Tracer-BN Series
Contents
1. nun den aib EN nanah 5 Protections Troubleshooting and Maintenance UN nM 52 Troublesh otnp octo cen rino ineo aa 1 Important Safety Information Save These Instructions This manual contains important safety installation and operating instructions for Tracer BN Series controller The following symbols are used throughout this manual to indicate potentially dangerous conditions or mark important safety instructions Please take care when meeting these symbols WARNING Indicates a potentially dangerous condition Use extreme caution when performing this task CAUTION Indicates a eritical procedure for safe and proper operation of the controller NOTE Indicates a procedure or function that is important for the safe and proper operation of the controller gt General Safety Information Read all of the instructions and cautions in the manual before beginning installation There are no user serviceable parts inside the Tracer BN series Do not disassemble or attempt to repair the controller Disconnect the solar module and fuse breakers near to battery before installing or adjusting the Tracer BN series Install external fuses breakers as required not allow water to enter the controller Confirm that power connections are tightened to avoid excessive heating from loose 2 General Information 2 1 Overview Thank you2. 3 2V 13 2 13 2V 9 17V Voltage Low Voltage Reconnect 2 6V 12 6V 12 6V 9 17V Voltage Under Voltage Warning 2 2V 12 2V 12 2V 9 17V Reconnect Voltage Under Volt Warning Volt 2 0V 12 0V 12 0V 9 17V Low Volt Disconnect Volt 1 1V 11 1V 11 1V 9 17V Discharging Limit Voltage 0 6V 10 6V 10 6V 9 17V Equalize Duration 2 hrs 2 hrs 0 3 hrs Boost Duration 2 hrs 2 hrs 2 hrs 0 3 hrs Notes User type is the user defined battery type The default value is the same as sealed type When modify it please follow the below logistic relation 27 a Over Voltage Disconnect Voltage gt Charging Limit Voltage gt Equalize Charging Voltage gt Boost Charging Voltage gt Float Charging Voltage gt Boost Reconnect Charging Voltage b Over Voltage Disconnect Voltage gt Over Voltage Reconnect Voltage c Low Voltage Reconnect Voltage gt Low Voltage Disconnect Voltage gt Discharging Limit Voltage d Under Voltage Warning Reconnect Voltage gt Under Voltage Warning Voltage gt Discharging Limit Voltage e Boost Reconnect Charging voltage gt Low Voltage Disconnect Voltage 28 Environmental Parameters Table 7 3 Environmental Parameter Ambient temperature range 35 Cto 55 C Storage temperature range 35 C to 80 C Humidity range S95 NC Enclosure IP30 Altitude lt 3000 m Mechanical Parameters Tracer1215BN Table 7 4 Mechan
3. Tracer2215BN Illumination Intensity 1000W m Temp 25 C 12V Conversion Efficiency Curves 98 T T Conversion Efficiency 96 92 50 100 150 200 250 Charging Power W 1 Solar Module MPP Voltage 16 5V 33V 66V Nominal System Voltage 12V 2 Solar Module MPP Voltage 33V 66V 98V Nominal System Voltage 24V 24V Conversion Efficiency Curves 300 350 400 Charging Power W 250 200 uoisisAuoD Tracer3215BN Illumination Intensity 1000W m Temp 25 12V Conversion Efficiency Curves Conversion Efficiency gt a D w 91 1 1 H i 1 H 0 50 100 150 200 250 300 350 400 Charging Power W i Solar Module MPP Voltage 16 5V 33V 66V Nominal System Voltage 12V 2 Solar Module MPP Voltage 33V 66V 98V Nominal System Voltage 24V 24V Conversion Efficiency Curves 100 1 Conversion Efficiency 88 1 1 1 0 100 200 300 400 500 Charging Power W 1 600 700 800 Tracer4215BN Illumination Intensity 1000W m Temp 25 C 12V Conversion Efficiency Curves 98 97r T Conversion Efficiency L3 93r 92 80 100 150 200 250 300 350 400 450 500 550 Charging Power W Solar Module MPP Voltage 16 5V 33 66V Nominal System Voltage 12V 2 Solar Module MPP Voltage 33V 66V 98V Nominal System Voltage 24
4. for selecting the Tracer BN series controller which represents advanced technology of our company The features are listed below 12V 24V automatic identify or user defined working voltage Excellent heat dissipation Using the integration of cast aluminum radiator shell the controller can be natural cooling Advanced maximum power point tracking technology to optimize using the solar system Peak conversion efficiency is as high as 98 Lock the MP point fast and the controller provides the industry s highest tracking efficiency of 99 Widely used automatic recognize day or night Several load methods are supported to convenient for different demand Support 4 charging options Sealed Gel Flooded and User defined Adopting temperature compensation and correcting the charging and discharging parameters automatically improving the battery lifetime Protection over temperature over charging PV and load short PV battery revered over current protection Actual power convenient and record function makes convenience to check the datum every day every month and every year RS 485 ports via the open standard Modbus protocol are supported to meet different occasion of demand With supporting PC monitoring software and remote meter MT50 it is convenient to check the real time data of controllers and set the parameters Support firmware update The Tracer BN series controller is for off grid solar sy
