Epsolar ViewStar Series, ViewStar VS4524BN User Manual

User Manual

Model:

VS4524BN

ViewStar series

——Solar Charge Controller

Important Safety Instructions

Please keep this manual for future review.

This manual contains all instructions of safety, installation and operation for VS BN series controller ("the
controller" as referred to in this manual).

General Safety Information

 Read carefully all the instructions and warnings in the manual before installation.

 No user serviceable components inside the controller. DO NOT disassemble or attempt to repair the

controller.

 Mount the controller indoors. Avoid exposure the components and do not allow water to enter the

controller.

 Install the controller in a well ventilated place. The controller’s heat sink may become very hot during

operation.

 Suggest installing appropriate external fuses/breakers.

 Make sure to switch off all PV array connections and the battery fuse/breakers before controller

installation and adjustment.

 Power connections must remain tight to avoid excessive heating from loose connection.

CONTENTS

1. General Information ........................................................................... 1

1.1 Overview ..................................................................................... 1

1.2 Characteristics ............................................................................. 2

2. Installation Instructions ..................................................................... 3

2.1 General Installation Notes ............................................................ 3

2.2 Installation and Wiring.................................................................. 3

3. HMI Interface ...................................................................................... 6

3.1 Button .......................................................................................... 6

3.2 Indicator ...................................................................................... 7

3.3 Operation Interface ...................................................................... 7

4. Accessories (optional) ..................................................................... 18

5. Protections, Troubleshooting and Maintenance ............................. 20

5.1 Protection .................................................................................. 20

5.2 Troubleshooting ......................................................................... 21

5.3 Maintenance ................................ .............................................. 22

6. Technical Specifications ................................ ................................ .. 23

Annex Mechanical Dimension Diagram .............................................. 24

1. General Information

1.1 Overview

ViewStar series solar charge controller adopts advanced digital control technology, LCD display and
automatical operation. With the features of Pulse Width Modulation (PWM) battery charging and unique
control technology, the controller will improve the long battery life efficiently. Our controller has many
unique features and easy to use.
The controller could charge battery and discharge automatically for off-grid photovoltaic (PV) systems.
The charging process has been optimized for long battery life and improved system performance. The
comprehensive self-diagnostics and extensive electronic protection can prevent damage against
incorrect wiring or system faults.

Features:

 12/24VDC &automatically identifying system voltage
 3-Stage intelligent PWM charging:Bulk, Boost/Equalize, Float
 Support 4 charging options: Sealed, Gel, Flooded and user
 Lithium battery self-activating function
 Battery temperature compensation function
 Actual power display and record function
 New SOC method calculate the battery capacity accurately
 Wide feasibility and recognize day or night automatically
 Several load control methods
 Hundred percent full load operation in working environment temperature range within charging &

discharging

 Extensive electronic protections
 Graphical dot-matrix LCD and 4 buttons combinations as HMI (human-machine interface) for full

menu and easy operation

 RS-485 ports via the open standard Modbus protocol are supported for long-distance

communication and communication compatibility

 Monitoring and setting parameter via Mobile APP, PC Monitor setting software

1

1.2 Characteristics

❶

Battery slot
(battery model is CR2032-3.3V)

❼

RS485 communication port

❷

Local temperature sensor

❽

RTS★port

❸

Fault LED indicator

❾

Mounting Hole Φ4mm

❹

Charging LED indicator

❿

Load Terminals

❺

LCD ⓫ Battery Terminals

❻

Buttons

⓬

PV Terminals

★The controller is charging and discharging at the local temperature sensor when the remote
temperature sensor don’t connect. If the remote temperature sensor is damaged, the controller
will be charging or discharging at the default temperature 25℃.

2

2. Installation Instructions

2.1 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. So well ventilation of battery box is

recommended.

 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.

 Gel, Sealed or Flooded batteries are recommended, other kinds please refer to the battery manufacturer.
 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 3.5A/mm2 current density.

2.2 Installation and Wiring

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.
CAUTION: The ViewStar controller requires at least 150mm of clearance above and

below for proper air flow. Ventilation is highly recommended if mounted in an
enclosure.

