EPSOLAR CONTROLLER

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IPS48-100/200 H

PHOTOVOLTAIC-HYBRID

POWER SYSTEM CONTROLLER

USER’S BOOK

GUIDE FOR INSTALLATION

EPSOLAR CONTROLLER

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TABLE OF CONTENTS

1. DESCRIPTION ··········································· 1

2. FEATURES··············································· 1

3. SPECIFICATIONS ········································· 2

4. CONTROLLER LAYOUT PICTURE & BLOCK DIAGRAM············· 3

4.1. DC SWITCH BOARD TERMINAL·························· 5

4.2. I/O BOARD TERMINAL··································6

4.3. CABINET SIZE·········································7

4.4. IPS48-100/200H SOALR CONTROLLER BLOCK DIAGRAM····8

5. DESCRIPTION OF BLOCK DIAGRAM····························9

5. 1. CHARGE REGULATOR··································9

5.2. CONTROL BOARD······································9

5.3. ELECTRICITY ISOLATED INTERFACE BOARD················10

5.4. GRAPHIC LCD DISPLAY & KEYPAD························10

5.5. ABOUT COMMUNICATION·······························10

5.6. DISPLAY·············································10

6. INSTALLATION·············································11

7. DISPLAY & KEYPAD OPERATION GUIDE·························12

EPSOLAR CONTROLLER

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1. DESCRIPTION

The IPS48-100/200H PV CONTROLLER is the FULL-TECH controller solution for your

telecommunication, residential, remote monitoring equipment and hybrid power needs.

FULL-TECH because we gather into the most advanced and innovative features in the

advanced controller systems, such as EXPERT CONTROL SYSTEM developed by us. It

addresses the optimum, precise, high ratio available needs of your batteries as well as

loads.

2. FEATURES

Industrial blocking electricity design structure.

High reliability, anti- interference, efficiency, EMC, Easy installation and

maintenance.

Advanced double Micro-Processor (MCU) control circuit structure to separately

processing the real-time control and the running management, to ensure and

allow real-time control MCU to fulfill flexible controller configuration.

Based on the EXPERT CONTROL SYSTEM, to optimize SOC for batteries charge

and discharge.

Three equalized/boost/float regulation is used. The regulation voltages are

adjustable via the keypad and display. Up to four stage bank switching can be

used which allows taper charging in the boost mode and low speed switching

regulation in the float mode.

Optimized control for calculating of discharge-rate and temp compensation, to

allow exact discharge depth, and sure the batteries long life using.

Exact remote digital temp sensor（±0.1℃）,for the battery temp measurement

Full multi- parameter control

Multi PV array charge input (4, 6 choose)

240×128 dots STN GRAPHIC LCD of wide running temperature, 4 buttons

keyboard, to form operate display interface. Only easily move cursor to check

parameter and setting.

Power MOSFET drive board, interface board, control board, use isolated work

power. Dada exchange of board to board, use PHOTOCOUPLE to isolate

electricity. A/D Sample channels also isolated. Integrated electricity isolation to

allow high anti- interference and security of program running.

High performance 12 bit A to D converter，to achieve precise A/D resolution rate

Hall current sensor used for each PV array changing current, load current and

generator current sample circuit. To get synchronization sample, no power

losing current sample, as well as isolated electricity sample. Isolated amplifier

also used for each voltage sample channel.

Power MOSFET drive, use 5 times rating current design and low resistance

MOSFET module. To get very low power loss, overload ability, and good running

in impact load.

Each Power MOSFET module embedded protection circuit, fault self monitor

alarm output.

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Auto control or remote control operate backup generator ON/OFF, online

real-time monitoring work condition of generator, and gather generator data of

current, temperature alarm, oil capacity alarm.

512K BYTE FLASHROM for data logging, more than two month data saving.

Real-time clock with backup power

System safety: Reverse polarity protected, transient protection, circuit breakers

on arrays

Multi I/O port, control port, outside sample port, alarm.