5. modules 7 Battery Terminals Connect batteries 8 Load Terminals Connect loads 9 RS 485 Port RJ45 interface Connect with PC or MTSO to monitor or update firmware 2 2 Optional Accessories 1 Remote Temperature Sensor Model RTS300R47K3 81A Acquiring of battery temperature for undertaking temperature compensation of control parameters the standard length of the cable is 3m length can be customized The RTS300R47K3 81A connects to the port Sth on the controller Note unplug the RTS the temperature of battery will be set to a fixed value 25 C 2 Remote Meter Model 50 The digital remote meter displays system operating information error indications and self diagnostics Information displayed on a backlit LCD display is easy to read and large buttons make navigating the meter menus easy The meter can be flush mounted in a wall or frame The 50 standard edition is supplied with one 2 meter long cable The MT50 connects the Tracer BN series with the RJ45 interface 3 Super Parameter Programmer Model SPP 01 The SPP 01 can realize one key setting operation which is suitable for bulk quantity products setting in the projects 4 USB To RS 485 converter Model CC USB RS485 150U 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 connects to theRS 485 Port 9th on the co
6. to a suitable battery or reset the working voltage Remove all faults and click the button to resume to work No output load terminals Over load or Short circuit Remove or reducin the load and click the button the controller will resume to work after 3 seconds FF 5 3 Maintenance voltage to activate the controller NOTE If all the led are off please check the voltage of battery At least 9V NOTE If the charging led is steady off without miswire check the PV input voltage which should be higher than battery s The following inspections and maintenance tasks are recommended at least two times per year for best performance Check that the controller is securely mounted in a clean and dry environment Check that the air flow and ventilation around the controller is not blocked Clear all dirt or fragments on the heat sink 21 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 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 corrosi
7. Tracer BN Series Maximum Power Point Tracking Solar Charge Controller INSTRUCTION MANUAL Thank you very much for selecting our product This manual offers important information and suggestions with respect to installation use and troubleshooting etc Please read this manual carefully before using the product and pay attention to the safety recommendations in it Tracer BN Series Maximum Power Point Tracking Solar Charge Controller Tracer Model Tracer1215BN Tracer2215BN Tracer3215BN Tracer4215BN 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 Contents 1 Important Safety Information 2 Genetal Informations isissssesessssesscsssasosssssescssesescesessavesessssasosssesevsesesessesebssseseosasaeessoeas 2 Over VIN ascen ento NIRE aa AN 2 2 Optional AGCGeSSOBIBS sae nana endi o Ga Io EDAN SN 3 Installation InStrUCtiONS oo o moo mooooooomisnien anne 3 1 General Installation Notes in bhn banana 3 2 Mountingf ss gt gt gt 4 Operation 09 98 B eene 4 1 MPPT TeGhnOlOgY on 4 2 Battery Charging Information 4 3 LBDIBGiICations DUREN BNN NA 4 4 Setting
8. V 24V Conversion Efficiency Curves 100 92r Conversion 90 88r 86 i i i i 0 100 200 300 400 500 600 700 800 900 1000 1100 Charging Power W Tracer1215BN Dimensions mm Tracer 2215BN Dimensions ET I 1 Tracer3215BN Dimensions mm maBAAaaal Tracer4215BN Dimensions mm
