Skip to content
Manuals and Docs

EcoPhi Portal

You can currently find our manuals here: https://ecophi.io/download-page/

Play

1 Introduction

1.1 Description and function of the EcoPhi Plant Controller

The EcoPhi Plant Controller is a modern communication edge device that has been specially developed for the requirements of renewable energy systems. The device enables the monitoring and control of serial devices, sensors, and actuators and provides a central platform for data processing.

The Plant Controller was developed by EcoPhi, a company specializing in innovative IoT solutions for renewable energy. EcoPhi focuses on providing efficient and robust technologies that enable customers to optimally operate and monitor their systems. The Plant Controller is an important building block in this offering, as it ensures reliable data collection and a stable connection to the EcoPhi Cloud.

The EcoPhi Plant Controller is a central component of modern energy systems that combines several essential functions. It was developed to collect data from connected external devices and sensors, process it locally, and make it accessible via a cloud platform. The Plant Controller is not only used to collect data, but also to control devices in renewable energy systems.

In addition to data acquisition, the Plant Controller can also send control commands to connected devices. This includes, for example, the control of inverters, battery systems, or generators, giving it an active role in energy management. Integration into the EcoPhi Cloud extends the functions to include remote monitoring and control, enabling operators to efficiently manage their systems remotely.

The Plant Controller is therefore more than a simple data logger – it is an intelligent communication device that links data and control commands in one system and creates the basis for effective energy management.

1.2 Safety instructions

The installation and operation of the EcoPhi Plant Controller requires compliance with basic safety regulations to ensure the safety of persons and equipment:

Installation by qualified personnel

  • The Plant Controller may only be installed and maintained by qualified specialist personnel to avoid risks such as electric shocks or malfunctions.

Switch off the power supply

  • Before installation or maintenance, ensure that the power supply to the device is disconnected.

Use the components supplied

  • Only use the parts recommended or supplied by EcoPhi to ensure functionality and safety.

Seal cable glands

  • Open cable glands must be properly sealed before commissioning to prevent the ingress of moisture or foreign bodies.

Notes on correct cabling and proper connections

  • Approximately 80% of all problems in connection with the installation of the EcoPhi Plant Controller are caused by incorrect cabling and connections.
  • It is strongly recommended to use shielded cables.
  • Ensure that there are no sources of interference near the cables, e.g., motor cables, power cables, high-power cables.
  • The greater the distances, the greater the influence of possible sources of interference.
  • Connect cables properly and not via loose plug contacts or simple insulating tape.
  • If necessary, remove the supplied terminals from sensors supplied by EcoPhi, as they are not intended for permanent use, but only to show that the wiring is correct.
  • If necessary, use the heat-shrink tubing supplied to extend and connect the cables.
For serial devices:
  • Avoid star connections; the maximum distance for star connections is 100 m. A 120 Ohm resistor at the end of the connections improves transmission.
For pulse sensors:
  • Avoid magnetic interference fields in the vicinity of pulse sensors, e.g., door sensors or water meters.

1.3 Glossary for the EcoPhi Plant Controller

  • 2FF (Mini SIM): A specific SIM card format that is used with the EcoPhi Plant Controller.
  • 4-20mA mode: Standard for analog signal transmission, often used with industrial sensors. The current range (4 to 20 mA) represents the measured value of the sensor.
  • AI (Analog Input): Analog inputs that can detect changing states of sensors, usually through a sensor signal of 0-10V or 4-20mA.
  • AO (Analog Output): Analog outputs that send signals to external devices.
  • APN (Access Point Name): Network name that is required for the mobile connection to send and receive data via the mobile network.
  • Bar chart: Visualization on the Plant Controller display that graphically shows the current value of an analog sensor.
  • CSV (Comma-Separated Values): A file format used in the Plant Controller to save or import configurations and settings.
  • DI (Digital Input): Digital inputs that can recognize binary states (on/off) of sensors or switches.
  • DO (Digital Output): Digital outputs that send signals (on/off) to external devices such as relays or contactors.
  • Ethernet: Wired network interface used for a stable connection and data transmission.
  • GND (Ground): Earthing point in the Plant Controller that is important for the safe connection with other devices.
  • Modbus: A communication protocol used in the Plant Controller to communicate with devices such as inverters or sensors via RS485 or TCP/IP.
  • RS232: A standard for serial communication used in the Plant Controller for certain devices.
  • RS485: A serial communication protocol that is often used in industrial applications. The Plant Controller supports it for connection to sensors and other devices.
  • SD card: A storage medium used in the Plant Controller for data backup and configuration updates.
  • SNR (Signal-to-Noise Ratio): Ratio of signal strength to noise, which describes the quality of a radio connection.
  • SSID (Service Set Identifier): Name of a WLAN network that is required for the WiFi connection of the Plant Controller.
  • VCC (Voltage Common Collector): Supply voltage for sensors or other connected devices.
  • WiFi: Wireless network interface of the Plant Controller, which is used to connect to the EcoPhi Cloud or local networks.

