iTracer Series
Contents
1. IT6415ND Dimensions Unit mm 51 Version V2 32. 10 0 Dimensions es sd sd O ee deed ee N ees De dd ee eg vee de eos 45 1 0 Important Safety Information This manual contains important safety installation and operating instructions for the iTracer Series MPPT solar controller Save these instructions The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions 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 gj gt e important for safe and proper operation of the controller General Safety Information Read all of the instructions and cautions in the manual before installation There are no user serviceable parts inside the controller Do not disassemble or attempt to repair the controller Mount the controller indoors Prevent exposure to the elements and do not allow water to enter the controller Install iTracer controller in well ventilated places the iTracer controller heatsink may become very hot during operation Install external fuses breakers as required Disconnect the solar module load and fuse breakers near to battery before installing or adjusting the controller Power connections must remain tight to avoid excessive heating from a loose connection
3. is chosen in inverse Press OK again to enter the Edit Mode Use f or button y to move the cursor between the time parameters and data bit Use button to modify the value and set the period of log for browse When the period is set press OK to enter the corresponding details Log Number time the voltage and current of battery are included in every work log item and are shown in the Work Log interface warning event sequence number warning event start or end time the fault status and values are all included in every event log item and are shown in the Alarm Log interface 22 gt Clock Set The interface of Clock Set is shown as follow Press OK to enter the Clock Set interface when the inverse cursor Clock Set point to Clock Set item Press ESC button to exit Jan 16 2014 17 12 28 Date and Time can be adjusted in this interface Press OK and input the 6 digit user password and then Date and Time could be adjusted The format of date is YYYY MM DD the one of time is HH MM SS When the set is over press OK to save or press ESC button to cancel save success will be promoted if adjusted and save operated successfully Input Password Save Cancel Save success 000000 NOTE The log after the current time will be erased when the clock has be adjusted gt D
4. Several load control methods are supported to convenient for different demand Protection Over temperature over charging PV and load short PV battery revered PV reverse current protect at night over current protection Actual Power Display and record function make convenience to check the datum every day every month and every year Log function work logs and alarm logs are all recorded Firmware update convenience to after service and maintenance service The controller features a built in fuzzy control algorithm that maximizes the energy from the solar module s and charge the battery The battery charging process has been optimized for long battery life and improved 2 system performance The comprehensive self diagnostics and electronic protection functions can prevent damage from installation mistakes or svstem faults Please take the time to read this operation s manual and become familiar with the controller This will help you make full use of all the functions and improve your PV svstem 2 2 Models amp Parameters Maximum 150 Volt de systems RS 232 RS 485 and CAN port IT3415ND v Rated charge discharge current 30A v PV input Max Power 1600W v 12V 24V 36V 48V system voltage and auto work IT4415ND v Rated charge discharge current 45A v PV input Max Power 2400W v 12V 24V 36V 48V system voltage and auto work IT6415ND v Rated charge discharge current 60A v PV input Max Power 3200W v
5. 2 0 General Information 2 1 Overview Thank you for selecting the iTracer Series MPPT solar controller The controller is a high end industrial class product based on multiphase synchronous rectification technology and has the features of high efficiency and reliability The features are listed below 12V 24V 36V 48V Voltage DC systems Smart tracking algorithm that finds and maintains operation at the solar array peak power point with the tracking efficiency as high as 99 7 Multiphase synchronous rectification technology ensures peak conversion efficiency is up to 98 7 High effective conversion efficiency at small power charging with multiphase power decentralized control and improves the generated energy Double processors architecture with high speed and performance improves the response speed and optimizes the performance of the system Multiphase control technology optimizes charging current smoothness reduces ripple and improves the system generating efficiency Excellent EMC design Excellent heat dissipation Using the integration of cast aluminum radiator shell the controller can be natural cooling 128 64 dot matrix LCD intuitively displays data and state 6 buttons combinations for easy operation RS 232 CAN RS 485 ports via the open standard Modbus protocol are supported to meet different occasion of demand Support 4 charging preprogram options Sealed Gel Flooded and User defined
