EP Solar LS1024RD User manual

LS1024RD / LS1524RD / LS2024RD
—— Dual load solar light controller
Thank you very much for selecting our product!
This manual offers important information and
suggestions with respect to installation, use and
troubleshooting, etc. Please read this manual
carefully before using the product and pay attention
to the safety recommendations in it.
EPSOLAR
☆Design patent NO.：
201130028317.3
☆Utility model patent NO.：
201120064092.1
INSTRUCTION
MANUAL

LS1024RD / LS1524RD / LS2024RD
—— Dual load solar light controller
Installation and Operation Manual
Specification Summary
Nominal system voltage 12 / 24VDC*
Maximum PV input voltage 50V
Nominal charge / discharge current
LS1024RD 10A
LS1524RD 15A
LS2024RD 20A
* The controller will recognize the system rated voltage when start up. If
the battery voltage is lower than 18V, it will recognize the system as 12V.
If the battery voltage is greater than 18V, it will recognize the system as
24V.
LandStar

Contents
1 Important Safety Information.....................................1
2 General Information...................................................2
2.1 Product Overview................................................2
2.2 Product Features..................................................3
3 Installation Instructions..............................................4
3.1 General Installation Notes ...................................4
3.2 Mounting.............................................................4
3.3 Wiring.................................................................6
4 Operation..................................................................10
4.1 PWM Technology .............................................10
4.2 Battery Charging Information............................10
4.3 LED Indicators..................................................12
4.4 Setting Operation...............................................14
5 Protections, Troubleshooting and Maintenance........17
5.1 Protection ..........................................................17
5.2 Troubleshooting ...............................................18
5.3 Maintenance ..................................................20
6 Warranty ..................................................................21
7 Technical Specifications...........................................22

1
1 Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating instructions
The following symbols are used throughout this manual to indicate
potentially dangerous conditions or mark important safety instructions，
please take care when meeting these symbols.
WARNING: Indicates a potentially dangerous
condition. Use extreme caution when
performing this task.
CAUTION: Indicates a critical procedure for
safe and proper operation of the controller.
NOTE: Indicates a procedure or function that
is important for the safe and proper operation
of the controller.
General Safety Information
Read all of the instructions and cautions in the manual before beginning
installation.
There are no user serviceable parts inside the controller. Do not
disassemble or attempt to repair it.
Install external fuses/breakers as required.
Disconnect the solar module and fuse/breakers near to battery before
installing or adjusting the controller.
Do not allow water to enter the controller.
Confirm that power connections are tightened to avoid excessive heating
from loose connection.

2
2 General Information
2.1 Product Overview
Thank you for selecting LandStar series dual load solar light controller that
adopts the most advanced digital technique and operates fully automatically.
The Pulse Width Modulation (PWM) battery charging can greatly increase
the lifetime of battery. It has various unique functions and quite easy to use,
such as:
12/24V automatic recognition
High efficient Series PWM charging, increase the battery lifetime and
improve the solar system performance.
Use MOSFET as electronic switch, without any mechanical switch
Widely used, automatically recognize day/night.
Digital LED menu, only one key solve all setting simply
Intelligent timer function with 1-15 hours option
Dual load output, enhance the flexibility of the system.
Gel, Sealed and Flooded battery type option.
Adopt temperature compensation, correct the charging and discharging
parameters automatically and improve the battery lifetime.
Electronic protection: Overheating, over charging, over discharging,
overload, and short circuit.
Reverse protection: any combination of solar module and battery.
The controller is for off-grid solar system, especially in solar light system,
and protects the battery from being over charged by the solar module and
over discharged by the loads. The charging process has been optimized for
long battery life and improved system performance. The comprehensive
self-diagnostics and electronic protection functions can prevent damage from
installation mistakes or system faults.
Though the controller is easy to operate and use, please take your time to
read this manual and become familiar with it. This will help you make full
use of all the functions and improve your solar PV system.

3
2.2 Product Features
Figure 2-1 LandStar characteristics
1 –Temperature Sensor
Measure ambient temperature and make temperature compensation for
charging and discharging.
2 –Charging status LED indicator
An LED indicator that shows charging status and also indicates when a solar
input fault condition exists
3 –Battery status LED indicator
An LED indicator that shows battery status
4 –Battery type setting indicator
The indicator will be on when select battery type.
5 –Load 2 setting indicator
The indicator will be on when set load 2.
6 –Load 1 setting indicator
The indicator will be on when set load 1.
7 –LED digital display
Display the load work mode and status
8 –Setting button (in manual mode used for load ON/OFF)
Set load work mode and select battery type.
9 –Solar Module Terminals
Connect solar modules.