1.4 Technical data

1.4.1 Power consumption

  • Maximum load: The Plant Controller can consume up to 30 watts under maximum load. This typically occurs during intensive use, such as when numerous devices are connected or during high data transfer rates.
  • Average load: In normal operation, the average power consumption is around 3 to 4 watts. This varies depending on the number and type of sensors connected, the frequency of data transmission, and the communication interfaces used (e.g., WiFi or Ethernet).
  • Backup power: The Plant Controller is equipped with an internal battery that supports operation for up to 4-5 hours during a power failure. This ensures continuous data logging and uninterrupted communication once power is restored.
  • Alternative power supply: The device can also be powered by an external supply (11.5V to 30V DC). However, stable operation is guaranteed only if specifications are met. A minimum supply of 14V DC is required for 0-10V analog output configuration.

1.4.2 Data consumption

  • Typical data usage: A typical system with moderate sensors and devices consumes about 200 MB monthly. However, this can vary based on the number of connected sensors, transmission intervals, and system configuration.
  • Optimized for efficiency: The Plant Controller minimizes unnecessary data transfer and repetitions, making it suitable for systems with limited data volumes or mobile connections.

1.5 Components of the EcoPhi Plant Controller

1.5.1 Scope of delivery

The standard delivery includes:

  • Key for opening the housing
  • Mains cable with switch
  • 2-, 3-, and 4-pin connectors for the distribution board
  • Heat-shrink tubing for cable insulation
  • Cable glands (gland, nut, rubber ring, plug)
  • Brackets and screws for wall mounting

1.5.2 Inner components of the Plant Controller

  1. Power supply: Integrated unit ensuring reliable energy supply for all components.
  2. Distribution board: Simplifies connections for external devices, sensors, and actuators.
  3. Data logger/main unit: Core component for data processing, storage, communication, and control logic.
  4. WiFi antenna: Provides wireless connectivity to local networks.
  5. GSM antenna: Ensures mobile network connectivity. Can be mounted outside the housing if the signal is weak.

1.5.3 Display

  • Resolution: 240x160 pixels with a resistive touchscreen.
  • Functions: Displays I/O status, battery levels, communication interfaces, and operational statuses.

1.5.4 LED indicators

  • LED A: Internet connection status:
    • Green: SIM card connection
    • Orange: WiFi connection
    • Red: Ethernet connection
  • LED S1: General system status
  • LED S2: Mobile network activity

1.5.5 Distribution board

The distribution board has the following pin assignments:

  • DI 1-8: Digital inputs for sensors/switches
  • DO 1-8: Digital outputs for relays
  • AI 1-4: Analog inputs (0-10V and 4-20mA modes)
  • AO 1-4: Analog outputs
  • RS232: Serial communication
  • RS485: Serial communication with industrial devices

1.5.6 SD card

  • Functions:
    • Stores data temporarily during offline periods.
    • Saves images from connected cameras.
    • Enables configuration updates via a CSV file.

1.6 Tools required

To install the Plant Controller, the following tools are needed:

  • Electric screwdriver (slotted)
  • Heat-shrink tubing or soldering materials
  • Hot air dryer or lighter
  • Cordless drill for wall mounting

2 Installation instructions

2.1 Quick Guide

  1. Preparation:
    • Ensure access to the EcoPhi Cloud.
    • Select an accessible location with reliable network coverage.
    • Prepare tools and check the delivery contents.
  2. Mechanical installation:
    • Mount the Plant Controller securely using screws and wall plugs.
    • Seal unused cable openings with the provided plugs.
  3. Electrical connections:
    • Connect the power supply and sensors.
    • Configure inputs/outputs and RS485/RS232 connections.
  4. Commissioning:
    • Register the device on the EcoPhi Cloud platform.
    • Check connectivity using LED indicators.
  5. Final check:
    • Verify all connections and ensure stable operation.

2.2 Preparations

2.2.1 Access to the EcoPhi portal

  1. User account: Register at www.portal.ecophi.io.
  2. Device registration:
    • Log in and create or select a site.
    • Add the Plant Controller as a data source using its device ID.
  3. Site settings:
    • Configure sensors, actuators, and device-specific settings.