6. 12V 24V 36V 48V system voltage and auto work The auto work setting allows the controller to detect the system voltage automatically on start up Array voltage should never exceed maximum PV input voltage Refer to the solar module documentation to determine the highest expected array Voc open circuit voltage as defined by the lowest expected ambient temperature for the system location 2 3 Characteristics Figure 2 1 iTracer features 1 Heat Sink Aluminum heat sink to dissipate controller heat 2 LCD Display the status and data 3 Battery LED indicator Three states of battery LED indicator show charging status 4 Charging LED indicator Indicate that the battery is charging or not 5 Fault LED indicator Indicate that controller faults 6 Buttons Browse or modify all parameters 7 RS 232 port Monitor controller bv PC and update controller software 8 RS 485 port Monitor controller bv PC and update controller software 9 RTC battery Power to RTC batterv model is CR2032 10 Remote Temperature Sensor port MC1 5 5 08 2L Connection for a RTS Remote Temperature Sensor optional to remotely monitor battery temperature 11 Remote Battery Voltage Sensor port MC1 5 5 08 2L Connection for RBVS Remote Battery Voltage Sensor to provide accurate battery voltage measurement 12 CAN bus port MC1 5 3 81 4L Communicate with other CAN BUS devices via our co
7. 14 4V 4 6V 9 17V Float voltage 13 8V 13 8V 3 8V 9 17V Boost return voltage 13 24 13 24 3 2V 9 17V Low voltage reconnect 12 6V 12 6V 2 6V 9 17V Under voltage recover 12 2V 12 2V 2 2V 9 17V Under voltage warning 12V 12V 12V 9 17V Low voltage disconnect 11 1V 11 1V 1 1V 9 17V Discharging limits voltage 10 6V 10 6V 0 6V 9 17V Equalize duration 120min 120min 0 180min Boost duration 120min 120min 120min 10 180min The following rules must be observed when modify the parameters value in user battery type factory default value is the same as sealed type Rulel High Volt Disconnect gt Charging limit voltage 2 Equalization voltage gt Boost voltage 2 Float voltage gt Boost return voltage Rule2 High Volt Disconnect gt Over Voltage Reconnect 30 Rule3 Low voltage reconnect gt Low voltage disconnect gt Charging limit voltage Rule4 Under voltage recover gt Under voltage warning 2 Charging limit voltage Rules Boost return voltage gt Low voltage reconnect gt Password Press OK to enter the Password Set interface when the inverse cursor points to Password Para item Press ESC button to exit Note The factory default password is 000000 Sys Password Old PSW 00000 New PSW 000000 gt Default Set Under the main menu interface when the inverse cursor to restore the default option press the OK button to e
8. 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 or LCD 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 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 Warning Risk of electric shock Make sure that all the power is turned off before above operations and then follow the corresponding inspections and operations 33 6 0 Other instructions 6 1 PC Software iTracer controller can be connected to a common PC monitoring software bv supporting USB communication cable developed bv the EPsolar companv Monitoring software can remote single or more controllers to modifv the parameters configure load mode and others in the PV svstem management username a
9. overvoltage the charging will enter into boost charging stage e Float Charge 17 After the Boost voltage stage iTracer will reduce the batterv voltage to float voltage setpoint When the batterv is fullv recharged there will be no more chemical reactions and all the charge current transmits into heat and gas at this time Then the iTracer reduces the voltage to the floating stage charging with a smaller voltage and current It will reduce the temperature of batterv and prevent the gassing and charge 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 Once 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 remain below the Boost Return Voltage the controller will exit Float stage and return to Bulk charging Equalize WARNING Risk of explosion N Equalizing flooded battery would produce explosive gases so well ventilation of battery box is recommended NOTE Equipment damage FS Equalization may increase battery voltage to the level damaging to sensitive DC loads Verify that all load allowable input voltages are greater 11 than the equalizing charging set point voltage
10. 0 300 400 500 600 700 800 900 1000 1100 Charging Power W 4 Solar MPPT Voltage 17V 34V 68V System Voltage 48V 43 48V Conversion Efficiencv Curves Conversion Efficiency 90 0 200 400 600 800 1000 1200 1400 Charging Power W 44 Test model IT4415ND 1 Solar MPPT Voltage 66V 98V 115V Svstem Voltage 12V 12V Conversion Efficiencv Curves 0 100 200 300 400 500 600 Charging Power W 2 Solar MPPT Voltage 33V 66V 98V 115V System Voltage 24V 24V Conversion Efficiency Curves 99 T T T T T T T T 8 li l l i l l l l l i 00 200 300 400 500 600 700 800 900 1000 1100 1200 Charging Power W 45 3 Solar MPPT Voltage 66V 98V 115V Svstem Voltage 36V 36V Conversion Efficiencv Curves 99 T T T T T T T o Co o NI 96 95 94 Conversion Efficiency 90 93 921 i i 0 200 400 600 800 1000 1200 1400 1600 1800 Charging Power W 7 N SES NE END 4 Solar MPPT Voltage 66V 98V 115V System Voltage 48V 48V Conversion Efficiency Curves 99 T T T T T T T o Conversion Efficiency 90 o co co wo B al o N o do i 00 1600 1800 2000 2200 2400 600 800 1000 1200 14 Charging Power W o o o N o B o o 46 Test model IT6415ND 1 Solar MPPT Voltage 17V 34V 68V System Voltage 12V 12V Conversion Efficiency Curves 98 l oo o o o o Co o N A O C
