EPEVER MPPT to PC using RS485 or WiFi

Introduction
This blog provides two methods for connecting an EPEVER MPPT with RS485 capability to a Windows PC running Solar Station Monitor.

EPEVER Solar Station Monitor

Direct Connection
Direct connection utilises hardware consisting of an FTDI USB to RS485 adaptor, part USB-RS485-WE with an RJ45 male to screw terminal adaptor to connect to the EPEVER MPPT.

Details for the various connections using the FTDI adaptor are pictured below.

RS485 connections A, B and 0 V were used; no termination resistor was added to the circuit.

FDTI RS485 to EPEVER MPPT

Wired USB FTDI to RJ45 adaptor.

FDTI RS485 to RJ45 8-Way Screw Terminal for EPEVER MPPT

FTDI adaptor wiring from USB-RS485-WE manual.

USB-RS485-WE Connections (Courtesy FTDI)

 Pinout for RJ45 connector.

RJ45 Pinouts (Courtesy Huawei)

There were no requirements to change the Windows setup for the FTDI adaptor. This device appears as a standard COM port. This COM port was then selectable in the EPEVER Solar Station Monitor application.

Wireless Connection
The wireless connection makes use of an Elfin EW11A. This device bridges RS485 and wireless station and or access point.

Elfin EW11A (Courtesy Hi-Flying)

Also used in the hardware solution was the optional Elfin adaptor cable. For connecting to the EPEVER MPPT, an RJ45 male to screw terminal adaptor was utilised. Since the EW11A requires DC 5 V, an further connection to a power supply is also required.

 

Elfin EW11A to EPEVER MPPT

Elfin EW11A to RJ45 8-Way Screw Terminal

The computer running EPEVER Solar Station Monitor required a software Ethernet to COM port bridge. The HW Virtual Serial Port application from HW-Group was used.
Side note. The EPEVER WiFi 2.4 G RJ45 A adaptor was tested separately however because WiFi Station mode was required, the EPEVER was not suitable.

Elfin EW11A Setup
This tests in this blog were geared towards verifying that wireless communications with the MPPT were practicable. The final goal was to interface the EPEVER with Home Assistant.

Using the I.O.T Workshop application from High-Flying, the EW11A was configured for station mode, TCP server and the port settings were configured for consistency with Home Assistant. Ethernet port number 8899 (MQTT) was used. The Comment and Application Guide from Eniris was used as the primary reference document.

Removed from the screen capture below are the login details (admin and password), wireless station ID and associated password.

EW11A Device Setup for EPEVER MPPT Using I.O.T Workshop

No UART protocol was selected. Telnet was disabled and web interface was kept enabled.

EW11A Device Detail for EPEVER MPPT Using I.O.T Workshop

The UART settings 115200, 8, N, 1 were left as default.

EW11A Serial Setup for EPEVER MPPT Using I.O.T Workshop

Virtual Serial Port
For this blog the HW Virtual Serial Port application from HW-Group was used. The default configuration of the application required changes. For example, if the option Network Virtual Terminal (NVT) was enabled, communications with the EPEVER MPPT were sporadic or only specific values were received correctly. Other tools offering an Ethernet to COM virtual com port may offer similar configuration options which should be validated.

HW Virtual Serial Port Settings for EPEVER MPPT and Elfin EW11A

Shown on the Virtual Serial Port page is the IP and port for the Elfin EW11A.

HW Virtual Serial Port Page for EPEVER MPPT with Elfin EW11A

With the Elfin EW11A configured and powered, clicking Create COM in the virtual serial port application established the Ethernet link. Shortly after COM4 appeared in Windows Device Manager.

Serial Port Created Using HW Virtual Serial Port

With a connection established to the EW11A and the EPEVER MPPT, the EPEVER application could communicate with the MPPT. This was indicated by the change in counter values (Rx and Tx).

HW Virtual Serial Port Connected to EPEVER MPPT with Elfin EW11A

Solar Station Monitor
No changes were made to the setup of the EPEVER Solar Station Monitor application other than configuring the required COM port to communicate with the Virtual COM port. The default port settings were used.

EPEVER COM Port Settings

 

After clicking Start Monitor in the application, data was exchanged within a few seconds.

The capture below was taken after sunset with the MPPT load active.

EPEVER Solar Station Monitor (Load Active)

The capture below was taken during sunlight hours.

EPEVER Solar Station Monitor (During Daylight)

For the capture below, the EPVER monitoring tool was restarted to capture the transition between load OFF and ON.

EPEVER Solar Station Monitor Graphed Data Showing Load ON

EPEVER Solar Station Monitor Graphed Data Showing Load OFF

Final Thoughts
This post offered two methods for connecting an EPEVER MPPT with a Windows PC running Solar Station Monitor application. The WiFi connection and subsequent testing using the Elfin EW11A served as preliminary work to develop a dedicated circuit board to bridge the EW11A with the EPEVER MPPT.