RS-232 communication port ( for MODEN，GPRS, etc)

Warranty 2 years

CONTROLLER OUT LOOK PICTURE

OUTLOOK OPERATE PANEL

MAINTIAMANCE BACK OF LCD DISPLAY & KEY BOARD

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3. SPECIFICATIONS

Nominal Voltage 48 Volt

Supply current maximum 180 mA

Supply current typical 160 mA

Charge Regulator

Array amount 4(100A)/6(200A)

Array input voltage maximum 96 Volt

Solar charge current maximum per bank 35 Amp

Voltage drop of charge circuit < 0.15 Volt

Total solar charge current 100/200A Amp

Equalized charge voltage setting range 55 ~ 65 Volt (Default 60)

Boost charge voltage setting range 53 ~ 60 Volt (Default 56)

Float charge voltage setting range 50 ~ 58 Volt (Default 54)

Boost cut in voltage setting range 48 ~ 54 Volt (Default 51)

Temp compensation 1 ~ 9 mV/℃/Cell (Default 5)

Wire entry size 16(100A)/16(200A) mm2

Output Voltage Control

Continuous output current maximum 50 Amp

Current overload limit 100 Amp

Over discharge cut off voltage 42 ~ 48 Volt

Over discharge return voltage 49 ~ 55 Volt

Voltage drop of discharge circuit 0.1 Volt

Wire entry size of battery and load 35(100A)/95(200A) mm2

Optional wire entry size of battery 35(100A)/95(200A) mm2

Generator

Generator current measurement 400 Amp ( DC side)

Auto cut in voltage setting range 46 ~ 48 Volt

(cut in voltage = batt low voltage)

Relay capacity of start Generator 1/220 Amp / Volt AC

Generator oil low fault alarm port 1 rely signal input

Generator over temperature alarm port 1 rely signal input

Other alarm

Battery lower voltage alarm setting range 46 ~ 48 Volt

Battery over voltage alarm 68 Volt

LCD display & communication

LCD view area 114×64 mm×mm

Resolution of dots 240×128 DOTS

Communication RS-232

Environment

Operating temperature range -35 ~ + 55 ℃

LCD display temperature -20 ~ + 55 ℃

Protection class IP66

Altitude < 5000 metres

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4. CONTROLLER LAYOUT PICTURE & BLOCK DIAGRAM

Note: The picture is for example of 100A

ISOLATED POWER BOARD

MOSFET POWER MODULE

INTERFACE BOARD

CONTROL BOARD

CONTROL BOARD

HALL SENSOR BOARD

LCD BOARD BACK

I/O BOARD

LCD DISPLAY

KEY BOARD

DC SWITCH BOARD

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4.1. DC SWITCH BOARD TERMINAL

EXPLANATION：

1、 Ground terminal

2、＋PV（1～6）－ Terminals for solar panel. 6 arrays.

3、＋BAT（1～2）－ Terminals for battery bank. BAT 1 is for main battery charging, BAT2 is

for

generation charging.

4、＋LOAD － Terminal for DC48V load

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4.2. I/O BOARD TERMINAL

pin definition device pin definition device

1 +12V generator

HALL sensor

A S1 generator

ON/OFF port 2 GND1 B S2

3 HALL

Output

C S3 Load Switch

4 -12V D S4

5 NC E +24V

6 GND2 digital temp

sensor

F over temp generator alarm

& state input 7 Tb Signal G oil low

fault 8 +5V H Running

ok 9 +12V Modem power I GND

10 GND2 J EL

Load Error

RS232 port

pin definition

2 RXD data receive

3 TXD data transfer

5 GND power

1 2 3 4 5 6 7 8 9 10

A B C D E F G H I

J

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4.3. CABINET SIZE

IPS48-100H mounting dimension

IPS48-200H mounting dimension

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4.4.

