. Signal names and typical wire colors for a straight-thru patch cable and special crossover cable are shown in Figure 3.

Installation and Operation Manual

CROSSOVER & STRAIGHT-THRU ETHERNET CABLES

COMPUTER

OR UCM

COMPUTER ROUTER UCM

STRAIGHT-THRU

PATCH CABLE

¾ CAUTION: Do not plug the UCM’s Ethernet connector into anything other than a router or similar 10baseT Ethernet compatible device or damage may result which will void the limited warranty. Utilizing good

UCM DIRECT COMPUTER CONNECTION

wiring practices total maximum cable length should be limited to 329 feet (100m).

FIGURE 3

CROSSOVER

CABLE

10baseT Ethernet compatible computer,

This option allows a single computer to directly connect to the UCM without a router or internet access. Direct connection is the simplest means to communicate with the UCM and will likely be required to access and configure communication settings for UCM access via a router or over the Internet.

1) Connect UCM to powered charge controller with 4-pin telephone cable supplied

Confirm heartbeat/power LED is blinking indicating charge controller is powered and UCM is powered and operating.

2a) Windows XP ― Configure computer’s TCP/IP settings for direct connection with UCM

For Windows XP operating system go to Control Panel, Network Connections, and select Properties for the LAN Hardware device. From the Local Area Connection Properties window select Internet Protoco l (TCP/IP) and select Properties. Record the present Internet Protocol (TCP/IP) Properties settings for subsequent restoration which will likely be Obtain an IP Address Automatically and Obtain DNS Server Address Automatically. Enter the Internet Protocol (TCP/IP) Properties settings shown below and select OK and then OK again to exit the Local Area Connection Properties window. There may be some delay as the computer reconfigures TCP/IP communications.

Direct Connect TCP/IP settings

Blue Sky Energy – Universal Communication Module

2b) Windows 7 ― Configure computer’s TCP/IP settings for direct connection with UCM

For Windows 7 operating system go to Control Panel, and under Network and Internet category select View Network Status and Tasks. From within the Network and Sharing Center window that appears select Change Adapter Settings. Right click on Local Area Connection and select Properties. In the Local Area Connection Properties window that appears select Internet Protocol Version 4 (TCP/IPv4) and then select

Properties. Record the present Internet Protocol Version 4 (TCP/IPv4) Propert ies settings for subsequent restoration which will likely be Obtain an IP Address Automatically and Obtain DNS Server Address Auto matically . Enter the Int ernet Protocol V ersion 4 (TCP/IPv4) Properties settings shown below and select OK. You will be presented with a warning “Warning - Mul tip le de fa ult ga teway s …” . Select Yes and Close to exit the Local Area Connection Properties window. There may be some delay as the computer reconfigures TCP/IP communications.

Direct Connect TCP/IP settings

2c) Other systems ― Configure computer’s TCP/IP settings for direct connection with UCM

For other operating systems including Windows Vista enter the same equivalent settings changes per 2a or 2b as described in the operating system documentation.

3) Connect UCM to computer with crossover cable supplied

Confirm LINK LEDs on UCM’s Ethernet connector and on the computer’s Ethernet connector are both ON indicating a communication link is

established between computer and UCM. A crossover type cable supplied with the UCM must be used for direct connection to a computer.

4) Logon to the UCM’s web site & Record UCM’s MAC ID

Enter the UCM’s IP Address into your web browser. The UCM uses a fixed IP Address with a factory default of 192.168.1.235 which may be changed if desired on the UCM Setup page. For Windows Internet Explorer enter the web address in the form;

http://192.168.1.235

You should be presented with the UCM’s password logon screen as shown below which confirms UCM operation and communication. To

logon to the UCM web site enter the default password admin and select Submit and then Enter Remote to get to the UCM’s Top Menu web page. Select the UCM Setup page to view the MAC ID which is unique to this particular UCM and record the MAC ID for later use. If you are unable to

get to the password screen because the IP Address or other UCM communication settings have been changed you may restore all UCM defaults

by performing a Restore As Shipped Factory Defaults function.

UCM MAC ID: _____________________________________ (unique to this particular UCM)

Installation and Operation Manual

5) Restore computer TCP/IP settings to their original settings

When finished with direct connect communication restore the computer’s original Internet Protocol (TCP/IP) Properties settings recorded above which are likely Obtain an IP Address Automatic ally and Obtain DNS Server Address Automatically. If these settings are not restored the

computer will not be able to communicate with a hard wired connection to the router or the internet. Be certain to reconnect the computer to the

router with a standard patch cable as the crossover cable supplied with the UCM will not work for this purpose unless the router can detect and

UCM CONNECTION USING A ROUTER

correct for a crossover type cable.

This option allows one or more computers to connect to the UCM via your router and LAN (Local Area Network). Special communication settings may be required in the UCM, router, or both to allow UCM access over your LAN. Computers on your LAN must be able to communicate with the UCM through the router before attempting to communicate with the UCM over the Internet.

1) Connect UCM to powered charge controller with 4-pin telephone cable supplied

Confirm heartbeat/power LED is blinking indicating charge controller is powered and UCM is powered and operating.

3) Connect UCM to ROUTER

Connect UCM to an available port on the Router with a user supplied standard CAT-5 network patch cable. The crossover cable supplied with the UCM cannot be used for this purpose and a straight-thru cable is required unless the router can detect and correct for a crossover type

cable. Confirm the LINK LED on UCM’s Ethernet connector is ON and the Router’s link active indication for the port being used is ON indicating a communication link is established between the Router and UCM.

2a) Attempt to logon to the UCM’s web site

From a computer attached to the Router enter the UCM’s IP Address into the web browser. The UCM uses a fixed IP Address with a factory default IP Address of 192.168.1.235 which may be changed if desired on the UCM Setup page. For Windows Internet Explorer enter the web address in the form;

http://192.168.1.235

If you are presented with the UCM’s password logon screen as shown above the UCM is communicating across your LAN and further router or UCM setup for LAN communication is unnecessary. If you are unable to get to the password screen because the IP Address or other UCM

communication settings may have been changed, perform a Restore As Shipped Factory Defaults function and try again.

2b) Modify router configuration if necessary and logon to the UCM’s web site

If you are still unable to get to the password screen the UCM and/or router may require special settings to allow the router to communicate with the fixed IP Address UCM. Refer to the router’s documentation regarding communication setup for fixed IP Address devices. However, many routers require two things be changed, 1) Change the UCM’s IP Address to be within the IP Address range the router can assign via DCHP, and

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2) Add the new UCM IP Address to the routers DCHP Reservation list to reserve the UCM’s new IP Address for exclusive use by the UCM.

direct connection between the UCM and a computer using the supplied crossover

cable as described previously is necessary to configure UCM communication settings including the IP Address. If you are unable to get to the password screen because communication settings in the UCM have been changed you can temporarily force the UCM to use default communication settings by rebooting the UCM with DIP #4 IP-A turned ON. This special communication mode will temporarily show and use default communication settings on the UCM Setup page. If no changes are made at this time, previous changes made to these settings will return following reboot with DIP #4 OFF. If settings changes are made at this time such as changing the IP Address the new settings will be used following reboot with DIP #4 OFF You may also restore all UCM defaults including

communication settings and password by performing a Restore As Shipped Factory Defaults function.

Record the UCM’s new IP Address for later use.

UCM IP Address: ______________________________

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