Installation Procedure:

Figure 2-1 Mounting

3

Step 1: Determination of Installation Location and Heat-dissipation Space

Figure 2-2 Schematic of wiring

Determination of installation location: The controller shall be installed in a place with sufficient air flow
through the radiators of the controller and a minimum clearance of 150 mm from the upper and lower
edges of the controller to ensure natural thermal convection. Please see Figure 2-1: Mounting

CAUTION: If the controller is to be installed in an enclosed box, it is important to ensure
reliable heat dissipation through the box.

Step 2：Connect the system in the order of ❶battery ❷ load ❸PV array in accordance with Figure

2-2,”Schematic Wiring Diagram” and disconnect the system in the reverse order❸❷❶.
CAUTION: While wiring the controller do not close the circuit breaker or fuse and make sure that the

leads of "+" and "-" poles are connected correctly.

CAUTION: A fuse which current is 2 times the rated current of the controller.

NOTE: The controller is common negative one.

CAUTION: Don’t connect the loads with surge power exceeding the ratings.

CAUTION: Secure all wiring for mobile applications. Use cable clamps to prevent cables from

swaying. Unsecured cables create loose and resistive connections which may lead to
excessive heating and fire.

WARNING: Risk of explosion or fire! Never short circuit battery positive (+) and negative (-) or
cables.

4

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.

Step 3：Grounding

VS BN series is a common-negative controller, where all the negative terminals of PV array, battery and
load can be grounded simultaneously or any one of them will be grounded. However, according to the
practical application, all the negative terminals of PV array, battery and load can also be ungrounded,
but the grounding terminal on its shell must be grounded, which may effectively shield the
electromagnetic interference from the outside, and prevent some electric shock to human body due to
the electrification of the shell.

CAUTION: For common-negative system, such as motorhome, it is recommended to use a
common-negative controller; but if in the common-negative system, some common-positive
equipment are used, and the positive electrode is grounded, the controller may be damaged.

Step 4：Powered on the controller

Closing the battery fuse will switch on the controller. Then check the status of the battery indicator (the
controller is operating normally when the indicator is lit in green). Close the fuse and circuit breaker of
the load and PV array. Then the system will be operating in the preprogrammed mode.

CAUTION: If the controller is not operating properly or the battery indicator on the controller
shows an abnormality, please refer to 5.2 “Troubleshooting”.

5

3. HMI Interface

Button

Note

Menu

Cursor left button

Cursor up

Number add button

Cursor down

Number reduce button

Enter

cursor right button

3.1 Button

6

3.2 Indicator

Indicator

Color

Status

Instruction

Green

On Solid

Charging

Red

Flashing

(6Hz)

PV:
Measure Err,
MOS-I Short,
MOS-C Short,
MOS Break

BATT:

OVD,Over Temp

LOAD:

Overload,Short,

MOS Short

DEVICE:

Over Temp

&

Green & Red

Flashing

(6Hz)

BATT:

Rated V Err

3.3 Operation Interface

1) Initialization Interface

When controller is powered on, the following picture will be painted during the initialization:

2) Main Menu Interface

After controller is initialized, the monitoring interface will update automatically. Press button
to main menu 1 interface which displays the following contents:

7

Press button to enter into main menu 2 and main menu 3 interface which displays the
following contents:

3) Monitoring

Display：Solar array voltage and current→Battery voltage and current→Battery temperature and battery

SOC→Load voltage and current→Real-time clock and imaging system status→System status→
Charging energy statistics→Discharging energy statistics

8

System status icons:

Icons

Status

Icons

Status

Day ON

Night OFF

▲

Charging

Normal

Normal UVW

LVD LVD

System

Status

System

Status

PV

Connect

BATT

LVD

Measure Err★

Normal

MOS-C Short★

Rated V Err★

Disconnect

UVW

MOS-I Short★

OVD★

MOS Break★

OverTemp★

BATT

charging status

Equalize

LOAD

On

Float

OverLoad★

Boost

Off

No Charge

Short★

▲Icons indicating battery charging are dynamic effects.