9. age 23 7 Technical Speeifications Electrical Parameters Table 7 1 Description Parameter Nominal system 12VDC 24VDC Auto voltage work Tracer1215BN 10 Tracer2215BN 20 Rated charge current Tracer3215BN 30A 4215 40A Tracer1215BN 10A Rated discharge Tracer2215BN 20 current Tracer3215BN 20 Tracer4215BN 20A Maximum battery 32V voltage Max solar input 150VDC voltage 24 input power Tracer1215BN 130W 12V 260W 24V Tracer2215BN 260W 12V 520W 24V Tracer3215BN 390W 12V 780W 24V Tracer4215BN 520W 12V 1040W 24V lt 50mA 12V Self consumption lt 27mA 24V Charge circuit lt 0 26V voltage drop Discharge circuit lt 0 15V voltage drop Temperature compensate 3mV C 2V default coefficient Communication RS485 RJ45 interface Battery Voltage Parameters parameters is in 12V system at 25 C please use double value in 24V Control Parameters Table 7 2 Battery charging setting Gel Sealed Flooded User Over Voltage Disconnect 16 0V 16 0V 16 0V 9 17V Voltage Charging Limit Voltage 15 0V 15 0V 15 0V 9 17V Over Voltage Reconnect 15 0V 15 0V 15 0V 9 17V Voltage Equalize Charging Voltage 14 6 14 8V 9 17V Boost Charging Voltage 42V 14 4V 14 6V 9 17V Float Charging Voltage 3 8V 13 8V 13 8V 9 17V Boost Reconnect Charging
10. 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 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 15Vde 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 10 Current VS Voltage in 12V system Output power in 12V system Tracer ical Maximum Typical Battery Maximum _ Power Moree spree Power Traditional p Point 5 rs Point Controller Operating Range CURRENT POWER 10 1517 VOLTAGE 10 1517 VOLTAGE Figure 4 1 Nominal 12V Solar Module I V curve and output power graph The array is the voltage where the product of current and voltage Amps Volts is greatest which falls on the knee of the solar module I 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 and power system loads The greater the difference between battery voltage and the Vmp of the module
11. ent the battery damaged from overcharging or over discharged 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 5 2 Troubleshooting Trouble Shooting Table 5 1 Faults Troubleshooting exc LED indicator o ont during daytime PV array Denn PV and when sunshine disconnectio A falls on PV n connections are modules correct and tight properly LE voltage Battery LED higher than en indicator green over voltage d en fast blink disconnect are voltage OV Mere Load is normal charging pr HE a will return to green orange voltage automatically when fully charged The controller cut off Battery low the output Battery LED voltage automatically LED indicator red disconnect indicator will return color to green automatically when fully charged 20 All the LED indicators blink battery orange indicator blink Too high temperature of controller When heat sink of the controller exceeds 85 U the controller wil automatically cut input and output circuit When the temperature below 75 C the controller will resume to work All the LED indicators blink red indicator blink System voltage error Check whether the battery voltage match with the controller working voltage Please change
12. ervoltage 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 Overcurrent The Tracer BN series controller will limit battery charging current to the Maximum Battery Current rating Therefore an over sized solar array will not operate at peak power Load Overload 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 restarting controller Load Short Circuit Fully protected against load wiring short circuit Once the load short more than guadruple rate current the load short protection will start automatically After five automatic load reconnect attempts the fault must be cleared by restarting controller Reverse Polarity Fully protection against PV reverse polarity no damage to the controller will result Correct the miswire to resume normal operation Battery Reverse Polarity Fully protection against battery reverse polarity no damage to the controller will result Correct the miswire to resume normal operation Damaged Remote Temperature Sensor If the temperature sensor short circuited or damaged the controller will be charging or 19 discharging at the default temperature 25 C to prev
13. ging stage Float Charge After the Boost voltage stage Tracer BN series will reduce the battery voltage to Float voltage setpoint When the battery is fully recharged there will be no more chemical reactions and all the charge current transmits into heat and gas at this time Then the Tracer BN series reduces the voltage to the floating stage charging with a smaller voltage and current It will reduce the temperature of battery and prevent the gassing also 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 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 12 maintain the battery at the Float setpoint Should the battery voltage remains below the boost reconnect charging voltage the controller will exit Float stage and return to Bulk charging Equalize A A A WARNING Risk of explosion Equalizing flooded battery can produce explosive gases so well ventilation of battery box is necessary CAUTION Equipment damage Equalization may increase battery voltage to the level damaging to sensitive DC loads Ensure that all load allowable input voltages are greater than the equalizing charging set point voltage CAUTION E