2.2.2 Site preparations

  • Remove any packaging material from the device.
  • Attach and seal cable glands for weatherproofing.
  • Seal unused openings with the provided plugs.

2.3 Connection with the EcoPhi Cloud

2.3.1 Connection options

The Plant Controller supports:

  1. SIM card: Insert a compatible mini SIM (2FF). Configure APN settings if required.
  2. WiFi: Configure via the EcoPhi platform, SMS, or a temporary hotspot.
  3. Ethernet: Use a standard CAT cable for a stable wired connection.

2.3.2 Changing Internet settings

  • Via SMS: Send commands to the SIM card number (e.g., "status" or "restart").
  • Via SD card: Create a command.csv file with desired settings.
  • Via the EcoPhi portal: Adjust settings under “Site Settings.”

2.3.3 LED lights

  • LED A: Internet connection status.
    • Flashing: Attempting connection.
    • Solid: Connection established.

2.3.4 Antennas

  • The GSM and WiFi antennas are pre-installed.
  • Antennas can be mounted externally for better reception if required.

2.4 Cabling

2.4.1 Circuit diagram

The distribution board supports:

  • Digital inputs (DI)
  • Digital outputs (DO)
  • Analog inputs (AI: 0-10V or 4-20mA)
  • Analog outputs (AO)
  • RS232/RS485 communication

2.4.2 Connection guidelines

  • Use the provided connectors for secure connections.
  • Follow the color coding and pin assignments.

2.5 Wall mounting

  1. Location: Ensure good network coverage and accessibility.
  2. Installation:
    • Attach brackets to the housing.
    • Mount the device using screws and plugs.
  3. Cable management: Route cables neatly through the grommets.

3 Controls

3.1 Individual controls

The EcoPhi Plant Controller controls are customized for individual applications and available only upon request. These controls are tailored to specific system requirements.

  • Settings of control parameters:
    • Assign control logic: Define conditions to trigger specific control actions.
    • Data provisioning: Provide controllers with necessary data points, such as sensor data or operating states.
    • Optimize system performance: Monitor and adjust control parameters to ensure optimal functionality.

3.2 Energy management system (EMS)

EcoPhi offers an energy management system (EMS) designed for complex renewable energy systems. The EMS provides intelligent control and optimization of energy flows in systems with multiple energy sources and consumers.

  • Commissioning: The EMS must be set up by EcoPhi or a certified partner to ensure correct configuration and reliable operation.
  • Role assignment: Assign devices with the correct roles (e.g., energy generation, storage, or consumption) during setup. Incorrect assignments can lead to system errors.

4 Error messages

LEDs flash red quickly

This indicates a critical software error that renders the device inoperable. Steps to resolve:

  1. Restart the device: Press the restart button to reset the device. This may temporarily fix the issue and re-establish the platform connection.
  2. Contact support: If the issue persists, report the problem to EcoPhi Support with the exact time of occurrence and any observed symptoms.

Touch screen unresponsive; LEDs S1 and S2 flash monotonously or are off

This may indicate an internal fault, often caused by grounding issues with connected devices.

Steps to resolve:

  1. Disconnect the device: Remove the Plant Controller from the power supply and disconnect connected devices.
  2. Contact EcoPhi Support: Report the issue, including details about connected devices and cabling.
  3. Check grounding: Ensure all connected devices share a common ground potential to prevent voltage differences.

Sensor or externally connected device not responsive

  1. Check cable connections: Ensure cables are firmly connected and undamaged.
  2. Check display status:
    • For analog and digital sensors: Verify live signals on the display.
    • For RS485/RS232 connections: Diagnose via the EcoPhi platform or debugging tools.
  3. Check RS485 device configuration:
    • Verify Modbus ID and cable polarity.
    • Ensure proper termination resistor (120 Ohm) is installed at the end of the RS485 line.
    • Avoid routing RS485 cables near high-voltage lines to reduce interference.

5 Support and further information

If you encounter issues during installation, configuration, or operation of the EcoPhi Plant Controller, contact the EcoPhi support team.

  • Submit a ticket: EcoPhi Support Request
  • Required information:
    • Device serial number
    • Detailed problem description
    • Any error messages observed

EcoPhi Renewables Engineering GmbH
Alter Schlachthof 33
76131 Karlsruhe
www.ecophi.io

This project is supported by the German Federal Ministry for Economic Affairs and Climate Action as part of the Renewable Energy Solutions Programme of the German Energy Solutions Initiative.