11. 5mm 35mm 35mm Mounting Hole 010 Environmental Parameters iii LCD Temp 20 C 70 C Ambient Temp 25 C 55 Storage Temp 30 C 85 C Humidity 95 N C Enclosure IP20 40 Protection Solar input short protection Solar input reversed polaritv protection Solar input reverse current protect at night Batterv reversed polaritv protection Batterv over voltage disconnect protection Batterv over voltage reconnect protection Batterv over temperature disconnect protection Load short disconnect protection Load overload disconnect protection Controller over temperature disconnect protection Abbreviation HVD High voltage disconnect LVD Low voltage disconnect OVT over temperature UVW Under voltage warning 4l 9 0 Conversion Efficiency Curves Test model IT3415ND 1 Solar MPPT Voltage 66V 98V 115V System Voltage 12V 12V Conversion Efficiency Curves i 50 100 150 200 250 300 350 400 Charging Power W 2 Solar MPPT Voltage 33V 66V 98V 115V System Voltage 24V 42 24V Conversion Efficiency Curves ej o B oO Go Conversion Efficiency co al o N 91 l l l dir 200 300 400 500 600 700 800 Charging Power W 3 Solar MPPT Voltage 66V 98V 115V Svstem Voltage 36V 36V Conversion Efficiencv Curves 99 T T T T T T o o o o al o N Co Conversion Efficiency o B o Go a ti iii 00 20
12. Batt Curr 2 2A Batt Day Max Consumed Energy 13 5V 1 1kWh D Batt Day Min Load Power 11 7V 30 5W Batt State Charge State Generated Energy Normal Float 1 5kWh D Batt SOC PV Volt PV Power 51 25 4V 85 5W Press OK to enter the monitoring interface when the inverse cursor point to monitor item 21 The parameters in monitoring interface are onlv for browse Press 1 LI button to browse the parameters interfaces in turns There are 5 battery status Normal UVW Under voltage warning LVD Low voltage disconnect Over Voltage Over Temperature and 4 charging stages no charging equalized boost float The load status has only ON or OFF status gt Log Info There are two items of log record as shown blew lt 1 gt Work Log Work Log Query No 1 79 sui From 2012 01 01 2012 01 01 00 00 lt 2 gt r arm Log K To 2012 06 08 Batt Volt 13 3V Total 79 Batt Cur 0 0A lt 1 gt Work Log Alarm Log Query No 1 10 GT From 2012 01 01 Batt OVD Begin To 2012 06 08 2012 01 04 14 20 Total 10 Para 17 20V Press OK to enter the monitoring interface when the inverse cursor point to monitor item Press ESC button to exit Work Log and Alarm Log could be browsed in this interface the operation is as follows Press OK to enter the Work Log or Alarm Log interface respectively when the item
13. NOTE Equipment damage IS Over charging and excessive gas precipitation mav damage the batterv plates and activate material shedding on them Too high and equalizing charge or for too long mav cause damage Please carefullv review the specific requirements of the batterv used in the svstem Certain tvpes of batteries benefit from periodic equalizing charge which can stir the 18 electrolvte balance batterv voltage and complete chemical reaction Equalizing charge increases the batterv voltage higher than the standard complement voltage which gasifies the battery electrolyte The controller will equalize the battery on 28 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 When the sunshine is weak and Charging current is less than 1 5Amps the controller couldn t fully follow the maximum power tracking Therefore don t evaluate in that condition 43 LED Indication Charging LED Indicator Status Green Blink Charging Green OFF No charging a Battery LED Indicator Status Green ON Normal Green slow blink Full Orange ON Under voltage warning Red ON Low voltage disconnect Red Blink Battery over temperature Green fast blink Hi
14. attery Polarity Reversed Fully protection against PV or and Battery reverse polarity no damage to the controller will result Correct the miswire to resume normal operation Over Temperature Protection If the temperature of the controller heat sinks exceeds 85 C the controller will automatically start the overheating protection and recover below 75 C e Load Over Load If the load current exceeds the maximum load current rating 1 05 times the controller will disconnect the load Overloading must be cleared up through reducing the load and then press the button Load Short Circuit Fully protected against load wiring short circuit Once the load short the load short protection will start automatically After five automatic load reconnect attempt the fault must be cleared by restarting controller or pressing the button A NOTE Overload fault and load short fault will be cleared every day so 33 the faults which aren t caused bv hardware can be solved intelligentiv 5 2 Troubleshooting O Charging LED indicator off during daytime when sunshine falls on solar modules properly Solution Confirm that PV and battery wire connections are correct and tight O Battery LED indicator green fast blink and LCD displaying OVD Probable Cause Battery voltage is larger than over voltage disconnect voltage OVD Solution Check if battery voltage too high and disconnect solar modules gt Fau