14. ible The suggested distance is within 150mm NOTE Unplug the RTS the temperature of battery will be set to a fixed value 25 C 4 4 1 MPPT Technology The Tracer BN series utilizes Maximum Power Point Tracking technology to extract maximum power from the solar module s The tracking algorithm is fully automatic and does not require user adjustment Tracer BN series 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 Tracer BN series MPPT technology will boost the solar charge current For example a system may have 8 Amps of solar current flowing into the Tracer BN series and 10 Amps of charge current flowing out to the battery The Tracer BN series does not create current Rest assured that the power into the Tracer BN series is the same as the power out of the Tracer BN series Since power is the product of voltage and current VoltsxAmps the following is true 1 Power Into the Tracer BN series Power Out of the Tracer BN series 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 battery voltage it follows that the battery current must be proportionally greater than the solar input current so that input and output power
15. ical Parameter 196mm x 117 8mm x Dimension 36mm Mounting Detail in dimensions dimension drawing Mounting hole size 4 7 Power cable 4mm Weight 0 9kg Mechanical Parameters Tracer2215BN Table 7 5 Mechanical Parameter 216 6mm x 142 6mm x Dimension 56mm Mounting Detail in dimensions dimension drawing Mounting hole size 04 7 Power cable 10mm Weight 1 5kg Mechanical Parameters Tracer3215BN Table 7 6 Mechanical Parameter 280 7mm x 159 7mm x Dimension 60mm Mounting Detail in dimensions dimension drawing Mounting hole size 04 7 Power cable 16mm 30 Weight 2 3kg Mechanical Parameters Tracer4215BN Table 7 7 Mechanical Parameter 302 5mm x 182 7mm x Dimension 63 5mm Mounting Detail in dimensions dimension drawing Mounting hole size 04 7 Power cable 25mm Weight 2 9kg 31 Power Conversion Efficiency Curve Tracer1215BN Illumination Intensity 1000W m Temp 25 C 12V Conversion Efficiency Curves Conversion Efficiency 6 zl i 1 2 40 60 80 100 120 140 Charging Power W 1 Solar Module MPP Voltage 16 5V 34V 66V Nominal System Voltage 12V 2 Solar Module MPP Voltage 34V 66V 98V Nominal System Voltage 24V 24V Conversion Efficiency Curves 100 T T T T Conversion Efficiency P 1 0 50 100 150 200 250 300 Charging Power W
16. link temperature All LED Indicators All LED indicators Table 4 3 Indicator Status Blink Battery LED in Red Work voltage error Blink Battery LED in Orange Controller over temperature 4 4 Setting Operation RJ45 RJ45 SPP RJ45 USB 3 RS485 to USB Three methods to configure the controller Remote meter MT50 MT100 Use standard twisted net cable model CC RS485 RS485 200U MT 2 Super parameter programmer SPP 01 Use standard twisted net cable model CC RS485 RS485 200U One key easily configure and apply to batch setting 3 PC monitoring setting software Solar Station Monitor Use USB to RS485 converter cable with model CC USB RS485 150U Controller Comm Port RJ45 RS485 PC Ethernet Port RJ45 Controller Comm Port RJ45 RS485 PC USB Port LE 17 WARNING Do not use the standard N twisted net cable to connect the device and PC net interface or the permanent damage will occur Load Set Mode 1 Manual Control default 2 Light ON Off 3 Light ON Timer 4 Time Control Battery Type 1 Gel 2 Sealed default 3 Flooded 4 User NOTE Please refer to user guide or contact with the sales for the detail of setting operation 5 Protections Troubleshooting and Maintenance 5 1 Protection PV Array Short Circuit When PV short circuit occurs the controller will stop charging Clear it to resume normal operation Ov
17. ntroller 3 Installation Instructions 3 1 General Installation Notes eBe very careful when working with batteries Wear eye protection Have fresh water available to wash and clean any contact with battery acid Uses insulated tools and avoid placing metal objects near the batteries Explosive battery gasses may be present during charging Be certain there is sufficient ventilation 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 Use with Sealed batteries only under the controller requires Battery connection may be wired to one battery or a bank of batteries The following instructions refer to a singular battery but it is implied that the battery connection can be made to either one battery or a group of batteries in a battery bank Select the system cables according to 3A mm current density 3 2 Mounting 12V or 24V 1 Connect components to the charge controller in the sequence as shown above and pay much attention to the Red and Black 2 After installation power the battery and check the battery indicator on the controller it will be green If it s not green please refer to chapter 5 3 The battery fuse should be installed as close to battery as poss