System status :

9

DEVICE

Normal

MOS Short★

OverTemp★

★When fault with inverse cursor above exists for 2 minutes along without any operation, it will

Parameter

Detail

ID

Range：1~200

Clock

Format:dd-mm-yyyy hh-mm-ss

Password

Default：000000

jump into that page automatically.

4) Device Set

Display：Date set→ID and LCD backlight time set→TempUnit set

 Device parameters

 Clear Energy

Press and hold both and button for 3 seconds to enter factory mode in the main
interface. The authority code to clear Energy Log is 102206 as default. The clear operation can’t be
recalled, so take care!

10

5) Parameter Set

◆The interface will prompt only when the SOC is selected in the Batt Mng Mode.
Display：Temperature compensation coefficient→Control parameters interface 1/2/3/4/5

11

 Lead-acid battery parameters

Battery type

Voltage

Sealed

Gel

Flooded

User

Over Voltage Disconnect Voltage

16.0V

16.0V

16.0V

9～17V

Charging Limit Voltage

15.0V

15.0V

15.0V

9～17V

Over Voltage Reconnect Voltage

15.0V

15.0V

15.0V

9～17V

Equalize Charging Voltage

14.6V

——

14.8V

9～17V

Boost Charging Voltage

14.4V

14.2V

14.6V

9～17V

Float Charging Voltage

13.8V

13.8V

13.8V

9～17V

Boost Reconnect Charging

Voltage

13.2V

13.2V

13.2V

9～17V

Low Voltage Reconnect Voltage

12.6V

12.6V

12.6V

9～17V

Under Voltage Warning

Reconnect Voltage

12.2V

12.2V

12.2V

9～17V

Under Voltage Warning Voltage

12.0V

12.0V

12.0V

9～17V

Low Voltage Disconnect Voltage

11.1V

11.1V

11.1V

9～17V

Discharging Limit Voltage

10.6V

10.6V

10.6V

9～17V

Equalize Duration

120 min

——

120 min

0～180 min

Boost Duration

120 min

120 min

120 min

10～180 min

The parameters are in 12V system at 25 ºC, please double the values in 24V system.

Note：

1）When the battery type is sealed, gel, flooded，the adjusting range of equalize duration is 0 to180min
and boost duration is 10 to180min.

2）The following rules must be observed when modify the parameters value in user battery type(factory
default value is the same as sealed type):
a. Over Voltage Disconnect Voltage > Charging Limit Voltage ≥Equalize Charging Voltage ≥Boost
Charging Voltage ≥Float Charging Voltage > Boost Reconnect Charging Voltage;
b. Over Voltage Disconnect Voltage > Over Voltage Reconnect Voltage;
c. Low Voltage Reconnect Voltage > Low Voltage Disconnect Voltage≥Discharging Limit Voltage;
d. Under Voltage Warning Reconnect Voltage > Under Voltage Warning Voltage ≥Discharging Limit
Voltage;
e. Boost Reconnect Charging Voltage > Low Voltage Reconnect Voltage.

12

6) Load Set

Display：①Manual /②Light On/Off /③Light On+Timer /④Time

 Threshold voltage value
Night Time Threshold Voltage: 6V/12V,12V/24V

Day Time Threshold Voltage: 5V/12V,10V/24V

13

 Load working mode

1. Manual(default)

Control ON/OFF of the load via the button or remote commands.

2.Light ON/OFF

3.Light ON+Timer

4.Time

Control the load ON/OFF time through setting the real-time clock.

NOTE: In the mode of Light ON/OFF and Light ON/Timer, the Load is turned on after
10Min. delay.

14

7) Rated Value

Batt

System nominal voltage

Battery capacity range

12V/24V/Auto

Range :0~9999AH

Battery Type

Note

Sealed (default)

Constant value▲

GEL

Constant value▲

Flooded

Constant value▲

User

Defined by user▲

▼ System Nominal Voltage and Battery Rate Setting

 Battery Type

▲The parameters refer to the Lead-acid battery parameters (Parameter Set).

