Epever SolarV AN Series User manual

www.solarv.de

USER MANUAL

Model:

1210AN

2210AN

3210AN

4210AN

TRACER AN SERIES - MPPT SOLAR CHARGER CONTROLLER

www.solarv.de

CONTENTS

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

1.1

Overview...........................................................................................................................................1

1.2

Characteristics.................................................................................................................................. 2

1.3

Naming Rules of Controller models..................................................................................................2

1.4

Maximum Power Point Tracking Technology...................................................................................3

1.5

Battery Charging Stage..................................................................................................................... 4

Installation Instructions............................................................................................................................... 7

2.1

General Installation Notes................................................................................................................7

2.2

PV Array Requirements.................................................................................................................... 7

2.3

Wire Size..........................................................................................................................................10

2.4

Mounting........................................................................................................................................ 11

Operation................................................................................................................................................... 14

3.1

Button............................................................................................................................................. 14

3.2

Interface..........................................................................................................................................14

3.3

Setting.............................................................................................................................................16

3.4

Accessories (optional).....................................................................................................................21

Protections, Troubleshooting and Maintenance.......................................................................................22

4.1

Protection.........................................................................................................................................22

4.2

Troubleshooting...............................................................................................................................23

4.3

Maintenance.................................................................................................................................... 24

Technical Specifications.............................................................................................................................. 25

Annex I Conversion Efficiency Curves......................................................................................................... 27

Annex II Mechanical Dimension Diagram...................................................................................................31

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Important Safety Instructions

Please keep this manual for future review. This manual contains all instructions of safety, installation and

operation for Tracer AN series Maximum Power Point Tracking (MPPT) 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.

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General Information

1.1

Overview

Tracer AN series controller is based on common negative design and advanced MPPT control algorithm,

with LCD displaying running status, this product is artistic, economical and practical. The MPPT control

algorithm can minimize the maximum power point loss rate and loss time, quickly track the maximum

power point of the PV array and obtain the maximum energy from solar modules under any conditions; and

can increase the ratio of energy utilization in the solar system by 20%-30% compared with a PWM charging

method.

Limiting the charging power & current and reducing charging power functions ensure the system stable with

over PV modules in high temperature environment. and increase the professional protection chip for the

RS485 port, further improving the reliability and meeting the different application requirements.

Tracer AN series controller owns self-adaptive three-stage charging mode based on digital control circuit,

which can effectively prolong the lifespan of battery and significantly improve the system performance. It

also has comprehensive electronic protection for overcharge, overdischarge, PV & battery reverse etc, to

ensure the solar system more reliable and more durable. This controller can be widely used for RV,

communication base station, household system, field monitoring and many other areas.

Features：

100% charging and discharging in working environment temperature

High quality and low failure rate components(ST/IR/Infineon) to ensure service life

Advanced MPPT technology, with efficiency no less than 99.5%

Maximum DC/DC conversion efficiency of 98%

Ultra-fast tracking speed and guaranteed tracking efficiency

Advanced MPPT control algorithm to minimize the MPP loss rate and loss time

Accurate recognition and tracking of multiple-peaks maximum power point

Wide MPP operating voltage range

Limit charging power & current over rated range

Support the lead-acid and lithium batteries with the needed tem. compensation

Real-time energy statistics function

Power reduction automatically over temperature range

Multiple load work modes

Comprehensive electronic protection

RS485 with 5V/200mA protected output for no power devices, with Modbus

Monitor and set the parameters via APP or PCsoftware

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1.2

Characteristics

Figure 1 Product Characteristics

❶

SELECT button

❻

RS485 communication port

❷

★

RTS port

❼

Mounting Hole Φ5mm

❸

PV Terminals

❽

ENTER button

❹

Battery Terminals

❾

LCD

❺

Load Terminals

★If the temperature sensor is short-circuited or damaged, the controller will charge or discharge at the

default temperature setting of 25 ºC.

1.3

Naming Rules of Controller models

EXAMPLE:

Tracer 1 2 10 AN

Common Negative System Max.PV

opencircuitvoltage100V System

Voltage12/24VDC Charge &

discharge current10A Product

Series

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Input power (PPV)= Output power (PBat)

Input voltage (VMpp) *input current (IPV) =Battery voltage (VBat) *battery current (IBat)

1.4

Maximum Power Point Tracking Technology

Due to the nonlinear characteristics of solar array, there is a maximum energy output point (Max Power

Point) on its curve. Traditional controllers, with switch charging technology and PWM charging

technology, can’t charge the battery at the maximum power point, so can’t harvest the maximum energy

available from PV array, but the solar charge controller with Maximum Power Point Tracking (MPPT)

Technology can lock on the point to harvest the maximum energy and deliver it to the battery.

The MPPT algorithm of our company continuously compares and adjusts the operating points to attempt

to locate the maximum power point of the array. The tracking process is fully automatic and does not

need user adjustment.

As the Figure 1-2, the curve is also the characteristic curve of the array, the MPPT technology will ‘boost’ the

battery charge current through tracking the MPP. Assuming 100% conversion efficiency of the solar system, in

that way, the following formula is established:

Normally, the VMpp is always higher than VBat, Due to the principle of conservation of energy, the IBat is

always higher than IPV. The greater the discrepancy between VMpp &VBat, the greater the discrepancy

between IPV& IBat. The greater the discrepancy between array and battery, the bigger reduction of the

conversion efficiency of the system, thus the controller’s conversion efficiency is particularly important in

the PV system.