15. controller will begin charging If the battery LED error exists or LCD interface alarms refer to section 5 0 for troubleshooting WARNING Disconnect the battery will produce interference to the load when the controller is work at charging WARNING Don t do the battery reversed polarity test within 10 minutes after power off 14 4 0 Operation 4 1 MPPT Technologv The iTracer utilizes Maximum Power Point Tracking technology to extract maximum power from the solar array The tracking algorithm is fully automatic and does not require user adjustment iTracer technology will track the array maximum power point voltage Vmp as it varies with weather conditions ensuring that maximum power is harvested from the array through the course of the day Current Boost In many cases iTracer MPPT technology will boost the solar charge current For example a system may have 8 Amps of solar current flowing into the iTracer and 10 Amps of charge current flowing out to the battery The iTracer does not create current Rest assured that the power into the iTracer is the same as the power out of the iTracer Since power is the product of voltage and current Voltsx Amps the following is true 1 Power Into the iTracer Power Out of the iTracer 2 Volts InxAmps In Volts OutxAmps Out Assuming 100 efficiency Actually the losses in wiring and conversion exist If the solar module s Vmp is greater than the batter
16. cts for a period of TWO 2 years from the date of shipment to the original end user e Claim Procedure Before requesting warrantv 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 If the products failure is caused by customers misuse or not following the manual It won t be responsible for the free maintenance We will ask for the raw material cost And please refer to above procedure 39 8 0 Specifications Electrical Parameters Nominal Svstem Voltage Nominal Batterv Current Maximum Solar Input Voltage Batterv Voltage Range Maximum Input Power 12V 24V 36V 48V Self Consumption Grounding Mechanical Parameters IT3415ND T4415ND IT6415ND 12Vdc 24Vdc 36Vdc 48Vdc Auto 30A 45A 60A 150Vdc 8 72Vdc 400W 600W 800W 800W 1200W 1600W 1200W 1800W 2400W 1600W 2400W 3200W 1 4 2 2W Common Negative Grounding IT3415ND IT4415ND IT6415ND LxWxH L 358mm 382mm 440mm W 219mm 231mm 231mm H 102mm 107mm 110mm Net Weight 3 7kg 4 6kg 5 9kg Terminal 2
17. d power system loads The greater the difference between battery voltage and the Vmp of the module the more energy is wasted iTracer MPPT technology will always operate at the Vmp resulting in less wasted energy compared to traditional controllers Conditions That Limits the Effectiveness of MPPT The Vmp of a solar module decreases as the temperature of the module increases In very hot weather the Vmp may be close or even less than battery voltage In this 16 situation there will be verv little or no MPPT gain compared to traditional controllers However svstems with modules of higher nominal voltage than the batterv bank will alwavs have an arrav Vmp greater than batterv voltage Additionallv the savings in wiring due to reduced solar current make MPPT worthwhile even in hot climates 4 2 Batterv Charging Information The iTracer has a 4 stages batterv charging algorithm for rapid efficient and safe batterv charging Figura4 2 iTracer charging algorithm Bulk Charge In this stage the battery voltage has not yet reached boost voltage and 100 of available solar power is used to recharge the battery Boost Charge When the battery has recharged to the Boost voltage setpoint constant voltage regulation is used to prevent heating and excessive battery gassing The Boost stage remains for some time and then goes to Float Charge Every time when the controller is powered on if it detects neither over discharged nor
18. d manually load can be output If the battery OFF power is enough and the controller works well load will keep open 25 Light On Off Load control mode can be set Manual Light On Off to light control in this On 05 0V TIOM interface Parameters in the Light On Timer Off 06 0V T 10M table below Time Parameter Detail When solar module voltage goes below the point of NTTV Night Time Night Time Threshold Threshold Voltage the solar controller will recognize the starting voltage Voltage and turn on the load after pre set time delay when the battery power is enough and the controller works well When solar module voltage goes above the point of DTTV Day Time Day Time Threshold Threshold Voltage the solar controller will recognize the starting voltage Voltage and turn off the load after pre set time delay Solar energy confirms delay time If the solar energy meets the condition Delay time to the action it will be execute The range of delay time value is 0 to 99 minutes 26 Light On Timer Manual Light On Timer Light On Timer Light On Off On 05 0V TIOm OnTI 01H 00M Ligh Ont Tine Off 06 0V T10m OnT2 01H 00M Time NightTime 12 00 Load control mode can be set to light time control in this interface Parameters in the table below Parameter Detail Working Time 1 The open time of load in the light mode after dusk Wo
19. dministrator password 111111 as default See the specific instructions related software user guide Software interfaces are shown below Spaten E View Communication Parameter Monitoring i Maintenance Help OO SSBEBMEO ee in Explorer co S COM Doesn t exsist or not Energy 2 Istervalto io omera 0 Station Name ID jevice State Array State Charging State Load State lt gt 2013 12 18 17 54 00 Selar Station Monitor Start up Figure6 1 Globe Monitoring 36 EPSolar Administrator Spaten E VievQ Communicationil Parameter Monitoring Maintenance K Help QD Si 88 BAO E BB Station Explorer cons i COM Doesn t exsist or not Station Nane m Interval Bi Array Information Battery Information DC Load Information Controller Information Array Current A Battery Voltage V Battery Current A Load Current A G O E E Device Temp C i Array Voltage V Max Voltage V Min Voltage V Load Voltage V G BI B State l Array Power W Battery Temp T Battery SOC I 4 L a Load Control B Working State g Charging State g Battery State Load State Manual Energy Generated kWh Real Time Curve Daily Da Voltage Real Time Curve V Monthly Annual ow Power Total Energy Consumed kWh Daily Monthly Annual Total 2013 12 18 17 54 00 Selar Station Monitor Start up Figure6 2 Real Time Mo
