ALENCON PODD User manual

Alencon Point of Data Distribution -
PODD
Communication device that provides user interaction for controlling and
monitoring alternative energy assets and helps generate more energy
from a PV or energy storage installation
INSTALLATION, OPERATION AND MAINTENANCE MANUAL
FOR THE PODD DEVICE
PM005 Revision 5
Alencon Systems LLC
330 Warminster Rd., Suite 380 | Hatboro, PA 19040 | USA

PODD – Installation, Operation and Maintenance Manual
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© 2009-2019 by Alencon Systems LLC
This document is the confidential and proprietary information of Alencon Systems LLC. No part
of this document may be photocopied, reproduced, stored in a retrieval system, or transmitted in
any form or by any means whether electronic, mechanical, or otherwise without prior written
permission. Alencon Systems LLC reserves the right to change details in this publication
without notice.
Copyright Information: Any product names listed in this manual that are not registered
trademarks of Alencon Systems LLC and/or organization names mentioned may be trademarks
and/or registered trademarks of their respective companies.
Publication Number: PM005
Date and Revision
Revision ECO Date Author Approval Comment
0 8562 12/10/17 H. Fishman OF Original Release
1 8563 12/19/18 P. Shivshankaran HF Modification to incorporate
new features on SPOT V6
2 8564 6/27/19 T. Smiith HF Update to new PODD
features
3 8565 8/23/19 T. Smith HF Added installation
instructions
4 8566 11/11/19 T. Smith HF Added p installation guide
and POE injector guide
5 8567 7/19/21 J. Faber HF
Integrated both PODD and
HUB manuals, with
updated features.

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1 Contents
1 Contents ............................................................................................................................................. 3
2 Table of Figures ................................................................................................................................. 5
3 General Information ............................................................................................................................ 6
3.1 About This Guide ....................................................................................................................... 6
3.2 Glossary..................................................................................................................................... 7
3.3 Product Warranty ....................................................................................................................... 8
3.4 Technical Support and Assistance ............................................................................................. 9
3.5 Warnings, Cautions and Notes ................................................................................................... 9
4 PODD Kit: Component Parts ............................................................................................................ 10
4.1 PODD Device – Available with or without wireless capabilities ................................................. 10
4.2 PODD Site ............................................................................................................................... 10
4.3 PoE Supply Kit ......................................................................................................................... 11
4.4 RJ45 Termination Dongle ........................................................................................................ 11
4.5 Wifi Access Point – Only for use with a Multi PODD wireless configuration .............................. 11
4.6 Customized Communication Package – Dependent on System Implementation ...................... 12
4.7 Ordering Information ................................................................................................................ 12
5 Alencon Communication Environement (ACE) ................................................................................. 12
5.1 Single PODD ........................................................................................................................... 12
5.2 Multi PODD .............................................................................................................................. 13
6 PODD Applications ........................................................................................................................... 14
6.1 SPOT System .......................................................................................................................... 14
6.2 BOSS System .......................................................................................................................... 15
6.3 GARD System.......................................................................................................................... 15
7 PODD Installation ............................................................................................................................. 16
7.1 Installation Options .................................................................................................................. 16
7.2 Mounting .................................................................................................................................. 16
7.2.1 PODD Mounting Location ..................................................................................................... 16
7.2.2 Mounting Parts ..................................................................................................................... 16
7.2.3 Mounting Procedure ............................................................................................................. 17
7.3 Gounding ................................................................................................................................. 18
7.4 Wiring ...................................................................................................................................... 19
7.4.1 Wiring Specifications ............................................................................................................ 19
7.4.2 Wiring Configurations ........................................................................................................... 19
7.4.3 PODD Connectors ............................................................................................................... 20
7.5 Powering .................................................................................................................................. 20
7.5.1 Modbus RTU Power ............................................................................................................. 20
7.5.2 Network Side PoE Power ..................................................................................................... 20
7.5.3 Indicator LED ....................................................................................................................... 21
7.6 Establishing a Network Connection .......................................................................................... 22
7.6.1 PODD Setup without Network Connection ........................................................................... 22
8 Maintenance and Servicing .............................................................................................................. 24
8.1 General Maintenance ............................................................................................................... 24
8.2 Magnet Reset .......................................................................................................................... 24
8.3 PODD Replacement................................................................................................................. 24
9 Mechanical Drawings ....................................................................................................................... 25
10 PODD Site ................................................................................................................................... 27
10.1 Introduction .............................................................................................................................. 27
10.2 Version .................................................................................................................................... 27
10.3 Accessing the PODD Site ........................................................................................................ 27