8) Test Mode

Press or ，choose the Test Mode，then press and enter into test
mode interface below:

Press or ，when the inverse cursor stays ON/OFF，that is test on or test off
operations.

15

9) Password

Precent of charging

100% constant value

Precent of discharging

10~80%, Low SOC reconnect is higher Low SOC

disconnect than 5%

10) Batt Mng Mode

 SOC parameters

16

11) Factory Reset

12) Reboot Device

17

4. Accessories (optional)

Remote Temperature Sensor

(RTS300R47K3.81A)

Acquisition of battery temperature for undertaking temperature compensation of control

parameters, the standard length of the cable is 3m (length can be customized). The

RTS300R47K3.81A connects to the port (8th) on the controller.

NOTE: The temperature sensor short-circuited or damaged, the controller will be

charging or discharging at the default temperature 25 ºC.

USB to RS485 cable

CC-USB-RS485-150U

USB to RS485 converter is used to monitor each controller using Solar Station PC software.

The length of cable is 1.5m. TheCC-USB-RS485-150U connects to the RS485 Port on the

controller.

RS485 to RS485 cable

CC-RS485-RS485-200U

RS485 to RS485 converter is used to connect the accessories

SPP-02,MT50,eBox-WIFI-01,eBox-BLE-01,the standard length of the cable is 3m (length

can be customized).

Super Parameter Programmer

SPP-02

SPP-02 can realize one-key setting parameter operation.

Remote Meter

MT50

MT50 can display various operating data and fault info the system. The information can be

displayed on a backlit LCD screen, the buttons are easy-to-operate, and the numeric display

is readable.

WIFI Serial Adapter

eBox-WIFI-01

After the controller is connected with the eBox-WIFI-01 through the standard Ethernet cable

(parallel cable), the operating status and related parameters of the controller can be

monitored by the mobile APP software through WIFI signals.

RS485 to Bluetooth Adapter

eBox-BLE-01

After the controller is connected with the eBox-BLE-01 through the standard Ethernet cable

(parallel cable), the operating status and related parameters of the controller can be

monitored by the mobile APP software through Bluetooth signals.

NOTE: For setting and operation of accessory, please refer to accessory’s user manual.

18

WARNING: Do not use the standard twisted-net cable to connect the device and PC
net interface, or the permanent damage will occur.

19

5. Protections, Troubleshooting and Maintenance

PV Short Circuit

When not in PV charging state, the controller will not be damaged in case of a short-circuiting in the PV

array.

PV Reverse Polarity

When the polarity of the PV array is reversed, the controller may not be damaged and can continue to

operate normally after the polarity is corrected.

PV Over Voltage

When the PV voltage is higher 60V, the controller will cut off the charging automatically, and when the

voltage is lower than 55V, the controller will recover charging. automatically

Charging Battery Cut Off

Disconnect the battery when the controller is charged at rated power , the controller do not be damaged

Load Overload

When the load is overloading (The overload current is ≥ 1.05 times the rated load current), the controller

will automatically cut off the output. If the load reconnects automatically, it needs to be cleared by

pressing the Load button restarting the controller.

Load Short Circuit

Fully protected against load wiring short-circuit（≥2 times rated discharge current）. After five automatic

load reconnect attempt, the fault must be cleared by restarting the controller or pressing the switch

button.

Damaged 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.

Controller Overheating

The controller is able to detect the temperature inside the battery. The controller stops working when its

temperature exceeds 85 °C and restart to work when its temperature is below 75 °C.

TVS High Voltage Transients

The internal circuitry of the controller is designed with Transient Voltage Suppressors (TVS) which can

only protect against high-voltage surge pulses with less energy. If the controller is to be used in an area

with frequent lightning strikes, it is recommended to install an external surge arrester.

5.1 Protection

20

5.2 Troubleshooting

Faults

Possible reasons

Troubleshooting

Charging LED indicator is off during

daytime and the monitor shows

Disconnect.

