NSTHAI NSC2024R User manual

1
INSTRUCTION
MANUAL
NSC2024R Solar Light Controller
NSTHAI
☆ Design patent NO.：
201130028317.3
☆ Utility model patent NO.
：201120064092.1

เลขที่ 82/33 ซ.รัตนาธิเบศร์ 26/1 ต.บางกระสอ อ.เมือง จ.นนทบุรี 11000
โทร. 02-9657588 , 081-8465426 , 086-3411861 แฟกซ์ 02-9657599
E-Mail : [email protected] Website : http://www.nsthai.com

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NSC2024R (LS2024R)
Solar Light Controller
Installation and Operation Manual
Specification Summary
Nominal system voltage 12 / 24VDC*
Maximum PV input voltage 50V
Nominal charge / discharge current 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.
45 (1.77)
55 (2.16)
135 (5.31)
144 (5.67)
74.9 (2.95)

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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.
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. General Information
2.1 Product Overview
Thank you for selecting NSC series 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
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.

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•Widely used, automatically recognize day/night.
•Digital LED menu, only one key solve all setting simply
•Intelligent timer function with 1-15 hours option
•Unique dual timer function, enhance the flexibility of street light 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.
2.2 Product Features
Figure 2-1 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 battery voltage is higher than over voltage
disconnect voltage.
3 –Battery status LED indicator

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A LED indicator that shows battery status
4 –Battery type setting indicator
The indicator will be on when select battery type.
5 –Timer 2 setting indicator
The indicator will be on when set timer 2.
6 –Timer 1 setting indicator
The indicator will be on when set timer 1.
7 –LED digital display
Display the load work mode and status
8 –Setting button
Set load work mode and select battery type. (in manual mode used for load ON/OFF)
9 –Solar Module Terminals
Connect solar modules.
10 –Battery Terminals
Connect batteries.
11 –Load Terminals
Connect loads.
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.

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•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.
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.
Warm air
Cool air
150mm(5.9inches
)
150mm(5.9inches)

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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.
3.3 Wiring
NOTE: A recommended connection order has been provided for maximum safety
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 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
Fuse
150mm(5.9inches)
MAX

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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. Confirm the connection correct and turn on the power.
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. The load
terminal be exist voltage, connect carefully to avoid short circuit.
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. Confirm the connection correct and turn on the power.
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.
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. Be careful
operation when installing solar wiring.
Fuse
Load

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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
Step 4: Confirm Wiring
Double-check the wiring in step1 through 3. Confirm correct polarity at each connection. Verify that all six
terminals are tightened.
Figure 3-5 System wiring review
Solar Module
Battery
Load
Solar Module
Fuse
150mm(5.9inches)
MAX

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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.
4. Operation
4.1 PWM Technology (Series Pulse Width Modulation)
The controller adopts the advanced series pulse width modulation (PWM) charging mode. With range of 0-100%,
it can charge the battery quickly and stably under any condition of solar photovoltaic system. PWM charging mode
use automatic conversion duty ratio pulses to charge the battery. The battery can be fully charged safety and rapidly
with the pulse current. Intermissions make some oxygen and hydrogen generated by chemical reaction chemically
combined again and absorbed. It can eliminate concentration polarization and ohm polarization naturally and
reduce the internal pressure of the battery so that the battery can absorb more power. 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

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•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.
•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.
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.

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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
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.
•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.
Charging Status LED indicator
Table 4-1
Color
Indicator
Charging Status
Green
On Solid
Charging
Green
Fast Flashing
Over voltage
Charging Status LED indicator
Battery Status LED indicator

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•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.
•Overheating protection indicator:
When heat sink of the controller exceeds 85°C, 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.
4.4 Setting Operation
Dual timer function
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 LED indicator
Table 4-3
Color
LED digital tube
Load status
Red
“L” with slowly flashing
Overload or short circuit
Overheating protection indicator
Table 4-4
Color
LED digital tube
System status
Red
“H” with slowly flashing
Controller overheating
Light ON
Light OFF
Timer1
Sunset
Number
of hours
Midnight
Sunrise
Number
of hours
Timer2

