Epsolar: Instruction Manual

EPSOLAR
LS0512R
—— Solar Light Controller
INSTRUCTION
MANUAL
Please read this manual carefully before using the product！
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LandStar
LS0512R
—— Solar Light Controller
Nominal system voltage 12VDC

Maximum PV input voltage 35V
Nominal charge / discharge current 5A

Contents
1 Important Safety Information .................................. 1
2 General Information .................................................. 3
2.1 Product Overview........................................ 3
2.2 Product Features .......................................... 5
3 Installation Instructions ............................................ 7
3.1 Mounting....................................................... 7
3.2 Wiring.......................................................... 10
4 Operation ................................................................... 13
4.1 Battery Charging Information ................. 13
4.2 LED Indicators........................................... 16
4.3 Setting Operation....................................... 18
5 Protections, Troubleshooting and Maintenance . 22
5.1 Protection .................................................... 22
5.2 Troubleshooting ......................................... 23
5.3 Maintenance ............................................... 25
6 Warranty .................................................................... 26
7 Technical Specifications ......................................... 28

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 General Information
2.1 Product Overview
Thank you for selecting LandStar 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:
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.
 Only one key solve all setting simply
Intelligent timer function with 1-12 hours option
Adopt temperature compensation, correct the charging and
discharging parameters automatically and improve the battery
lifetime.
Electronic protection: over charging, over discharging, overload, and
short circuit.
Reverse protection for 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
1 2 3
1 1 1
4
1
5 6 7
1 1 1
Figure 2-1 LandStar characteristics
1 – Charging status LED indicator

An LED indicator that shows charging status and also indicates when
battery voltage is higher than over voltage disconnect voltage.
2 – Battery status LED indicator
An LED indicator that shows battery status.
3 – Load status LED indicators
Four LED indicators that show load work mode and status.

4 –Setting button
Set load work mode (in manual mode used for load ON/OFF).
5 –Solar Module Terminals
Connect solar modules.
6 –Battery Terminals
Connect batteries.
7 –Load Terminals
Connect loads.

3 Installation Instructions
3.1 Mounting
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.
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/mm2 current density.

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.

150mm(5.9inches) Warm air
150mm(5.9inches) Cool air
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 4mm 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.

3.2 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. Unsecured cables create loose
and resistive connections which may lead to
excessive heating and/or fire.
WARNING: Risk of explosion or fire! Never
short circuit battery positive (+) and negative (-)
or cables.
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.
10

Before battery is connected, make sure that battery voltage is greater
than 6V so as to start up the controller.
The load should be DC applicant with the same rated voltage as

battery’s. Controller offers power to loads through the battery voltage.
It is recommended that no less than 2 times rated current fuse is

connected with battery and load.
11

Step 1: Wiring
The recommended connection order has been provided as Figure3-2
indicated. Be sure the positive and negative polarity is correct and all
terminals are tightened.
Solar Module
3
1
Load
+ - + - + -
Fuse
Fuse 2
1
1 Battery
1
Figure 3-2 System wiring review
Step 2: 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.
12

4 Operation
4.1 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-current regulation is used to prevent heating and excessive
battery gassing. The Boost stage remains 120 minutes and then goes to
Float Charge.
13

·
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 reconnect
charging voltage, 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.
14

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.
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.
15

4.2 LED Indicators
Charging indicator Battery indicator 8H 4H 2H 1H
Setting button
Figure 4-2 LED indicators
 Charging status indicator

GREEN ON whenever sunlight is available for battery charging,
GREEN FAST FLASHING when battery over voltage.
Please refer to section 5 for troubleshooting.
16

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

Battery status indicator
RED ON when battery voltage in normal range

RED SLOWLY FLASHING when battery under voltage
RED FAST FLASHING when battery over discharged
Please refer to section 5 for troubleshooting.
Battery status LED indicator Table 4-2
Color Indicator Battery Status
Red On solid Normal

Red SLOWLY FLASHING Under voltage
Red FAST FLASHING 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) , 8H、4H、
2H、1H red LED indicator flashing together. Please refer to section 5
for trouble shooting.
17

Load status LED indicator Table 4-3
Color LED digital tube Load status
8H、4H、2H、1H
Red Flashing together Overload or short circuit
4.3 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 indicator.
Please refer to table 4-4 “Load Work Mode Setting”.
18

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. Manual mode
This mode is to turn ON and OFF the load by manual.
 Load Work Mode Setting
Press the setting button for more than 5 seconds till the indicator
flashes. Press the button, the corresponding indicator 8H、4H、2H、1H
will be on according to the following table.
The setting is finished when the indicator stop flashing.
19

Load work mode Table 4-4
Work mode 8H 4H 2H 1H
Dusk to Dawn,
○ ○ × ○
load will be on all night
Load will be on for 1 hour
× × × ○
after 10 minutes delay since sunset
Load will be on for 2 hours
× × ○ ×
× × ○ ○
× ○ × ×
× ○ × ○
× ○ ○ ×
× ○ ○ ○
○ × × ×
○ × × ○
20

○ × ○ ×
○ × ○ ○
○ ○ × ×
Test mode ○ ○ ○ ×
ON/OFF mode ○ ○ ○ ○
“○”LED indicator on “×”LED indicator off
21