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10.4 PODD Site Features ................................................................................................................ 28
10.5 Alencon Devices Tab ............................................................................................................... 29
10.5.1 Target Selection ............................................................................................................... 29
10.5.2 Command Selection ......................................................................................................... 29
10.6 Config Tab ............................................................................................................................... 31
10.6.1 Steps to Send a Configuration File to the Alencon Device ................................................ 31
10.7 Firmware Update Tab .............................................................................................................. 33
10.7.1 Steps to Update Firmware on Your Alencon Device ......................................................... 33
10.7.2 Error or Stall Recovery Process ....................................................................................... 34
10.7.3 Firmware Update Status and LOG Messages .................................................................. 34
10.7.4 PODD Update .................................................................................................................. 35
10.8 Maintenance Tab ..................................................................................................................... 35
10.8.1 Log Record Management ................................................................................................. 36
10.8.2 Metadata File ................................................................................................................... 36
10.8.3 Modbus Register Map ...................................................................................................... 36
10.9 Factory Test Tab ...................................................................................................................... 36
10.10 Settings Tab ......................................................................................................................... 36
10.10.1 Setting a Static IP Address ............................................................................................... 37
10.11 Device Replacement ............................................................................................................ 37
10.11.1 How to Update Metadata File ........................................................................................... 37
11 DCDC Emulator ........................................................................................................................... 38
11.1 DCDC Emulator Functionality .................................................................................................. 38
11.2 DCDC Emulator Install and Uninstall ........................................................................................ 38