4
10 –Battery Terminals
Connect batteries.
11 –Load 1 Terminals
Connect load 1.
12 –Load 2 Terminals
Connect load 2.
3 Installation Instructions
3.1 General Installation Notes
Read through the entire installation section first before beginning installation.
Be very careful when working with batteries. Wear eye protection. Have
fresh water available to wash and clean any contact with battery acid.
Uses insulated tools and avoid placing metal objects near the batteries.
Explosive battery gasses may be present during charging. Be certain there
is sufficient ventilation to release the gasses.
Avoid direct sunlight and do not install in locations where water can enter
the controller.
Loose power connections and/or corroded wires may result in resistive
connections that melt wire insulation, burn surrounding materials, or even
cause fire. Ensure tight connections and use cable clamps to secure cables
and prevent them from swaying in mobile applications.
Use with Gel, Sealed or Flooded batteries only.
Battery connection may be wired to one battery or a bank of batteries. The
following instructions refer to a singular battery, but it is implied that the
battery connection can be made to either one battery or a group of
batteries in a battery bank.
Select the system cables according to 3A/mm2current density
3.2 Mounting
NOTE: When mounting the controller, ensure free air
through the controller heat sink fins. There should be at
least 6 inches (150 mm) of clearance above and below the
controller to allow for cooling. If mounted in an
enclosure, ventilation is highly recommended.

5
WARNING: Risk of explosion! Never install the
controller in a sealed enclose with flooded batteries! Do
not install in a confined area where battery gassed can
accumulate.
Step 1: Choose Mounting Location
Locate the controller on a vertical surface protected from direct sun, high
temperature, and water. And make sure good ventilation.
Step 2: Check for clearance
Place the controller in the location where it will be mounted. Verify that
there is sufficient room to run wires and that there is sufficient room above
and below the controller for air flow.
Figure 3-1 Mounting and cooling
Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole locations on the
mounting surface.
Step 4: Drill Holes
Remove the controller and drill 4.5mm holes in the marked locations.
Step 5: Secure Controller
Place the controller on the surface and align the mounting holes with the
drilled holes in step 4.
Secure the controller in place using the mounting screws.
Warm air
Cool air
150mm(5.9inches)
150mm(5.9inches)

6
3.3 Wiring
NOTE: A recommended connection order has been
provided for maximumsafety during installation.
NOTE: The controller is a common positive ground
controller.
CAUTION: Don’t connect the loads with surge power
exceeding the ratings of the controller.
CAUTION: For mobile applications, be sure to secure
all wiring. Use cable clamps to prevent cables from
swaying when the vehicle is in motion. Unsecured
cables create loose and resistive connections which may
lead to excessive heating and/or fire.
Step1: Battery Wiring
WARNING: Risk of explosion or fire! Never short
circuit battery positive (+) and negative (-) or cables.
Figure 3-2 Battery connecting
Battery
150mm(5.9inches)
MAX
Fuse

7
Before battery is connected, make sure that battery voltage is greater than 6V
so as to start up the controller. If system is 24V, make sure battery voltage is
not less than 18V. System voltage can only be automatically recognized
when controller start up for the first time.
When install fuse, make sure that the biggest distance between the fuse
holder and the positive terminal of battery is 150mm.Do not insert a fuse at
this time.
Step 2: Load Wiring
The controller loads can be connected to such electrical equipments as lights,
pumps, motors and others. Controller offers power to loads through the
battery voltage.
Figure 3-3 Load Wiring
Connect the positive (+) and negative (-) of loads to controller load terminals
as shown in Figure 3-3.
An in-line fuse holder should be wired in series in the load positive (+) or
negative (-) wire as show in Figure 3-3. Do not insert a fuse at this time.
If wiring the load connection to a load distribution panel, each load circuit
should be fused separately. The total load draw should not exceed the load
rated current of controller.
Fuse
Load2
Load1
Fuse

8
Step 3: Solar wiring
WARNING: Risk of electric shock! Exercise caution
when handling solar wiring. The solar module(s) high
voltage output can cause severe shock or injury. Cover
the solar module(s) from the sun before installing solar
wiring.
The controller can accept12V, 24V nominal off-grid solar module(s).
Grid-tie solar module(s) may be used if the open circuit voltage of solar
module doesn’t exceed the Maximum PV input voltage of the controller.
The solar module(s) work voltage must be equal to or greater than the
system voltage.
Figure 3-4 Solar wiring
Solar Module