PV Array Disconnection

Check that PV and battery wire connections are correct and

tight.

Monitor interface PV shows Measure

Err, MOS-I Short, MOS-C Short, MOS

Break.

Fault indicator flashing

MOS-I Or MOS-C Damage

Please restart controller;

if the fault still exists, switch off controller immediately and

contact the supplier to make maintenance.

Monitor interface BATT shows LVD.

Battery Over Discharged

The controller cut off the output automatically and recover when

fully charged.

Charging and discharging circuit is off

and monitor interface BATT shows OVD.

Fault indicator flashing

Battery Over Voltage

switch off the wiring of solar array and measure the voltage of

battery whether is too high.

Charging and discharging circuit is off

and the BATT of monitoring interface

shows Over Temp.

Fault indicator flashing

Operating Ambient

Temperature

(local temperature sensor) Or

Battery Temperature

(remote temperature sensor)

Over Temperature

When operating ambient temperature or battery temperature

reaches exceeds 65ºC controller will cut off input and output

circuit automatically.

When the temperature is below 55℃, controller will

automatically reconnect input and output circuit.

Monitor interface BATT shows Rated V

Err.

Charging indicator and Fault indicator

flashing

System Voltage Error

Check whether the battery voltage is consistent with the system

voltage set by the controller.

Discharging circuit is off and monitor

shows Over Load.

Fault indicator flashing

Load Overload▽

①Please reduce the number of electric equipments.

②Restart the controller.

Discharging circuit is off and the LOAD

monitor shows Short.

Fault indicator flashing

Load circuit is short

①Check carefully loads connection, clear the fault.

②Restart the controller.

Charging and discharging circuit is off

Electronical Component

Please restart controller, if the fault still exists, cut off charging

21

and the LOAD of monitoring interface

shows MOS-I Short,Error.

Fault indicator flashing

Damage

and discharging circuit immediately and contact the supplier to

make maintenance.

Charging and discharging circuit is off

and the LOAD monitor shows Over

Temp.

Fault indicator flashing

Controller Overheating

When the temperature of controller exceeds 85℃, the

controller will cut input and output circuit. when it is below

75℃,the controller will automatically reconnect input and output

circuit.

▽When load power reaches 1.02-1.05 times, 1.05-1.25 times, 1.25-1.35 times, 1.35-1. 5 times more than nominal value, controller will
automatically close loads in 50 seconds, 30 seconds, 10 seconds and 2 seconds, respectively.

5.3 Maintenance

The following inspections and maintenance tasks are recommended at least two times per year for best performance.

 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.

 Check and confirm that LED or LCD is consistent with required. Pay attention to any troubleshooting or error indication .Take corrective action if

necessary.

 Tighten all the terminals. Inspect for loose, broken, or burnt wire connections.
 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, make inspection or other operations！

22

6. Technical Specifications

Item

VS4524BN

System nominal voltage

12∕24VDC Auto

Battery voltage range

9V ~32V

Max. PV open circuit voltage

60V

Rated charge current

45A

Rated discharge current

45A

Charge circuit voltage drop

≤0.69V

Discharge circuit voltage drop

≤0.17V

Battery type

Sealed / Gel / Flooded / User

Temperature compensate coefficient

-3mV∕℃∕2V（25℃）

Self-consumption

≤15mA/12V; ≤13mA/24V

RS485 interface

RS485(RJ45)

Remote temperature sensor interface

2P—3.81

Grounding

Negative

LCD temperature range

-20℃~ +70℃

Working environment temperature range

-25℃~ +50℃

Storage temperature range

-30℃~ +85℃

Relative humidity

≤95%,N.C.

Enclosure

IP30

Terminal

2AWG(35 mm2)

Weight

0.64 kg

23

Annex Mechanical Dimension Diagram

VS4524BN（Unit:mm）

Any changes without prior notice! Version number: 1.0

24

BEIJING EPSOLAR TECHNOLOGY CO., LTD.

Tel: [phone]
Fax: [phone]
E-mail：[email protected]
Website: http://www.epsolarpv.com/

http://www.epever.com/