5 Protection, Troubleshooting and
Maintenance
5.1 Protection
·
Load Overload
If the load current exceeds the maximum load current rating, the
controller will disconnect the load. 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.
·
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℃ to
prevent the battery damaged from overcharging or over discharged.
·
High Voltage Transients
PV is protected against high voltage transients. In lightning prone
areas, additional external suppression is recommended.
22

5.2 Troubleshooting
Trouble Shooting Table 5-1
Faults Possible reasons Troubleshooting

Charging LED PV Check that PV and
indicator off during array battery wire
daytime when disconnection connections are
sunshine falls on correct and tight.
PV modules
properly.
Green charging Battery voltage Check if battery
LED indicator fast higher than over voltage over high.
flashing voltage Disconnect the solar
disconnect module
voltage(OVD)
Red Battery Battery under Load output is
LED indicators voltage normal,, charging
SLOWLY LED indicator will
FLASHING return to red
automatically when
fully charged.
Red Battery Battery The controller cut
LED indicators over discharged off the output
FAST automatically, LED
FLASHING and indicator will return
loads not working. to red automatically
when fully charged.
23

8H、4H、2H、1H Over load Overload: Please
Red LED or short circuit reduce the load and

indicator flashing press the button once,
together the controller will
resume to work after
3s;
Short circuit: when
the first short-circuit
occurs, the controller
will automatically
10s; when a second
short-circuit occurs,
press the button, the
controller will
3s.
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!
24

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 on 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.
25

 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.
Notes: 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 LandStar 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.
26

• Claim procedure:
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.
27

7 Technical specifications
Electrical Parameters Table 7-1
Description Parameter
Nominal System Voltage 12V
Max. batt. Volt. to the controller 16V
Rated Battery Current 5A
Charge Circuit Voltage Drop ≤0.26V
Discharge Circuit Voltage Drop ≤0.15V
Self-consumption ≤6mA
Threshold Voltage Parameters Table7-2

NTTV(Night Time Threshold Voltage) 5V; x2/24V
DTTV (Day Time Threshold Voltage) 6V; x2/24V
28

Temperature Compensation Coefficient Table7-3
Temperature Compensation
-30mV/℃/12V（25℃ ref）
Coefficient(TEMPCO)*
* Compensation of equalize, boost, float and low voltage disconnect

voltage
29

Battery Voltage Parameters (temperature at 25℃) Table 7-4
Charging Parameters
Battery charging setting Sealed
Over Voltage Disconnect Voltage 16V
Charging Limit Voltage 15.5V
Over Voltage reconnect Voltage 15V
14.6V
Equalize Charging Voltage
14.4V
Boost Charging Voltage
13.8V
Float Charging Voltage
Boost Reconnect Charging 13.2V
Voltage
Low Voltage Reconnect Voltage 12.6V
Under voltage warning reconnect

12.2V
voltage
Under Voltage Warning Voltage 12V
Low Voltage Disconnect Voltage 11.1V
Discharging Limit Voltage 10.8V
Equalize duration 2 hours
Boost duration 2 hours
30

Environmental parameters Table 7-5
Environmental parameters Parameter
Working temperature -35℃ to +55℃
Storage temperature -35℃to +80℃
Humidity 10%-90% NC
Enclosure IP30
Mechanical Parameters Table 7-6

Mechanical Parameter Parameter
Overall dimension 97(3.82)x66(2.6)x25(0.98) mm/inches
Mounting dimension 86(3.39) x 44(1.73) mm/inches
Mounting hole size Φ5
Terminal 2.5mm2
Net weight 0.05kg
Final interpretation right of the manual belongs to our company.

Any changes without prior notice!
31

mm(inches)
25(0.98)
97(3.82)
86(3.39)
44(1.73)
66(2.6)
Dimensions

Version number: V6.0

BEIJING EPSOLAR TECHNOLOGY CO., LTD.
Tel：010-82894112 / 82894962
Fax：010-82894882
E-mail：[email protected]
Website: www.epsolarpv.com

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EPSOLAR

Please read this manual carefully before using the product！

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Nominal system voltage 12VDC

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Save These Instructions

WARNING: Indicates a potentially dangerous

CAUTION: Indicates a critical procedure for

NOTE: Indicates a procedure or function that

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 Read all of the instructions and cautions in the manual before

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High efficient Series PWM charging, increase the battery lifetime

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1 – Charging status LED indicator

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Read through the entire installation section first before beginning

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WARNING: Risk of explosion! Never install the

Step 1: Choose Mounting Location

Step 2: Check for clearance

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150mm(5.9inches) Cool air

Figure 3-1 Mounting and cooling

Step 3: Mark Holes

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NOTE: A recommended connection order has

CAUTION: Don’t connect the loads with surge

CAUTION: For mobile applications, be sure to

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The load should be DC applicant with the same rated voltage as

It is recommended that no less than 2 times rated current fuse is

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Figure 3-2 System wiring review

Step 2: Confirm power on

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Figure 4-1 PWM Charging mode

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WARNING: Risk of explosion!

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NOTE: Equipment damage!

Certain types of batteries benefit from periodic equalizing charge,

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Charging indicator Battery indicator 8H 4H 2H 1H

Figure 4-2 LED indicators

 Charging status indicator

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Color Indicator Charging Status

Green On Solid Charging

Green Fast Flashing Battery over voltage

RED ON when battery voltage in normal range

Color Indicator Battery Status

Red On solid Normal

 Load status indicator:

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