PSoC to Tracer MPPT 1210RN 2210RN 3215RN 4210RN with Bluetooth and Datalogger

Summary
Although the early EPSolar MPPT Tracer series with remote display have been surpassed by improved MPPT models with inbuilt LCDs, there are plenty of the earlier models that remain in operation. This project is Cypress PSoC 4 BLE based and features connection to the Tracer MPPT, load control, Bluetooth and data logging of the MPPT data.

MPPT
A number of other people have used the EPSolar MT-5 display to reverse engineer the communications protocol, however there was PC software from the same manufacturer which performed all the same functions, possibly more.

EPSolar Tracer RN MPPT

At last glance of the EPSolar website the Tracer series had reached obsolescence and the PC software on the site no longer supports the Tracer series.

Hardware
Initial documentation for the MPPT connections were taken from a site by Steve Pomeroy, another two sites by John Geek. The 8 way RJ connections to the Tracer were drafted with an optional zero ohm link added such that the MPPT could power the project. Buffers were added to the transmit and receive lines, although not a necessity, to ensure some protection for the PSoC from the real world.

EPSolar Tracer RJ45 Connections

For the display an OLED or LCD capable of being powered from 3.3V for both the logic and backlight was selected. In most instances this results in the LCD contrast voltage being negative however this was generated by the PSoC using the circuit shown below.

LCD Connections

Four momentary push buttons were used instead of the Cypress Capsense feature. This solution using switches was chosen only due to the design of the hardware as the PCB was to be mounted inside a box and away from the lid.

Buttons / User Interface Connections

The power supply regulator was chosen to be small and the usual buck topology. The LMR14203 has been my default single output regulator for some time, certainly there are newer devices with higher efficiency in the low current region of operation. In the event the display that was chosen could not have the backlight operate from 3.3V, a linear 5V regulator was added for testing.

Power Supply Connections

Even though the design incorporated Bluetooth, USB was added for debugging, downloading of data and upgrading of the PSoC. Field upgrades would be possibly by using the PSoC bootloader, a program allowing the active application to be updated some time in the future. The FTDI FT230X was chosen for the USB implementation however for those looking for a similar priced and reliable solution the Cypress CY7C65213A-32 would also be a good choice.

FTDI USB Connections

The PSoC selected was the CY8C4247LQI-BL483, which features a 48MHz System Clock, 128K FLASH and the all important Bluetooth. Although the PSoC4 libraries did not support SD at the time of writing, there are a few alternatives from the PSoC Community.

PSoC Connections and Supply Filtering

Lastly bringing all the sub-sheets together is the top sheet as shown below.

Project Top Sheet

PCB Enclosure
The PCB was designed to fit into a plastic enclosure with a clear lid, no bells no whistles. A Ritec case from a local supplier was used, the Altronics H0324.

Altronics H0324 enclosure

With the enclosure size selected the PCB dimensions were set to 98mm (W) x 75mm (H).

PCB Design

For the schematic and board design Altium was chosen since the board was mixed logic with RF. This combination was always in my mind a four layer board. The board layer stack would follow the usual two middle power planes and signals on the outside layers.

There were a number of parts added to the component database although none more interesting that the meandered inverted-F antenna (MIFA) to suit the PSoC4 BLE part. The antenna design was well documented in the Cypress Application Note - AN91455. This antenna was implemented as described on Page 10 of the Application Note.

PSoC4 BLE MIFA 

The board shape was drawn and a work guide added for the position of the four push buttons, then all components were place on the PCB.

Tracer MPPT Interface Board

With some quick shuffling of parts then an idea of the layout could take place.

Tracer MPPT Interface Board Parts Placement

Parts positions were changed on the PCB with some connectors and the SD card moved to the bottom layer.

Tracer MPPT Interface Board Final Part Placement

A few hours later the final route is shown below.

Tracer MPPT Interface Board Final Route

The board in 3D shows the stacking of the LCD and logic board.

Tracer MPPT Interface Board with LCD

PCB Prototype

The PCB was hand populated for both top and bottom layer. Some last minute modifications were made to the LCD connector and backlight control because the four line LCD had to be changed to another manufacturer. LCD supply pins were swapped.

Top Layer MPPT PCB Populated

Bottom Layer MPPT PCB Populated

To mount the LCD to the MPPT board, a male pin header was soldered to the bottom side of the LCD. To space the LCD and MPPT board 12mm tapped metal spacers were used.

Spacers for MPPT PCB and LCD

USB Check
Two of the hardware connections that were used for debugging this particular project were the Cypress MiniProg3 programmer and the USB port. Certainly the LCD or on-board status LED could also be useful although the background debugger and serial port usually work sufficiently.

With the USB connected between the MPPT board and a Windows PC, the FDTI chip was configured using the FTDI application FT Prog. This application was used to disable three unused CBUS pins and reconfigure the fourth for USB bus voltage detection.

FT Prog Scan

The Scan command was issued the the FTDI device was located.

FT Prog Default CBUS Settings

From the list shown in the Device Tree pictured above, the 'Hardware Specific' item was expanded and the 'CBUS signals' entry was selected.

FT Prog Updated CBUS Settings

The settings were modified as shown above which enabled voltage sensing for the USB - VBUS_Sense. All other CBUS pins were unused and therefore tristated.