9
Step 4: Confirm Wiring
Double-check the wiring in step1 through 3. Confirm correct polarity at each
connection. Verify that all eight terminals are tightened.
Figure 3-5 System wiring review
Step 5: Install Fuse
Install a suitable fuse in each fuse holder in the following order:
1. Battery circuit
2. Load circuit
Step 6: Confirm power on
When battery power is applied and the controller starts up, the battery LED
indicator will be green.
If the controller doesn't start up, or the battery status LED error exists, please
refer to section 5 for troubleshooting.
Solar Module
Load
Battery

10
4 Operation
4.1 PWM Technology (Series Pulse Width Modulation)
The controller adopts the advanced series pulse width modulation. With
range of 0-100%, it can charge the battery quickly and stably under any
condition of solar photovoltaic system.
The operating principle of PWM charging mode is as follows:
The battery is firstly charged with pulse current and recharged after it stops
charging for a while. It is repeated in this way for several times till the
battery is fully charged. Intermissions allow some oxygen and hydrogen
generated by chemical reaction can be chemically combined again and then
absorbed, which can eliminate concentration polarization and ohm
polarization naturally, and reduce the internal pressure of the battery.
Consequently, it makes next charging smooth and the more power is charged
to the battery. Intermittent pulse current charging mode makes battery have
more time to react, which reduces the gassing volume and makes battery
improve the acceptance rate of charging current.
4.2 Battery Charging Information
Figure 4-1 PWM Charging mode
·Bulk Charge
In this stage, the battery voltage has not yet reached boost voltage and 100%
of available solar power is used to charge the battery.
·Boost Charge
When the battery has recharged to the Boost voltage setpoint,
constant-voltage regulation is used to prevent heating and excessive battery
gassing.The Boost stage remains 120 minutes and then goes to Float Charge.

11
·Float Charge
After the battery is fully charged in Boost voltage stage, the controller
reduces the battery voltage to Float voltage set point. When the battery is
fully recharged, there will be no more chemical reactions and all the charge
current transmits into heat and gas at this time. Then the controller reduces
the voltage to the floating stage, charging with a smaller voltage and current.
It will reduce the temperature of battery and prevent the gassing, also
charging the battery slightly at the same time. The purpose of Float stage is
to offset the power consumption caused by self consumption and small loads
in the whole system, while maintaining full battery storage capacity.
In Float stage, loads can continue to draw power from the battery. In the
event that the system load(s) exceed the solar charge current, the controller
will no longer be able to maintain the battery at the Float setpoint. Should
the battery voltage remains below the Boost setpoint, the controller will exit
Float stage and return to Bulk charge.
·Equalize Charge
WARNING: Risk of explosion!
Equalizing flooded battery can produce explosive
gases, so well ventilation of battery box is necessary
NOTE: Equipment damage!
Equalization may increase battery voltage to the level
damaging to sensitive DC loads. Ensure that all load
allowable input voltages are greater than the equalizing
charging set point voltage.
NOTE: Equipment damage!
Over-charging and excessive gas precipitation may
damage the battery plates and activate material
shedding on them. Too high an equalizing charge or for
too long may cause damage. Please carefully review
the specific requirements of the battery used in the
system.

12
Certain types of batteries benefit from periodic equalizing charge, which can
stir the electrolyte, balance battery voltage and complete chemical reaction.
Equalizing charge increases the battery voltage, higher than the standard
complement voltage, which gasifies the battery electrolyte.
If the battery is being over discharged, the solar controller will automatically
turn to equalize charging stage, and the equalize stage remain 120mins.
Equalize charge and boost charge are not carried out constantly in a full
charge process to avoid too much gas precipitation or overheating of battery.
4.3 LED Indicators
Charging Status LED indicator Battery Status LED indicator
Figure 4-2 LED indicators
Charging status indicator
GREEN ON whenever sunlight is available for battery charging,
GREEN FAST FLASHING when system over voltage.
Please refer to section 5 for troubleshooting.
Charging Status LED indicator Table 4-1
Color
Indicator
Charging Status
Green
On Solid
Charging
Green
Fast Flashing
Over voltage