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2 Table of Figures
FIGURE 1: SINGLE PODD DEVICE .................................................................................................................................................. 10
FIGURE 2: PODD SITE, HOME TAB ................................................................................................................................................ 10
FIGURE 3: POE SUPPLY KIT FOR USE WITH PODD ......................................................................................................................... 11
FIGURE 4: RJ45 TERMINATION DONGLE ......................................................................................................................................... 11
FIGURE 5: WIFI ACCESS POINT PACKAGE ...................................................................................................................................... 11
FIGURE 6: SINGLE PODD CONFIGURATION WITH ALENCON SPOTS .............................................................................................. 13
FIGURE 7: MULTI PODD CONFIGURATION WITH ALENCON SPOTS ............................................................................................... 13
FIGURE 8: SPOT ACE SYSTEM ARCHITECTURE WITH MULTI PODD CONFIGURATION .................................................................. 14
FIGURE 9: BOSS ACE SYSTEM ARCHITECTURE WITH SINGLE PODD CONFIGURATION ................................................................ 15
FIGURE 10: GARD ACE SYSTEM ARCHITECTURE (WITH SPOTS) ................................................................................................. 15
FIGURE 11: HOOK SHAPED PODD MOUNTING BRACKET ON UNISTRUT© SUPPORT ........................................................................ 17
FIGURE 12: STRUCT CHANNEL NUTS ALIGNMENT WITH PODD MOUNTING BRACKET ..................................................................... 17
FIGURE 13: SCREW PLACEMENT IN STRUCT CHANNEL NUTS ........................................................................................................... 18
FIGURE 14: GROUND LUG PLACEMENT ........................................................................................................................................... 18
FIGURE 15: WATER-PROOF WIRING ON THE PODD ........................................................................................................................ 20
FIGURE 16: POE INJECTOR ............................................................................................................................................................. 20
FIGURE 17: EXAMPLE OF POE INJECTOR WITH PODD LAB SETUP ................................................................................................. 21
FIGURE 18: ANGRY IP SCANNER INTERFACE .................................................................................................................................. 22
FIGURE 19: WINDOWS COMMAND PROMPT APP ............................................................................................................................. 22
FIGURE 20: COMMAND TO FIND PODD IP ADDRESS ....................................................................................................................... 23
FIGURE 21: PODD IP ADDRESS AND PORT IN WEB BROWSER ........................................................................................................ 23
FIGURE 22: PODD RESET MAGNET AND GUIDE ............................................................................................................................. 24
FIGURE 23: MECHANICAL DIMENSIONS OF THE PODD .................................................................................................................. 25
FIGURE 24: MECHANICAL DIMENSIONS OF MOUNTING BRACKET ................................................................................................... 26
FIGURE 25: PODD SITE HOME SCREEN, FIRMWARE VERSION HIGHLIGHTED ................................................................................ 27
FIGURE 26: PODD SITE, TAB BAR HIGHLIGHTED .......................................................................................................................... 28
FIGURE 27: PODD SITE, DEVICE COMMAND SECTION HIGHLIGHTED ............................................................................................ 29
FIGURE 28: PODD SITE, DEVICE COMMAND OPTIONS ................................................................................................................... 30
FIGURE 29: PODD SITE, DEVICE COMMAND – SET CONTROL ........................................................................................................ 30
FIGURE 30: PODD SITE, CONFIGURATION TAB .............................................................................................................................. 31
FIGURE 31: PODD SITE, CONFIGURATION TAB – CHOOSE FILE ..................................................................................................... 32
FIGURE 32: PODD SITE, CONFIGURATION TAB – CONFIG DATA .................................................................................................... 32
FIGURE 33: PODD SITE, CONFIGURATION TAB – WRITE CONFIG .................................................................................................. 33
FIGURE 34: PODD SITE – WRITE CONFIG – LOG MESSAGES .......................................................................................................... 33
FIGURE 35: PODD SITE, FIRMWARE UPDATE TAB ......................................................................................................................... 33
FIGURE 36: PODD SITE – FIRMWARE UPDATE ............................................................................................................................... 34
FIGURE 37: PODD SITE – FIRMWARE UPDATE STATUS .................................................................................................................. 34
FIGURE 38: PODD SITE – PODD FIRMWARE UPDATE ................................................................................................................... 35
FIGURE 39: PODD SITE, MAINTENANCE TAB ................................................................................................................................ 35
FIGURE 40: PODD SITE, SETTINGS TAB ......................................................................................................................................... 36
FIGURE 41: PODD SITE, MAINTENANCE TAB ................................................................................................................................ 37

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3 General Information
All efforts have been made to ensure the accuracy of material provided in this document at
the time of release. Items are subject to continuous development and improvements. All
specifications and descriptions are subject to change without notice.
3.1 About This Guide
Purpose
This manual provides information about installing, operating, maintaining, and
troubleshooting the Alencon PODD device.
Who Should Read this Manual?
This manual should be read by anyone who needs to:
- Understand the product
- Plan the installation
- Install the product
- Commission the product
- Operate the product
- Maintain the product, as necessary

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3.2 Glossary
Word
(s)/Acronyms
Definition
SPOT
String Power Optimizer
and Transmitter
BOSS
Bi
-
directional Optimizer for Storage Systems
GARD
Ground Arc and Rapid Disconnect
ACE Alencon Communication Environment
A full communication system (including hardware and firmware)
designed by Alencon to control power conversion equipment.
Configurations:
 Single PODD: One PODD, directly connected to a network
of wired Alencon hardware, running the user interface
 Multi PODD: A centralized PODD running the user
interface which aggregates data from multiple distributed
PODDs
NOTE: Wireless packages are available for both the Single and
Multi PODD configurations
PODD Site/HUB The terms PODD Site and HUB (stands for Harvesting Utility
Block) are used interchangeably throughout
A software application used to monitor, control, and maintain
Alencon hardware, available as a webpage.
Features:
 Realtime Data Logging and Telemetry
 Alencon Device Control and Configuration
 Firmware Upgrades
PODD Point of Data Distribution
The physical networking hardware hosting the website application
and support
ing
Modbus TCP
communications.