FT Prog Program

To save the CBUS settings changes using FT Prog, the 'Program' command was used. As shown in the capture above a 'Program Devices' dialog allows for confirmation of the Program process then subsequent programming.

RealTerm Loopback Test for MPPT Board

In order to test the USB a dummy PSoC application was made to loopback the Tx and Rx pins, P0.4 and P0.5 respectively. RealTerm was then used to test the loopback at 921600 - no issues were noted.

Software - Prototype
After the initial hardware checks of the boards power rails some initialisation code was written to check the LCD, buttons and communications. Below is an example of the initialised LCD.

Initialised LCD for Testing

A prototype project, certainly with some bugs, is available for download below.

Prototype Tracer PSoC MPPT Interface

The prototype project implements communications to the Tracer MPPT and display of current MPPT readings to LCD. Some of the current MPPT readings are also sent to the USB port for logging.

Serial Data Logging
The data logging 'USB output' was rather raw code with the sole purpose of providing a console output capable of being imported into Microsoft Excel. The UART Update function was called every minute and send some basic information to a terminal application.

void UART_Update() 
{
    char UART_Buf[20];
    uint16_t UART_temp;

    UART_UartPutString(LINE1_PV);
    UART_temp = MPPTPanelVoltage;                           /* Temp memory to modify for display */
    sprintf(UART_Buf, "%d.%02d%s%c", (UART_temp/100), (UART_temp%100),"V",0x9);
    UART_UartPutString(UART_Buf);
    UART_UartPutString(LINE1_BV);
    UART_temp = MPPTBatVoltage;                             /* Temp memory to modify for display */
    sprintf(UART_Buf, "%d.%02d%2s%c", (UART_temp/100), (UART_temp%100),"V ",0x9);
    UART_UartPutString(UART_Buf);   
    UART_UartPutString(LINE2_BI);  
    UART_temp = MPPTBatteryCurrent;                         /* Temp memory to modify for display */
    sprintf(UART_Buf, "%d.%02d%s%c", (UART_temp/100), (UART_temp%100),"A",0x9);
    UART_UartPutString(UART_Buf);
    if (System.MPPT_Load_Is_On == true)
    {
        UART_UartPutString(" Load On\r\n");
    }
    else if (System.MPPT_Load_Is_On == false)
    {
        UART_UartPutString(" Load Off\r\n");
    }

}

Shown below is an example of the data output to a terminal application.

MPPT Example UART Output

The output panel voltage displayed in the terminal window was also used to verify the position and angle of the solar panel. Moving the solar panel a few degrees off axis to the sun appeared to make no appreciable difference in the readings.

MPPT Protocol
The protocol was verified and confirmed in another of my blogs which can be found at http://electronicmethods.blogspot.com.au/2017/03/tracer-mt-5-to-mppt-communications.html

SD Card
The SD card implementation was scheduled to use the Element 14 community project #50 implementation for the PSoC4, which uses a modified version of the Segger / Cypress EmFile. In early part of '18 an article appeared Hackser.io with an implementation using Segger libraries by Hima from Cypress allowing SCB (Serial Communication Block) or UDB's (Universal Digital Blocks) for communications to the SD card.

Downloading and compiling the example from Hackster illustrated how easily the project could be changed between SCB or UDB's. Another feature buried in the API's are related SD card functions which are non-blocking. For full details see the Hackster.io site with credit to Hima. Note the Segger library license requirement.

In the capture below, are the two additional directories for adding the SD Card libraries to the MPPT project.

PSoC4 SD Card Libraries Compiler Entries

Similarly the Linker references one additional directory.

PSoC4 SD Card Library Linker Entry

To test the SD Card the appropriate File System header file was included and blocking writes were made to the SD card - a snippet is shown below.

#include <FS.h>
...
...
if ((pFile) && (SD_Removed_Read() == false))
    {      
        UARTCrLf[0] = 0x0a;UARTCrLf[0] = 0x0d;

        FS_Write(pFile, PV_string, strlen(PV_string));
        FS_Write(pFile, "," , 1u);
        FS_Write(pFile, BV_string, strlen(BV_string)); 
        FS_Write(pFile, "," , 1u);
        FS_Write(pFile, BI_string, strlen(BI_string)); 
        FS_Write(pFile, "," , 1u);
        FS_Write(pFile, TE_string, strlen(TE_string));
        FS_Write(pFile, "," , 1u);
        FS_Write(pFile, LOAD_string, strlen(LOAD_string));
        FS_Write(pFile, UARTCrLf , strlen(UARTCrLf));

    }

The rather inelegant code above was for testing opening of the log file written to the SD card, by Excel, Libre Office or another similar application with CSV capabilities. Shown below is a sample of the log from the SD card.

0.00V,13.34V,0.00A,25C,OFF
0.14V,13.34V,0.03A,25C,ON 
0.14V,13.32V,0.02A,25C,ON 
0.14V,13.32V,0.02A,26C,ON 

Next up scheduling control of the SD card....