Solar

Array ＋

Bank 1－

Bank 2－

Bank 3－

Bank －

Note: for ISP48100, only 4 arrays

4

Load＋

Load－

Hall Current Sensor×4

ISP48100H SOALR CONTROLLER BLOCK DIAGRAM

Hall

Current

Sensor

＋

Battery

Bank

－

Circuit

Breaker

MOSFET

Switch

ON/OFF

Switch

Circuit

Breaker

Circuit

Breaker

Circuit

Breaker

Circuit

Breaker

MOSFET

Switch

MOSFET

Switch

MOSFET

Switch

MOSFET

Switch

240×128 DOTS

Graphic LCD

Display

4 KEY BOARD

1 Digital Temp

Sensor

2 Relays(S1/2)

SWITCH OUTPUTS

4 switch inputs

(IN1/2/3/4)

CONTROL BOARD RS-232

Serial port

1 Relays(s3) switch

output

generator/grid

GPRS

MODEN

Isolated

Power

Supply

±12V

＋24V

±12V

＋5V

Electricity Isolated

INTERFACE BOARD

6 6

EPSOLAR CONTROLLER

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5. DESCRIPTION OF BLOCK DIAGRAM

This section contains a description of the functions of each section in the block diagram.

5. 1. CHARGE REGULATOR

Charging:

Charge regulators are used to protect the storage batteries from overcharging. This

particular regulator uses a three state Equalized /boost/float type control scheme. The

photovoltaic panels are divided into 4 or 6 banks (or sub arrays).

In the boost mode, all banks are connected so that the full charge current flows into the

battery until its voltage reaches the taper voltage and remain 30 minutes. As the battery

voltage continues to rise, banks are progressively disconnected (beginning with bank 1),

If battery voltage 2V higher than boost voltage, two banks will be disconnect until only

one bank is charging. A time delay occurs between changes in bank connection

(adjustable 4 ~ 8 second) . This is necessary to allow the new conditions to stabilize and

prevent oscillation. Banks can be paralleled and the unit used as a one, two, or three

bank regulator by system monitor analysis program, to meet some charge mode need.

In case of the battery over-discharge occur, the battery will sustain the Equalized

maximum voltage, then the regulator will switch into the boost mode.

When the battery will sustain the boost maximum voltage, the regulator will switch into

the float mode. In this mode, the charge current is reduced to that level which is

necessary to keep the battery voltage within a preset float range. Floating the batteries

in float voltage range helps to keep them fully charged and prolongs their life. To

eliminate audio interference, the bank switching in the float mode can be no faster than

1 change 4 second.

When the battery voltage remains below the boost cut-in voltage for 3 minutes, the

regulator will switch back into boost mode and will remain in boost until the voltage

rises again to the boost maximum.

The charge current switching is done with rugged power MOSFET devices. These devices

result in a very low voltage drop across the bank switches when on and enable the unit

to achieve very low operating power dissipation. They are also arranged to as to block

reverse current flow due to panel wiring shorts and solar night loss currents. This design

eliminates the need for reverse blocking diodes.

The optional temperature sensor is able to compensate for battery temperature

variations over the range －40 ~ ＋65ºC.

Discharging:

The controller remain opening if without the error for load and close output when

over-load, short circuit, and over-discharging. When battery voltage higher than low

voltage reconnect, controller will start output automatically.

In case of over-load, short circuit protection, controller won’t start output auto. Please

check and shoot the trouble of load: Press “ESC” return to main menu, then press “ESC”

“PREVIOUS”.

5.2. CONTROL BOARD

Two MEGA128 series microcontroller are used to control the unit. One is for real-time

control, process all input data, and control model calculating, analyses, controls output.

EPSOLAR CONTROLLER

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Another is for systems manage, such as communications manage, data record and

transfer, as well as LCD display and keyboard manages, etc. These make the control

system having the fast response time.

5.3. ELECTRICITY ISOLATED INTERFACE BOARD

Voltages are measured using a high performance 12 bit A to D converter and an isolated

amplifier is used for main side and second side electricity isolate. Currents are

measured using 6 HALL current sensors. One of 6 HALL current sensors is outside the

cabinet to measure the generator current, near the GENERATOE DC ADAPTOR OUT

power line. To reduce the effects of noise and transients (or spikes), the voltage and

current measurements are processed through a digital smoothing filter with a time

constant of 0.5 sec. These sample methods fulfill an isolated measurement of no power

lose. Enhance the anti- interference and security reliability of system part and program

running.