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3.3 Product Warranty
Alencon Systems warrants to you, the original purchaser, that each of its products will be
free from defects in materials and workmanship for three years from the date of purchase.
Extended warrantees are also available for purchase.
This warranty does not apply to any products which have been repaired or altered by persons
other than repair personnel authorized by Alencon Systems, or which have been subject to
misuse, abuse, accident or improper installation. This warranty does not cover the repair or
replacement of any goods which fail as a result of damage in transit, misuse, neglect,
accident, act of God, abuse, improper handling, misapplication, modification, improper
storage, excessive stress, faulty or improper installation, testing or repair, negligent
maintenance or failure to comply with the written instructions for installation, testing, use or
maintenance (if any) provided by Alencon Systems. Alencon Systems assumes no liability
under the terms of this warranty as a consequence of such events.
Because of Alencon Systems’s high quality-control standards and rigorous testing, most of
our customers never need to use our warranty service. If an Alencon Systems product is
defective, it will be repaired or replaced at no charge during the warranty period. For out-of-
warranty repairs, you will be billed according to the cost of replacement materials, service
time and freight. Please consult Alencon Systems for more details. If you think you have a
defective product, follow these steps:
1. Collect all the information about the problem encountered (ie. issues you are
encountering in your PV array). Note anything abnormal when the problem occurs.
2. Call Alencon Systems or your licensed Alencon Systems dealer and describe the
problem. Please have your manual, product, and any helpful information readily available.
3. If your product is diagnosed as defective, obtain an RMA (return merchandise
authorization) number from your Alencon Systems Technical Support Proffesional. This
allows us to process your return more quickly.
4. Carefully pack the defective product (preferably in the original packaging material it was
shipped in), a fully-completed Repair and Replacement Order Card and a photocopy
proof of purchase date (such as your sales receipt) in a shippable container. A product
returned without proof of the purchase date is not eligible for warranty service.
5. Write down the RMA number

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3.4 Technical Support and Assistance
Visit the Alencon Systems web site at www.alenconsystems.com where you can find the
latest information about the product. Contact your distributor, sales representative, or
Alencon Systems technical support if you need additional assistance. Please have the
following information ready before you call:
1. Product name, serial number (label can be found on the PODD enclosure)
2. Description of your peripheral attachments including fusing and cables
3.5 Warnings, Cautions and Notes
Warning! Warnings indicate conditions, which if not observed, can cause personal
injury!
Caution! Cautions are included to help you avoid damaging hardware or losing
data.
Note! Notes provide optional additional information.

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4 PODD Kit: Component Parts
Alencon will provide a packing list with your shipment. Please make sure to check the
packing list matches your order and the items received. Every ACE purchase will include the
following components:
4.1 PODD Device – Available with or without wireless capabilities
The physical networking hardware that interfaces with Alencon’s devices and hosts the
PODD website application.
Figure 1: Single PODD Device
4.2 PODD Site
Firmware pre-loaded to the PODD that hosts the user interface, accessible through any PC
connected to the same network as the PODD.
Figure 2: PODD Site, Home Tab

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4.3 PoE Supply Kit
A PoE injection dongle and DC power supply for powering the PODD device. More
information on how to use can be found in section 7.5.2.
Figure 3: PoE Supply Kit for use with PODD
4.4 RJ45 Termination Dongle
Terminating resistors for the modbus communications line are used for reduction of noise
in the communciation infrastructure. The RJ45 dongle should be installed at the end of the
modbus RTU daisy chain (see section 7.4.2).
Figure 4: RJ45 Termination Dongle
4.5 Wifi Access Point – Only for use with a Multi PODD wireless
configuration
High power WiFi access that insures the wifi network will cover the installation field. More
information on how to use can be found in section 7.4.2.
Figure 5: WiFi Access Point Package