13
Battery status indicator
GREEN ON when battery voltage in normal range
GREEN SLOWLY FLASHING when battery full
ORANGE ON when battery under voltage
RED ON when battery over discharged
Please refer to section 5 for troubleshooting.
Battery status LED indicator Table 4-2
Color
Indicator
Battery Status
Green
On solid
Normal
Green
Slowly Flashing
Full
Orange
On solid
Under voltage
Red
On solid
Over discharged
Load status indicator:
When the load amp is 1.25times of rated current for 60 seconds, or the
load amp is 1.5 times of rated current for 5 seconds (overload); or load amp
is more than 3.5 times of rated current(Short Circuit) ,the LED digital tube
shows “L” with slowly flashing simultaneously. Please refer to section 5 for
trouble shooting.
Load status LED indicator Table 4-3
Color
LED digital display
Load status
Red
“L” with slowly flashing
Overload or short circuit
Overheating protection indicator:
When heat sink of the controller exceeds 85 ℃, the controller will
automatically cut input and output circuit, with LED digital tube showing
“H” with slowly flashing simultaneously. Please refer to section 5 for trouble
shooting.
Overheating protection indicator Table 4-4
Color
LED digital display
System status
Red
“H” with slowly flashing
Controller overheating

14
4.4 Setting Operation
Load Control Settings
1. Dusk to Dawn
When solar module voltage goes below the point of NTTV (Night Time
Threshold Voltage) at sunset, the controller will recognize the starting
voltage and turn on the load after 10 minutes delay. When solar module
voltage goes above point of DTTV (Day Time Threshold Voltage), the solar
controller will recognize the starting voltage and turn off the load after 10
minutes delay.
2. Light ON + Timer
When solar module voltage goes below the point of NTTV (Night Time
Threshold Voltage) at sunset; the solar controller will recognize the starting
voltage and turn on the load after 10 minutes delay. The load will be on for
several hours which users set through LED digital tube. Please refer to table
4-5 “Load Work Mode Setting”.
3. Test mode
This mode is the same as Dusk to Dawn. But there is no 10 minutes delay
when controller recognizes the starting voltage. When below the starting
voltage, the controller will turn on the load, if higher, it will turn off load.
The test mode makes it easy to check the system installation.
4. ON/OFF mode
This mode is to turn ON and OFF the load by manual.
Load Work Mode Setting
Load 1 Setting indicator Load work mode LED digital tube
Figure 4-3 Setting operation indicating
Load 2
Setting indicator
Battery type
Setting Indicator
Setting button

15
Press the setting button once and setting indicators will be changed once
among load 1, load 2 and battery type.
When load 1 setting indicator is on, press the setting button for more than 5
seconds till the LED digital tube flashes. Then press the setting button till the
desired number appears according to the following table. The setting is
finished till the digital tube stop flashing.
Setting work mode of load 2 is the same as load 1 when the load 2 timer is
on.
Load work mode Table 4-5
Load Work mode
LED
digital
No.
Enable
n
Dusk to Dawn, Load will be on all night
0
Load will be on for 1 hour after ten minutes delay since sunset
1
Load will be on for 2 hours after ten minutes delaysince sunset
2
Load will be on for 3 hours after ten minutes delaysince sunset
3
Load will be on for 4 hours after ten minutes delay since sunset
4
Load will be on for 5 hours after ten minutes delaysince sunset
5
Load will be on for 6 hours after ten minutes delaysince sunset
6
Load will be on for 7 hours after ten minutes delaysince sunset
7
Load will be on for 8 hours after ten minutes delaysince sunset
8
Load will be on for 9 hours after ten minutes delaysince sunset
9
Load will be on for 10 hours after ten minutes delaysince sunset
10
Load will be on for 11 hours after ten minutes delay since sunset
11
Load will be on for 12 hours after ten minutes delaysince sunset
12
Load will be on for 13hours after ten minutes delay since sunset
13
Load will be on for 14 hours after ten minutes delaysince sunset
14
Load will be on for 15 hours after ten minutes delay since sunset
15
Test mode
16
ON/OFF mode
17

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Note: There will be 10 minutes delay for the load to
turn on after sunset and to turn off before sunrise.
Because the controller requires 10 minutes of delay
before it starts to work. These constraints avoid false
transitions due to lightning or dark storm clouds.
Note: If either of the two loads is TEST MODE. The
two loads will be TEST MODE simultaneously.
Note: If either of the two loads is ON/OFF MODE. The
two loads will be ON/OFF simultaneously. But there is
an exception, as long as one of the loads is TEST
MODE, the TEST MODE will prevail.
Battery Type Setting
When battery type setting indicator is on, press the setting button for
more than 5 seconds till the LED digital tube flashes. Then press the setting
button till the desired number appears according to the following table. The
setting is finished till the LED digital display stops flashing.
Battery type setting Table 4-6
Battery type
LED Digital display
Sealed lead acid battery
1
Gel battery
2
Flooded battery
3