5.4. GRAPHIC LCD DISPLAY & KEYPAD

The controller uses a 240 x 128 dots STN graphic liquid crystal display to show its

information and a 4 key keypad to select which information is displayed, or to alter the

settings.

5.5. ABOUT COMMUNICATION

The controller has a serial port for connecting to remote monitoring and control

equipment. This serial port is available in forms - RS232.

The RS232 port has only transmit (TX) and receive (RX) and Signal Ground connections

available. The port has 15kV ESD protection. All of operation above can be processed on

remote PC by communication. PC monitor program introduction see the hand book “PV

Plant Remote Monitor System”.

5.6. DISPLAY

SEE 7 SECTION.

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6. INSTALLATION

This section provides some notes on installation.

Mounting

The cabinet is sealed to IP66 standard and so can be installed outside if necessary.

However, it is best if it is under cover and out of direct sunlight.

Temperature Sensor Using

If the temperature sensor is to be used, plug it into the two pin terminal on the temp PIN

of the I/O board. The sensor is polarized, but the connecter will not allow the sensor to

be connected back to front. So take care to connect the wire with the stripe on it to the

Temp input as shown.

The sensor acts as a digital communication device which is proportional to temperature.

This means that the cabling to the sensor can be extended without having to worry

about voltage drops along the wire.

The sensor must be installed in good thermal contact with the battery case. Do not

place the sensor near but out of contact with the batteries. This will give false correction

because the air temperature will not be the same as the battery temperature. Good

thermal contact can be achieved in the following ways:

1. Glue the sensor to the battery case as shown in diagram Figure 1.

2. Wedge the sensor in the gap between two batteries in the bank with a piece of foam

rubber. The foam rubber will hold it against the battery as well as sealing around it.

3. Place the sensor against the battery and cover it with a duct tape strip which goes all

the way round the battery and wraps back on itself a couple of times. This will prevent it

coming undone easily.

4. Sit one of the batteries on top of it. A space can be cut in the support shelf and a

piece of foam rubber used to hold it against the battery.

5. Wedge between the battery and the wall using foam rubber to insulate it from the

wall.

Notes:

1. It is very important to get the polarity of the TEMP SENSOR connection correct!

2. The TEMP SENSOR connection should installed before power turn on. During power

turn on, do not plug in or out the TEMP SENSOR.

Start Up

Install the regulator with all the circuit breaker switches switched off.

Turn on the battery switch first. The small red LED on the power board should come on

indicating power is good. The LCD display should also light up and display an initializing.

When the power board is O.K., turn on the load/limiter circuit breaker, check that the

load current and voltage are correct via the keypad.

Finally, turn on the charge circuit breakers. Check each bank in turn using Running

Monitoring Interface

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7. DISPLAY & KEYPAD OPERATION GUIDE

KEY BOARD DEFINITION AND USING

ENTER: Sure get in to the menu of cursor indicated, or finish and sure the input’s setting

item.

ESC: Back to previous menu, or cancel the input’s setting item

NEXT: move cursor to next menu, or minus digit

PREVIOUS: move cursor to previous menu, or plus digit

GETTING START

Power on, system go into Initializing. Few seconds later, show start picture. Then display

main menu, and cursor on the first line. You can use ▲ or ▼ key to move and select

menu you want.

IF THE FIRST START

Move cursor to “Parameter Query” menu, press “ENTER” key, display show “Parameter

setting” interface, then, check all work parameters if you need. Press “ESC” exit.

PARAMETER SETTING

Move cursor to “Parameter Setting” menu, press “ENTER” key, then show “ password”,

should input password as orderly pressing PREVIOUS, NEXT, ESC, ENTER, ESC, ENTER

key. The following interface displayed.

ENTER ESC NEXT PREVIOUS

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If move cursor to “Default Parameter” item, press ENTER key, load all default setting

parameter auto set and saving. When setting wrong, do this step.