20. e 29 2V Boost Charge 28 8V Float Charge 27 6V Boost Rect Volt 26 4V Low Volt Rect 25 2V You should input the user password see above before setting the parameters In setting mode all the parameters can be modified And will immediately effect when saved The detail and value range of control parameter are shown in the tables below Battery Charging Setting Battery Type Note Sealed default Constant value GEL Constant value flooded Constant value User Defined by user 29 Batterv Charging Mode Charging Mode Note Voltage Compensate Controlled bv voltage default SOC SOC mode controlled bv SOC charging or discharging value Others Parameter Default value Range Batterv capacitv 200Ah 1 9999Ah Temperature compensate 3mV C 2V 9 0mV coefficient Rated system voltage Auto Auto 12V 24V 36V 48V Precent of charging 100 100 constant value SOC charging mode Precent of discharging 30 10 80 SOC charging mode Battery Control Parameters All the coefficient is referred to 25 C and twice in 24v system rate triple in 36v system rate and quadruple in 48v system rate Battery Type Gel Sealed Flooded User High Volt Disconnect 16V 16V 16V 9 17V Charging limit voltage 15V 15V 15V 9 17V Over Voltage Reconnect 15V 15V 15V 9 17V Equalization voltage 14 6V 4 8V 9 17V Boost voltage 14 2V
21. e protection Have fresh water available to wash and clean anv contact with batterv acid Use insulated tools and avoids placing metal objects near the batteries Explosive battery gases 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 Ventilation is highly recommended if mounted in an enclosure Never install the iTracer in a sealed enclosure with flooded batteries Battery fumes from vented batteries will corrode and destroy the iTracer circuits 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 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 svstem cables according to 3A mm or less current densit
22. evice Parameter There are 3 interfaces about device parameter as shown blew Local ID Backlight Time T03 0001 60 s Storage Interval 10min Press OK to enter the Device Parameter interface when the inverse cursor point to Device Paral item Press ESC button to exit You should input the user password see above before setting the parameters The first interface shows the 4 digit controller s ID in networking and keeps the ID number unique in the networking or PC software or other device s couldn t search it The 2 interface shows the backlight time The range is from 1 to 90 seconds 60seconds default means that the backlight is never off The interval log is from 1 to 30 minutes 10minutes default 24 gt Load Mode Press OK to enter the Load Mode interface when the inverse cursor points to Load Mode item Press ESC button to exit Load Mode can be set through each menu item respectively Manual default the default load output can be Y Manual Manuali Control set ON OFF in this interface Light On Off ON Parameters in the table below Light On Timer Time Parameter Detail The load will open automatically after the controller is ON initialized If the battery power is enough and the controller works well load will keep open The load will keep off after the controller is initialized Only when open loa
23. gh volt disconnect N Fault LED 19 Indicator Status Red OFF Normal Red Blink Current abnormal Overload load short Indicator Fault Status Blink Batterv LED in Red Work voltage error Blink Batterv LED in Orange Controller over temperature 4 4 LCD Display amp Operation Initialization Ffficient Power LCD will paint the picture as shown on the left as soon aX SOLAR as it is powered on It indicates that initialization is normal when the interface goes automatically to the Rated Info interface gt Rated Info Rated Para Rated info of the controller will be displayed Monitor Rat Volt Chrg Cur interface will be switched after 3 seconds 48 0V 60 0A Disc Curr 60 0A gt Main Menu Click ESC button to return main menu in any monitoring interface There are 9 interfaces for monitoring as shown in the below picture 20 Press 1 LI button to move inverse cursor among 9 menus Press OK to enter corresponding interface 5 Load Set 9 Dev Msg 2 Log Info 6 Control Para gt 3 Clock Set 7 Sys Password 4 Local Para Set 8 Default Set gt Monitor There are 11 interfaces for monitoring as shown below 7 E Load State Load Volt Batt Temp ES ON 12 4V 21 C 104 ZOV 104 Local Temp Load Cur Temp Coefficient jan TOUTE amp 25 5 C 2 2A 3mV C 2V Total Generated 7 50kWh Total Consumed 5 50kWh Batt Volt 12 4V