Figure 1-2 is the maximum power point curve, the shaded area is charging range of traditional solar

charge controller (PWM Charging Mode), it can obviously diagnose that the MPPT mode can improve the

usage of the solar energy resource. According to our test, the MPPT controller can raise 20%-30%

efficiency compared to the PWM controller. (Value may be fluctuant due to the influence of the ambient

circumstance and energy loss.)

Figure 1-2 Maximum Power Point Curve

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In actual application, as shading from cloud, tree and snow, the panel maybe appear Multi-MPP, but in

actually there is only one real Maximum Power Point. As the below Figure 1-3 shows:

Figure 1-3 Mutil-MPP Curve

If the program works improperly after appearing Multi-MPP, the system will not work on the real max

power point, which may waste most solar energy resources and seriously affect the normal operation of

the system. The typical MPPT algorithm, designed by our company, can track the real MPP quickly and

accurately, improve the utilization rate of the array and avoid the waste of resources.

1.5

Battery Charging Stage

The controller has a 3 stages battery charging algorithm (Bulk Charging, Constant Charging and Float Charging)

for rapid, efficient, and safe battery charging.

Figure 1-4 Battery changing stage Curve

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A) Bulk Charging

In this stage, the battery voltage has not yet reached constant voltage (Equalize or Boost Voltage), the

controller operates in constant current mode, delivering its maximum current to the batteries (MPPT

Charging).

B) Constant Charging

When the battery voltage reaches the constant voltage setpoint, the controller will start to operate in

constant charging mode, this process is no longer MPPT charging, and in the meantime the charging

current will drop gradually, the process is not the MPPT charging. The Constant Charging has 2 stages,

equalize and boost. These two stages are not carried out constantly in a full charge process to avoid too

much gas precipitation or overheating of battery.

Boost Charging

The Boost stage maintain 2 hours in default, user can adjust the constant time and preset value of boost

voltage according to demand.

The stage is used to prevent heating and excessive battery gassing.

Equalize Charging

WARNING: Explosive Risk!

Equalizing flooded battery would produce explosive gases, so well ventilation of battery

box is recommended.

CAUTION: Equipment damage!

Equalization may increase battery voltage to the level that damages sensitive DC loads.

Verify that all load allowable input voltages are 11% greater than the equalizing charging

set point voltage.

CAUTION: 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.

Some types of batteries benefit from equalizing charge on a regular basis, which is able to stir electrolyte,

balance battery voltage and accomplish chemical reaction. Equalizing charge increases battery voltage,

higher than the standard complement voltage, which gasifies the battery electrolyte.

The controller will equalize the battery on 28th each month. The constant equalization period is 0~180

minutes. If the equalization isn’t accomplished in one-time, the equalization recharge time will be

accumulated until the set time is finished. 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.

NOTE:

1) Due to the influence of ambient circumstance or load working, the battery voltage can’t be

steady in constant voltage, controller will accumulateand

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calculate the time of constant voltage working. When the accumulated time reach to 3 hours, the

charging mode will turn to Float Charging.

2) If the controller time is not adjusted, the controller will equalize charge battery once every

month following the inner time.

C) Float Charging

After the Constant voltage stage, the controller will reduce charging current to Float Voltage setpoint. This

stage will have no more chemical reactions and all the charge current transforms 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 the battery and prevent the gassing and 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 charging stage, loads are able to obtain almost all power from solar panel. If loads exceed the

power, the controller will no longer be able to maintain battery voltage in Float charging stage. If the

battery voltage remains below the Recharge Voltage, the system will leave Float charging stage and return

to Bulk charging stage.

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Installation Instructions

2.1

General Installation Notes

Please read the entire installation instructions to get familiar with the installation steps before

installation.

Be very careful when installing the batteries, especially flooded lead-acid battery. Please wear eye

protection, and have fresh water available to wash and clean any contact with battery acid.

Keep the battery away from any metal objects, which may cause short circuit of the battery.

Explosive battery gases may come out from the battery during charging, so make sure ventilation

condition is good.

Ventilation is highly recommended if mounted in an enclosure. Never install the controller in a sealed

enclosure with flooded batteries! Battery fumes from vented batteries will corrode and destroy the

controller circuits.

Loose power connections and corroded wires may result in high heat that can 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.

Lead-acid battery and lithium battery 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.

Multiple same models of controllers can be installed in parallel on the same battery bank to achieve

higher charging current. Each controller must have its own solar module(s).

Select the system cables according to 5A/mm2or less current density in accordance with Article 690 of

the National Electrical Code, NFPA 70.

2.2

PV Array Requirements

(1) Serial connection (string) of PV modules

As the core component of PV system, controller could be suitable for various types of PV modules and

maximize converting solar energy into electrical energy. According to the open circuit voltage (Voc) and the

maximum power point voltage (VMpp) of the MPPT controller, the series number of different types PV

modules can be calculated. The below table is for reference only.

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