If move cursor to “Parameter Setting” item, and press ENTER key, the following two

pages interface displayed.

Press ENTER key, go next setting item; Press ESC key, go above setting item; Move

cursor by PREVIOUS or NEXT key to modify the digit value.

Saving the setting results

Saving the setting results by moving cursor to last item using ENTER key, press ENTER

key again, saving the setting result and back to previous menu.

Cancel setting and return

Cancel the setting results by moving cursor to first item using ESC key, press ESC key

again, cancel the setting result and back to previous menu.

SETTING PARAMETER MODIFY EXPLAIN

During setting, should meet following formula:

Equalized voltage value > Boost voltage value > Float voltage value > Charge return

value

Also the setting value should meet following table:

Rate

voltage

Equalized

voltage

Boost

voltage

Float

voltage

Charge

return

Lower

voltage

Over discharge

voltage

Over discharge

return

voltage

48V

Max

limit 65 60 58 54 49 48 55

Min

limit 55 53 50 48 48 42 49

default 60 56 54 51 48 45 52

RUNNING MONITORING INTERFACE

From “main menu”, select “Running Monitoring” item get in. The following 3 pages

interface displayed. Press ▲ or ▼ key view and cut page.

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RECORD QUERY

From “main menu”, select “Record Query” item get in. The following two pages interface

displayed. Press ▲ or ▼ key view and cut page.

Press ENTER or ESC key, moving cursor to Y (YEAR), M (MONTH), D (DAY), or H (HOUR)

item. Press ▲ or ▼ key modify time value. Then, press ENTER key, moving cursor to

“Cancel” or “Yes” item.

If select “Cancel” and press ENTER key, return previous menu.

If select “Yes” and Press ENTER key, display record data in the time. Show in following

interface. Press ▲ or ▼ key moving cursor to “ Prior ” item, or “Next ” item,

then press ENTER key, view other record item.

If going view, move cursor to “Continue” item, press ENTER key.

If want return “main menu”, move cursor to “Exit” item, press ENTER key.

MALFUNCTION QUERY

From “main menu”, select “Malfunction Query” item get in. The following two pages

interface displayed.

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Press ENTER or ESC key, move cursor to Y (YEAR), M (MONTH), or D (DAY) item. Press ▲

or ▼ key modify time value. Press ENTER key, move cursor to “cancel” item, If cancel

press ENTER key. if not, Press ▲ or ▼ key, move cursor to “Yes” item, then press ENTER

key to view the record data in the time, by using ▲ or ▼ key.

If going view, move cursor to “Continue” item, press ENTER key.

If want return “main menu”, move cursor to “Exit” item, press ENTER key.

DATE AND TIME SETTING

From “main menu”, select “Malfunction Query” item get in. Input pass word, same as

“Parameter Setting”. The following page interface displayed.

Press ENTER or ESC key, move cursor to Y (YEAR), M (MONTH), or D (DAY) item. Press ▲

or ▼ key modify time value.

Saving the setting results

Saving the setting results by moving cursor to last item using ENTER key, press ENTER

key again, saving the setting result and back to previous menu.

Cancel setting and return

Cancel the setting results by moving cursor to first item using ESC key, press ESC key

again, cancel the setting result and back to previous menu.

LCD DISPLAY BACK GROUND LED

Pressing of each key can light the LCD Display Back Ground LED. After several seconds

no key is pressed, the Back Ground LED auto OFF.

DATA LOGGING

Saving running data in to flash ROM at the time of 0, 20, 40 min in every hour for the

data recording. Flash ROM capacity can meet three months data recording. The data

include all of the displayed parameter data and running state. After three month’s data

recording, no download occur by the PC during the time, the flash will be auto clear for

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saving new data.

SYSTEM PART FAULT ALARM

When controller part diagnosed fault, LCD display will show the fault item in character

way. You can check the fault content in local or in remote monitoring PC.

If clear fault state, press ▲ and ESC key at same time,