24. iTracer Series Maximum Power Point Tracking Solar Charge Controller OPERATION MANUAL Thank you very much for selecting our product This manual offers important information and suggestion about installation use and troubleshooting etc Please read this manual carefully before using the product and pay attention to the safety recommendations in it ITracer Series Maximum Power Point Tracking Solar Charge Controller Models IT3415ND IT4415ND IT6415ND Contents 1 0 Important Safety Information 1 2 0 G n ral Informati n eiii 2 2 1 OVELVIEW iii 2 2 2 Models amp Parameters iis iese tie ie Bees ciedad 3 2 3 Characteristics ses EE Ee Es EL shale is 4 ZA Optional Accessories licia e a 7 3 0 Installation Instructions 8 3 1 General Installation Notes 8 3 2 A OE EE AE EE 9 33 AO a EE 10 4 0 Operation res 14 4 1 MPPT Techn6lOpy ee 14 4 2 Battery Charging Information 4 3 LEDUndiCationf MA MB MA OR A 4 4 LCD Display amp Operation ii 19 5 0 Protections Troubleshooting amp Maintenance 30 Sel Protections N NO RO ie 30 5 2 Troubleshooting eiii M EE ernia 31 5 3 Maintenance 32 6 0 Other instructions ss vissies TE 33 6 1 PC Software EE OR EE HON EE 33 EE EE N N 36 8 0 Specifications 37 9 0 Conversion Efficiency Curvesl iii 39
25. lt LED indicator blink LCD displaying Current Err Probable Cause Charging current in three phases is unbalanced Solution Disconnect solar modules and restart the iTracer if the fault still exists please contact the supplier to make maintenance gt Fault LED indicator blink LCD displaying Over Volt Probable Cause solar modular output is too high Solution Check solar component parameters matching the controller will disconnect the input if the voltage is over 150v and will Recovery below 145v gt Fault LED indicator blink LCD displaying Over Temp Probable Cause Heat sinks operational temperature is quite high to 85 C or above Solution The controller will automatically stop working When the temperature is below 75 C the controller will resu k O Cannot connect to the controller via RS 485 or RS 232 Probable Cause RS 485 serial baud rate setting error or serial USB adapter incorrect configuration Solution Check serial baud rate is set to 115200bps or not and choose the right COM port If using a serial USB adapter verify that the adapter software is installed and a serial COM port has been mapped 34 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
26. mpanv custom protocol 13 Solar Positive Terminal O Power connection for Solar Positive Terminal B 14 Solar Negative Terminal Power connection for Solar Negative terminal A 15 Load Negative Terminal Power connection for Load Negative terminal 16 Battery Negative Terminal Power connection for Battery Negative terminal 17 Battery Positive Terminal O Power connection for Battery Positive Terminal 18 Load Positive Terminal O Load connection for Load Positive Terminal 2 4 Accessories Remote Temperature Sensor Model RTS300R10KS 08A Acquiring of battery temperature for undertaking temperature compensation of control parameters the standard length of the cable is 3m length can be customized The RTS300R10K5 08A connects to the MC1 5 5 08 2L port 10 on the controller Note unplug the RTS the temperature of battery will be set to a fixed value 25 C USB To RS 485 converter Model CC USB RS485 150U 3 81 the USB To RS 485 converter is used to monitor each controller on the network using Station PC software and update the firmware The length of cable is 1 5m The CC USB RS485 150U 3 81 connects to the MC1 5 5 08 2L port 8 on the controller 3 0 Installation Instructions 3 1 General Installation Notes Read through the entire installation section first before beginning installation Be verv careful when working with batteries Wear ev
27. ng communication cables and make sure the cables are connected firmly during data transmitting the below features are supported with communication interface 1 Monitor each controller on the network using Station PC software update the firmware 2 Communicate with other module s made by EPsolar company with CAN bus e RS 232 RS 485 Connection The series port on iTracer controller is a standard 3 81 4P port See figure 2 1 for the port location The RS 232 port is 7 port and the RS 485 port is 8 port on the controller e CAN connection The CAN bus port is a standard MC1 5 3 81 4L connector Refer to 12 port on the controller in the figure 2 1 12 Step 4 Connect the Power Wires CAUTION Risk of electric shockl Use fuses or breakers in solar load and batterv circuits is recommended and make them keep OFF state before connection WARNING Risk of electric shockl Exercise caution when handling solar 100 Vdc when in sunlight Pay more attention for it WARNING Risk of explosion or fire Never short circuit battery A wiring The solar PV array can produce open circuit voltages in excess of Positive and negative or cables Pay more attention for it Battery Connection Connecting a fuse in series through battery positive in the circuit and the battery circuit fuse must be 1 25 to 2 times of the rated current Keep OFF before connection Connect battery positive and negative to battery terminals on the c
28. nitoring 37 Station Name os Device ID Rated Voltage V Rated Load Current A Rated Charging Current A Default Current Default Current Battery Type Sealed Rated Voltage Level Self recogn _ Charging Mode Volt Comp Boost Duration m 120 Battery Capaci ty Ah 200 Equilibrium Duration m 120 Temp Compensation Coefficient mV 2V Over Volt Disconnect Volt W 16 00 II Charging Limit Voltage 15 00 Over Volt Reconnect Volt V 15 00 Discharging Limit Volt M 10 60 FEE I fone Equilibrium Charging Volt 0 j14 60 Low Volt Disconnect Volt W 111 10 Boost Charging Volt Y 14 40 Low Volt Reconnect Volt Y 12 60 Float Cherging Volt V 13 80 Under Vol Warning Volt N 12 00 Boost Recon Charg Volt MI 13 20 Under Volt Warn Reco Volt OF fiz 20 Battery Charge 8 100 Battery Dischage 36 Restore Default Export Settings Station Name vr Device ID Load Control Mode 9 Manually On By Default Manually Off By Default Timing Control Turn Dn Timel ll Turn 0ff Timel C Turnin Time2 17 16 39 il Turn 0ff Time Light On Turn On Volt V 5 00 Delay m Turn 0f Volt 6 00 Delay Light On Time Work Time Work Time2 Night Time th Read Update Figure6 4 Load Configuration 38 7 0 Warrantv The iTracer charge controller is warranted to be free from defe