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The default night length is 10 hours. The controller can learn the night length referring to the previous night so as
to adapt to the different seasons. However, it will take some time to learn it.
Notes: when the “OFF” time set at timer 2 is later than local sunrise time, the controller
will turn off the load output at the sunrise time, which shows light control first!
•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. The controller has dual timer function. 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
Figure 4-3 Setting operation indicating
Setting button
Battery type
Setting Indicator
Timer2
Setting indicator
Timer1 Setting indicator
Load work mode LED digital tube

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Press the setting button once and setting indicators will be changed once among timer 1, timer2 and battery
type.
When timer 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 when the digital tube stop flashing.
Timer 2 setting is the same as timer 1 when the setting indicator is on timer2
Load work mode
Table 4-5
Timer1
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 delay since sunset
2
Load will be on for 3 hours after ten minutes delay since 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 delay since sunset
5
Load will be on for 6 hours after ten minutes delay since sunset
6
Load will be on for 7 hours after ten minutes delay since sunset
7
Load will be on for 8 hours after ten minutes delay since sunset
8
Load will be on for 9 hours after ten minutes delay since sunset
9
Load will be on for 10 hours after ten minutes delay since 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 delay since 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 delay since sunset
14
Load will be on for 15 hours after ten minutes delay since sunset
15
Test mode
16
ON/OFF mode
17

16
Load work mode
Table 4-6
Timer2
LED
Digital No.
Enable
n
Load will be on for 1 hour before sunrise
1
Load will be on for 2 hours before sunrise
2
Load will be on for 3 hours before sunrise
3
Load will be on for 4 hours before sunrise
4
Load will be on for 5 hours before sunrise
5
Load will be on for 6 hours before sunrise
6
Load will be on for 7 hours before sunrise
7
Load will be on for 8 hours before sunrise
8
Load will be on for 9 hours before sunrise
9
Load will be on for 10 hours before sunrise
10
Load will be on for 11 hours before sunrise
11
Load will be on for 12 hours before sunrise
12
Load will be on for 13hours before sunrise
13
Load will be on for 14 hours before sunrise
14
Load will be on for 15 hours before sunrise
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Notes: If timer 1 is Dusk to Dawn( 0), Test mode (16) or ON/OFF mode (17), the timer 2
will be enabled.
•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 4-7
Battery type
Digital tube display
Sealed lead acid battery
1
Gel battery
2
Flooded battery
3

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5. Protection, Troubleshooting and Maintenance
5.1 Protection
•PV Array Short Circuit
If PV array short circuit occurs, clear it to resume normal operation.
•Load Overload
If the load current exceeds the maximum load current rating, the controller will disconnect the load. The greater
the overload, the faster the load will be disconnected. A small overload could take a few minutes to disconnect.
Overloading must be cleared up through reapply power or pressing the setting button.
•Load Short Circuit
Fully protected against load wiring short-circuit. After one automatic load reconnect attempt, the fault must be
cleared by reapply power or pressing the setting button.
•PV Reverse Polarity
Fully protection against PV reverse polarity, no damage to the controller will result. Correct the miswire to
resume normal operation.
•Battery Reverse Polarity
Fully protection against battery reverse polarity, no damage to the controller will result. Correct the miswire to
resume normal operation.
•Damaged Local Temperature Sensor
If the temperature sensor short-circuited or damaged, the controller will be charging or discharging at the default
temperature 25°C to prevent the battery damaged from overcharging or over discharged.
•Overheating Protection
If the temperature of the controller heat sink exceeds 85°C, the controller will automatically start the overheating
protection.
•High Voltage Transients
Battery is protected against high voltage transients. In lightning prone areas, additional external suppression is
recommended.