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4.6 Customized Communication Package – Dependent on System
Implementation
Various antennas and cables can be purchased for wireless and wired configurations,
respectively. Each communication package will be customized per order to ensure the
correct hardware is provided for specific implementations. This includes making sure the
correct antenna is supplied depending on where PODDs will be mounted or the specific
length and type of cabling needed for installation.
4.7 Ordering Information
Model Number
Description
PODD
P
oint of Data Distribution device with website UI
Wifi Access Point Wifi Acccess Point for use with Centralized PODD if wireless
communucations is being used
Communication
Package
Customized package that provides the correct number of antennas
and cables needed for installation
5 Alencon Communication Environement (ACE)
The PODD can be used in different configurations, depending on application and
communications needs. A full communications system, designed by Alencon, is sometimes
referred to as ‘ACE’.
Communications Protocol:
Alencon devices support Modbus RTU communications to the PODD. The PODD converts
Modbus RTU to Modbus TCP for central PODD or SCADA integration.
Communications Hardware:
All configurations use Cat5e or newer ethernet cables of STP type. Each string of Alencon
devices will be terminated with an RJ45 terminator to reduce noise and reflections. More
information on wiring and cable spec can be found in section 7.4.1.
5.1 Single PODD
In this configuration, a single PODD is connected to a string of Alencon devices which will
supply power and transmit data to the PODD using Modbus RTU. The PODD will also be
connected to a local area network and provide a user interface to communicate with the
Alencon devices directly.

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Figure 6: Single PODD configuration with Alencon SPOTs
5.2 Multi PODD
In this configuration, a number of PODDs are connected together over a wired or wireless
network. There will be one “distributed PODD” dedicated to each string of Alencon devices
for power and data. The distributed PODDs across each field connect to the centralized
PODD over Wifi or wired ethernet. Each distributed PODD collects data from their specific
string of Alencon devices and forwards the data to the centralized PODD. The centralized
PODD then combines all device data and displays a field level view on the PODD site user
interface.
Figure 7: Multi PODD configuration with Alencon SPOTs

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6 PODD Applications
The PODD is ideal for commercial or utility scale photovoltaic (PV) systems that have Alencon
power conversion devices including the SPOT, BOSS, and/or GARD. This section details how
each of Alencon’s devices can be connected over a network using the PODD.
6.1 SPOT System
Alencon’s String Power Optimiziers and Transmitters (SPOTs) have up to four inputs and
can accommodate from 4 to 8 strings. Depending on the size and need of a PV array, the
SPOTs can be setup with a Single or Multi PODD configuration.
Figure 8: SPOT ACE System Architecture with Multi PODD configuration
NOTE: Each type of device (SPOT, BOSS, and GARD) can have communications daisy-
chained with any other type of device and still connected to a Local PODD.

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6.2 BOSS System
Alencon’s Bi-Directional DC-DC Optimizer for Storage Systems (BOSS) controls the charge
and discharge of individual battery racks with a galvanically isolated approach. BOSSs are
generally co-located and easily daisy chained to a PODD. An example BOSS system
architecture using a Single PODD configuration is shown in Figure 10.
Figure 9: BOSS ACE System Architecture with Single PODD configuration
6.3 GARD System
Alencon’s Ground Arc and Rapid Disconnect (GARD) System is a protection device to detect
harmful arc and ground faults in PV arrays. These can be configured as stand-alone
protection or be paired with other Alencon devices (ie. SPOT or BOSS).
Figure 10: GARD ACE System Architecture (with SPOTs)