29. nter to restore the default interface Under the main menu interface when the inverse cursor Default Set No Yes Clr Log Record to enter to restore the default interface and clear all logs points to restore the default option press the OK button MEE clear including work log and event log Note all parameters will be set to factory default and couldn t be recovery gt Device Message Under the main menu interface when the inverse cursor to the Dev Msg press the OK button to enter to Device Info interface ARM Msg DSP Msg Type IT6415ND Type IT6415ND Ver v01 00 v02 60 Ver v01 00 v02 60 SN 0420131210000001 SN 0420131210000001 The Model software and hardware version and SN number are shown in this 31 interface 32 5 0 Protections Troubleshooting amp Maintenance 5 1 Protections e PV Short Circuit When PV short circuit occurs the controller will stop charging Clear it to resume normal operation e PV Over Voltage If PV voltage is larger than maximum input open voltage 150V PV will remain disconnected and warning until the voltage falls safely below 145V PV voltage cannot be too high otherwise it may damage the controller please verify the PV parameter e PV Over Current The iTracer controller will limit battery current to the Maximum Battrery Current rating An over sized solar array will not operate at peak power e PV or and B
30. ommunication signal transmission NOTE The iTracer is a negative ground controller Anv negative connection of solar load or batterv can be earth grounded as required CAUTION For mobile applications be verv certain that all wirings are connected securelv Use cable clamps to prevent cables from swaving when the vehicle is in motion Unsecured cables create loose and resistive connections which mav lead to excessive heating and or fire Step 1 Remote Temperature Sensor Connection RTS300R10K5 08A gt CAUTION The controller will perform temperature compensation for charging parameters according to the device temperature inside a battery Both the RTS300R10K5 08A and the battery will be CAUTION Equipment Damage Never place the temperature sensor damaged The included remote temperature sensor RTS300R10K5 08A is recommended for effective temperature compensated charging Connect the RTS300R10K5 08A to the10 port MC1 5 5 08 2L on the controller see figure 2 1 The cable standard length is 3 meters and could be customized There is no polarity so either wire or can be connected to either screw terminal No damage will result if connect the RTS300R10K5 08A to the remote battery voltage sense port but the connection will not be recognized Step 2 Remote Battery Voltage Sensor Connection NOTE When connecting Remote Battery Voltage Sensor please pay attention to and see figure 2 1 CAUTION Be caref
31. ontroller in the figure 2 1 Please pay much attention to and Solar Module s Connection Connecting a breaker in series in the solar circuit is recommended and the breaker must be 1 25 to 2 times of the rated current Keep OFF before connection Connect solar positive and negative to solar terminals on the controller in the figure 2 1 Please pay much attention to and Solar array short circuit protection and the reversed polarity connection will trigger automatically Load Connection Connecting a breaker in series in the load circuit is recommended and the breaker must be 1 25 to 2 times of the rated current Make it keep OFF state before connection Connect load positive to 18 port and negative to 15 port on the controller in TER the figure 2 1 Please pay much attention to and confirm the cable is connected tightly and right Load short circuit protection and the reversed polarity connection will trigger automatically 13 Step 5 Power Up NOTE The controller is only powered by battery so it will not work when FS only connecting to solar input Confirm that all connections are correct especially the Solar Battery and load polarities Turn the battery disconnect switch on first Observe that the LED s indicate a successful start up refer to section 4 0 Turn the solar disconnect on If the solar array is in full sunlight the charging LED will blink and the
32. onversion Efficiency 90 Oo o B 7 i i 0 100 200 300 400 500 600 700 800 900 Charging Power W 2 Solar MPPT Voltage 34V 68V 115V System Voltage 24V 24V Conversion Efficiency Curves 100 T T T 98 96 94 92 Conversion Efficiency 90 90 88 0 200 400 600 800 1000 1200 1400 1600 Charging Power W 47 3 Solar MPPT Voltage 68V 115V Svstem Voltage 36V 36V Conversion Efficiencv Curves 98 T T T T T T T T 96 94h 92 90 88 Conversion Efficiency 86 84 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 Charging Power W 4 Solar MPPT Voltage 68V 115V System Voltage 48V 48V Conversion Efficiency Curves 100 I T T 98 96 94 92 Conversion Efficiency 90 88 0 300 600 900 1200 1500 1800 2100 2400 2700 3000 3300 Charging Power W ar eee i DE 48 10 0 Dimensions IT3415ND Dimensions Unit mm 49 IT4415ND Dimensions Unit mm Hi l