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5.2 Troubleshooting
Trouble Shooting
Table 5-1
Faults
Possible reasons
Troubleshooting
Charging LED indicator off
during daytime when sunshine
falls on PV modules properly.
PV array disconnection
Check that PV and battery wire
connections are correct and tight.
Green charging LED indicator
fast flashing
Battery voltage higher
than over voltage
disconnect voltage(OVD)
Check if battery voltage over high.
Disconnect the solar module
Battery LED indicators are
orange
Battery under voltage
Load output is normal, charging LED
indicator will return to green
automatically when fully charged.
Battery LED indicators RED
color and loads not working.
Battery over discharged
The controller cut off the output
automatically, LED indicator will
return to green automatically when
fully charged.
Digital tube displays “L” with
red slowly flashing
Over load or short circuit
Overload: Please reduce the load and
press the button once, the controller
will resume to work after 3s;
Short circuit: when the first short-
circuit occurs, the controller will
automatically resume to work after
10s; when a second short-circuit
occurs, press the button, the controller
will resume to work after 3s.
Digital tube displays “H” with
red slowly flashing
Too high temperature of
controller
When heat sink of the controller
exceeds 85 ℃, the controller will
automatically cut input and output
circuit. When the temperature below
75℃, the controller will resume to
work

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Notes: No LED indicator. Measure battery voltage with multimeter. Min.6V can start up
the controller.
Notes: No charging status LED indicator with normal connection. Measure the input
voltage of solar module, the input voltage must be higher than battery voltage!
5.3 Maintenance
The following inspections and maintenance tasks are recommended at least two times per year for best controller
performance.
•Check that the controller is securely mounted in a clean and dry environment.
•Check that the air flow and ventilation around the controller is not blocked. Clear all dirt or fragments one
the heat sink.
•Check all the naked wires to make sure insulation is not damaged for serious solarization, frictional wear,
dryness, insects or rats etc. Maintain or replace the wires if necessary.
•Tighten all the terminals. Inspect for loose, broken, or burnt wire connections.
•Check and confirm that LED digital tube is consistent with required. Pay attention to any troubleshooting or
error indication .Take necessary corrective action.
•Confirm that all the system components are ground connected tightly and correctly.
•Confirm that all the terminals have no corrosion, insulation damaged, high temperature or burnt/discolored
sign, tighten terminal screws to the suggested torque.
•Inspect for dirt, insects and corrosion, and clear up.
•Check and confirm that lightning arrester is in good condition. Replace a new one in time to avoid
damaging of the controller and even other equipments.
NOTE: Dangerous with electric shock! Make sure that all power source of controller is cut
off when operate above processes, and then make inspection or other operations!
6. Warranty
The NSC charge controller is warranted to be free from defects for a period of TWO (2) years from the date of
shipment to the original end user. We will, at its option, repair or replace any such defective products.
•Claim procedure:

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Before requesting warranty service, check the Operation Manual to be certain that there is a problem with the
controller. Return the defective product to us with shipping charges prepaid if problem cannot be solved. Provide
proof of date and place of purchase. To obtain rapid service under this warranty, the returned products must
include the model, serial number and detailed reason for the failure, the module type and size, type of batteries
and system loads. This information is critical to a rapid disposition of your warranty claim.
•This warranty does not apply under the following conditions:
1. Damage by accident, negligence, abuse or improper use.
2. PV or load current exceeding the ratings of product.
3. Unauthorized product modification or attempted repair
4. Damaged occurring during shipment.
5. Damage results from acts of nature such as lightning, weather extremes
6. Irreclaimable mechanical damage.
7. Technical specifications
*Compensation of equalize, boost, float and boost reconnect voltage.
Electrical Parameters
Table 7-1
Description
Parameter
Nominal System Voltage
12/24VDC Auto work
Maximum Battery Voltage
32V
Rated Battery Current
20A
Charge Circuit Voltage Drop
≤0.26V
Discharge Circuit Voltage Drop
≤0.15V
Self-consumption
≤6mA
Threshold Voltage Parameters
Table 7-2
Description
Parameter
NTTV (Night Time Threshold Voltage)
5V; x2/24V
DTTV (Day Time Threshold Voltage)
6V; x2/24V
Temperature Compensation Coefficient
Table 7-3
Description
Parameter
Temperature Compensation Coefficient(TEMPCO)*
-5mV/°C/12V（25°C ref）