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7 PODD Installation
This section provides information on how to install a PODD in the field and access the PODD
site user interface.
7.1 Installation Options
Single PODD
A single PODD is installed at one end of a daisy chained RS-485 network. The total length
of the cabling should not exceed 100 meters. An antenna will be included for the PODD if
wireless package is purchased.
Multi PODD
The centralized PODD will be stand-alone and installed in a central location. That PODD is
powered through the 120VAC to 24VDC power supply and POE injector. Each distributed
PODD will be installed at one end of a daisy chained RS-485 network. For a wired network,
all distributed PODDs will be daisy chained together, ending with the centralized PODD. If
the wireless package is purchased, an antenna will be provided for each distributed PODD
and a WiFi access point will be used for the centralized PODD.
7.2 Mounting
Each PODD will be shipped with the mounting bracket already installed.
7.2.1 PODD Mounting Location
The distributed PODDs will be mounted near the strings of Alencon devices while the
central PODD will typically be mounted close to the inverter.
7.2.2 Mounting Parts
The PODD can be easily mounted using standard Unistrut© along with spring loaded
channel nuts. The attached hook shaped bracket allows for the PODD to be easily hung on
the unistrut and then fastened using a Hex hed screw. Recommended hardware for
mounting is as follows:
 Unistrut© – Any typical zinc plated or galvanized steel unistruts
 Strut Channel Nuts with Spring, 13/16" Channel High, 5/16-18 – x2 per PODD
 Hex Head Screw, Grade 8 Steel, 5/16"-18 Thread Size, 1" Long – x2 per PODD

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7.2.3 Mounting Procedure
To install the PODD in the field:
1. With the Unistrut© support structure already in place, hang the PODD mounting bracket
on the top channel.
Figure 11: Hook shaped PODD mounting bracket on Unistrut© support
2. Next, align the bottom mounting holes on the PODD bracket with the bottom channel
and struct channel nuts.
Figure 12: Struct channel nuts alignment with PODD mounting bracket

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3. Finally, secure the PODD in place by placing the screws into the stuct channel nuts.
Figure 13: Screw placement in struct channel nuts
7.3 Gounding
The external ground lug is found next to the three RJ45 connectors on the bottom of the
PODD. The ground lug can be loosened and tightened with a standard flathead
screwdriver. This MUST be connected to Earth ground. Not properly grounding the PODD
can cause the PODD to malfunction and be damaged.
Figure 14: Ground lug placement

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7.4 Wiring
7.4.1 Wiring Specifications
The PODD and connected hardware should all be compatible with the following spec:
 RS-485 (4 wire) standard – defines the necessary electrical characteristics of
cabling, transmitters and recievers. All Alencon devices, including the PODD, have
internal hardware compliant with RS-485.
 STP Cat5e (or better) cable – other RS-485 compliant cable types can be used,
but Cat5e is most common. Note that Cat5e cables will have a max run length of
100m.
 RJ45 T-568B connector – all communications ports on Alencon devices accept
male RJ45 connectors as input.
7.4.2 Wiring Configurations
Single PODD Configuration:
 Connect a cable between the Modbus RTU port on the PODD and the Alencon
devices. All Alencon devices can be daisy-chained together.
 Connect the RJ45 termination dongle to the final Alencon device on the Modbus
RTU daisy chain.
 For Wired: Connect a cable between the WAN port on the PODD and a nearby
Ethernet switch.
 For wireless: Connect the purchased antenna to the adapter on top of the PODD.
Multiple PODDs Configuration:
 Distributed PODDs: All distributed PODDs will be setup identically to the single
PODDs outlined above.
 Centralized PODD: Use the WAN port to connect the PODD to 24V power and a
network switch (see section 7.5.2).
 If setting up a wireless Central PODD, an additional connection between the LAN
port on the PODD and provided MicroTik access point is required.

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7.4.3 PODD Connectors
Each PODD has three ports which are labeled on the bottom of the front mounting plate.
To connect a cable to any of these ports:
1. Remove the water proof cap and grommet.
2. Feed the cable though the removed cap and grommet.
3. Replace the cap and grommet, tightening to reseal the port.
Figure 15: Water-proof wiring on the PODD
7.5 Powering
7.5.1 Modbus RTU Power
The PODD is most commonly powered via a 24V signal from the networked Alencon
device (SPOT, BOSS, or GARD). Simply connect a Cat5e (or newer) cable between the
peripheral device comms port and the PODD ModbusRTU port. PODD should turn on
within 2 minutes and green LED indicator will turn on when ready.
7.5.2 Network Side PoE Power
When using the PODD in a lab setup where power from Alencon devices is not readily
available, a POE injector is a convenient solution. A POE injector combines a network
connection and power into an RJ45 port as seen below.
Figure 16: POE Injector