33. rking Time 2 The open time of load in the light mode before dawn The controller calculated the total length of the night bv self learning Night time The time should be more than 3 hours working time 1 yiz vil Light ON Light OFF working time 2 EE Al vy Light ON Light OFF Night Time A a M Mi Dusk Dawn 27 Time Manual Time Control 1 Time Control 2 Light On Off On Time 19 00 On Time 05 00 Light OntTimer Off Time 02 00 Off Time 06 00 Time Single Double Load control mode can be set to time control in this interface Parameters in the table below Parameter Detail Time Control 1 Set the begin and end time 1 of the load output Time Control 2 Set the begin and end time 2of the load output Single The load output according to timel Double The load output according to timel and time2 28 gt Control Parameter Press OK to enter the Device Parameter interface when the inverse cursor point to Control Para item Press IESC button to exit There are 10 interfaces for Control Parameters as shown below Temp Coefficient 3mV C 2V Rated Volt AUTO Batt Manag Char SOC 100 Disc SOC 30 Vol Com SOC Equalize Time 60 min Boost Time 60 min Low Volt Disc 22 2V Discharge Limit 21 6V Over Volt Disc 32 0V Charge Limit 30 0V Under Volt Rect 24 4V Under Volt Warn 24 0V Over Volt Rect 31 0V Equalize Charg
34. ul when installation Please never plug the voltage sensor wires into to the RTS300R10K5 08A terminals 10 Port This will PA cause an alarm or damage the controller The voltage at the battery terminals on the controller may differ slightly from the real battery voltage due to connection and cable resistance The remote battery voltage 11 sensor will enable the controller to detect the battery voltage more exactly and avoid voltage deviation The battery voltage sensor connection is not required to operate the controller but it is recommended for the best performance The voltage sensor wires should be cut into the length as required The wire size can range from 0 25 to 1 0 mm 24 to 16 AWG Maximum length is 3m Connect the remote battery voltage sensor wires to the 11 port MC1 5 5 08 2L on the controller see figure 2 1 A twin cord cable is recommended but not required Please be careful to and when connecting No damage will result if the polarity is reversed but the controller can t read a reversed sensor voltage Plugging the voltage sensor wires into to the RTS300R10K5 08A terminals 10 Port will cause an alarm or damage the controller Step 3 Communicate Connection WARNING Shock Hazard Should not be any communication cables and power lines intertwined Separate them as far as possible to void electric shock There are three kinds of communication RS 232 RS 485 and CAN BUS Please use matchi
35. v 3 2 Mounting NOTE The iTracer controller requires at least 150mm of clearance above FS and below for proper air flow Ventilation is highly recommended if mounted in an enclosure WARNING Risk of explosioni Never install the iTracer in a sealed enclose with flooded batteries Do not install in a confined area where batterv gas can accumulate Stepl Choose a Mounting Location Place the iTracer controller on a vertical surface protected from direct sunlight high temperatures and water Step2 Check for Clearance Place the iTracer in the location where it will be mounted Verifv sufficient room to run wires and sufficient room above and below the controller for air flow Step3 Mark Holes es LI I 11 WARM AIR t AT LEAST COOL AIR 150mm FITITITITITITT Figure3 1 Required mounting clearance for air Mark the four 4 mounting hole locations on the mounting surface Step 4 Drill Holes Remove the controller and drill four sizeable holes at the marked locations Step 5 Secure the 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 3 Wiring y y NOTE A recommended connection order has been provided for maximum safety during installation NOTE Do not entangle all wiring together Communication cable and power wires should be as far as possible to avoid interfering 10 c
36. y voltage it follows that the battery current must be proportionally greater than the solar input current so that input and output power are balanced The greater the difference between the maximum power voltage and battery voltage the greater the current boost Current boost can be substantial in systems where the solar array is of a higher nominal voltage than the battery An Advantage Over Traditional Controllers Traditional controllers connect the solar module directly to the battery when 15 recharging This requires that the solar module operate in a voltage range that is below the module s Vmp In a 12V system for example the battery voltage may range from 11 to 15Vdc but the module s Vmp is typically around 16 or 17V Figure 4 1 shows a typical current VS voltage output curve for a nominal 12V off grid module Current vs Voltage in 12V system Output power in 12V system Re Typical Battery N mum age dinge fore TT Point A ti ec Trad z PA i ee ce Operating Range ce 3 U 10 1517 VOLTAGE i 10 1517 VOLTAGE Figure 4 1 Nominal 12V solar module l V curve and output power graph The array Vmp is the voltage where the product of current and voltage Ampsx Volts is greatest which falls on the knee of the solar module l V curve as shown in Figure4 1 Because Traditional controllers do not operate at the Vmp of the solar modules s energy is wasted that could otherwise be used to charge the battery an
Download Pdf Manuals
Related Search