18. on 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 CAUTION Risk of electric shock Make sure all the power is turned off before above operations and then follow the corresponding inspections and operations 22 6 Warranty The Tracer BN Series charge controller is warranted to be free from defects for a period of TWO 2 years from the date of shipment to the original end user Claim Procedure Before requesting warranty 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 This Warranty Does Not Apply Under The Following Conditions 1 Damage by accident negligence abuse or improper use 2 PV or load current exceeding the ratings of product 3 Unauthorized product modification or attempted repair 4 Damaged occurring during shipment 5 Damage results from acts of nature such as lightning weather extremes 6 Irreclaimable mechanical dam
19. quipment 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 Certain types of batteries benefit from periodic equalizing charge which can stir the electrolyte balance battery voltage and complete chemical reaction Equalizing charge increases the battery voltage higher than the standard complement voltage which gasifies the battery electrolyte If it detects that the battery is being over discharged the solar controller will 13 automatically turn the battery to equalization charging stage and the equalization charging will be 120mins Equalizing charge and boost charge are not carried out constantly in a full charge process to avoid too much gas precipitation or overheating of battery 14 4 3 LED Indications Charging Indicator Battery Indicator e Charging Indicator Charging LED indicator Table4 1 Indicator Status Green blink Charging Green steady OFF No charging e Battery Indicator Battery LED indicator Table 4 2 Indicator Status Green steady ON Normal Green slow blink Full Under voltage Orange steady ON warning Red steady ON Low voltage 15 disconnect High volt Green fast blink disconnect Battery over Red b
20. stem and control the charging and discharging of the battery The controller features a smart tracking algorithm that maximizes the energy from the solar PV module s and charge the battery At the same time the low voltage disconnect function LVD will prevent the battery from over discharging The battery charging process has been optimized for long battery life and improved system performance The comprehensive self diagnostics and electronic protection functions can prevent damage from installation mistakes or system faults In addition the Tracer BN series controller has a RJ45 interface to allow communication with other accessory Although the Tracer BN series controller is very simple to configure and use please take your time to read the operator s manual and become familiar with the controller This will help you make full use of all the functions and improve your solar PV system E 240000009 Figure 2 1 Tracer BN Series Characteristics 1 Heat Sink Cast aluminum heat sink to dissipate controller heat 2 Charging LED Indicator Indicate that the battery is charging or not 3 Battery LED Indicator Show charging status 4 Key Switch the load on off in the manual mode and clear the part of faults 5 Temperature Sensor Port Connect remote temperature sensor to measure ambient temperature and make temperature compensation for charging and discharging 6 Solar Module Terminals Connect solar
21. the more energy is wasted Tracer BN series 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 situation there will be very little or no MPPT gain compared to traditional controllers However systems with modules of higher nominal voltage than the battery bank will always have an array Vmp greater than battery voltage Additionally the savings in wiring due to reduced solar current make MPPT worthwhile even in hot climates 4 2 Battery Charging Information Four Charging Stage The Tracer BN series has a 4 stage battery charging algorithm for rapid efficient and safe battery charging 11 Figure 4 2 Tracer BN series MPPT 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 120 minutes and then goes to Float Charge Every time when the controller is powered on if it detects neither over discharged nor overvoltage the charging will enter into boost char
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