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Epsolar iTracer Series Operation Manual

Solar charge controller
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EPsolar
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.

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Summary of Contents for Epsolar iTracer Series

  • Page 1 EPsolar 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...
  • Page 3 Series —— Maximum Power Point Tracking Solar Charge Controller Models: IT3415ND/IT4415ND/IT6415ND Final interpretation right of the manual belongs to EPsolar. Any changes without prior notice!
  • Page 4 Contents 1.0 Important Safety Information ..............1 2.0 General Information ................2 2.1 Overview ..................2 2.2 Models & Parameters ..............3 2.3 Characteristics ................. 4 2.4 Optional Accessories ............... 7 3.0 Installation Instructions ................8 3.1 General Installation Notes ............... 8 3.2 Mounting ..................
  • Page 5 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.
  • Page 6 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: ...
  • Page 7 functions can prevent damage from installation mistakes or system 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 system.
  • Page 8 2.3 Characteristics...
  • Page 9 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.
  • Page 10 8 – RS-485 port Monitor controller by PC and update controller software. 9 –RTC battery Power to RTC, battery 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 –...
  • Page 11 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 EPsolar 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.
  • Page 12 3.0 Installation Instructions 3.1 General Installation Notes  Read through the entire installation section first before beginning installation.  Be very careful when working with batteries. Wear eye protection. Have fresh water available to wash and clean any contact with battery acid. ...
  • Page 13 3.2 Mounting NOTE: The iTracer controller requires at least 150mm of clearance above and below for proper air flow. Ventilation is highly recommended if mounted in an enclosure. WARNING: Risk of explosion! Never install the iTracer in a sealed enclose with flooded batteries! Do not install in a confined area where battery gas can accumulate.
  • Page 14 WARM AIR AT LEAST COOL AIR 150mm Figure3-1 Required mounting clearance for air flow Step3:Mark Holes 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.
  • Page 15 NOTE: The iTracer is a negative ground controller. Any negative connection of solar, load or battery can be earth grounded as required. CAUTION: For mobile applications, be very certain that all wirings are connected securely. Use cable clamps to prevent cables from swaying when the vehicle is in motion.
  • Page 16 1) Monitor each controller on the network using EPsolar Station PC software; update the firmware； 2) Communicate with other module(s) made by EPsolar company with CAN bus;...
  • Page 17 battery circuits is recommended, and make them keep OFF state before connection. WARNING: Risk of electric shock! Exercise caution when handling solar wiring. The solar PV array can produce open-circuit voltages in excess of 100 Vdc when in sunlight. Pay more attention for it. WARNING: Risk of explosion or fire! Never short circuit battery Positive (+) and negative (-) or cables.
  • Page 18 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 controller will begin charging.
  • Page 19 4.0 Operation 4.1 MPPT Technology 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.
  • Page 20 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 to 15Vdc but the module’s Vmp is typically around 16 or 17V.
  • Page 21 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.
  • Page 22 After the Boost voltage stage, iTracer 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 iTracer reduces the voltage to the floating stage, charging with a smaller voltage and current.
  • Page 23 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. 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.
  • Page 24 Indicator Status Red OFF Normal Red Blink Current abnormal Overload load short All Indicator Indicator Fault Status Blink（Battery LED in Red） Work voltage error Blink(Battery LED in Orange) Controller over temperature 4.4 LCD Display & Operation  Initialization LCD will paint the picture as shown on the left as soon Efficient Power as it is powered on.
  • Page 25 Press OK to enter corresponding interface. 1.Monitoring 5.Load Set 9.Dev Msg 2.Log Info 6.Control Para 3.Clock Set 7.Sys Password 4.Local Para Set 8.Default Set 设备参数  Monitor There are 11 interfaces for monitoring, as shown below: Load State Load Volt. Batt Temp 12.4V 21ºC...
  • Page 26 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.  Log Info There are two items of log record as shown blew. Work Log Query 1/79 <1>Work Log...
  • Page 27  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 Date and Time can be adjusted in this interface. Press OK and 17:12:28 input the 6 digit user password and then Date and Time could be adjusted.
  • Page 29  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 √...
  • Page 30 Light On/Off Load control mode can be set to light control in this interface. ◎ Manual Light On/Off Parameters in the table below: ◎ Light On/Off On 05.0V T 10 M ◎ Light On+Timer Off 06.0V T 10 M ◎ Time Parameter Detail When solar module voltage goes below the point of NTTV (Night Time...
  • Page 31 Light On+Timer ◎ Manual Light On+Timer Light On+Timer ◎ Light On/Off On 05.0V T 10 m On T1 01H:00M ◎ Light On+Timer Off 06.0V T 10 m On T2 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...
  • Page 32 Time ◎ Manual Time Control 1 Time Control 2 ◎ Light On/Off On Time 19 : 00 On Time 05 : 00 ◎ Light On+Timer 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...
  • Page 33  Control Parameter Press OK to enter the Device Parameter interface when the inverse cursor point to Control Para item. Press ESC button to exit. There are 10 interfaces for ‘Control Parameters’ as shown below. Temp Coefficient Over Volt. Rect Batt Type Over Volt.
  • Page 34 Battery Charging Mode Charging Mode Note Voltage Compensate Controlled by voltage(default) SOC mode, controlled by SOC charging or discharging value Others Parameter Default value Range Battery capacity 200Ah 1~9999Ah Temperature compensate -3mV/ºC/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...
  • Page 35 Rule3: Low voltage reconnect > Low voltage disconnect ≥ Charging limit voltage; Rule4: Under voltage recover > Under voltage warning ≥ Charging limit voltage; Rule5: Boost return voltage > Low voltage reconnect;  Password Press OK to enter the Password Set interface when the inverse cursor points to Password Para item.
  • Page 36 5.0 Protections, Troubleshooting & Maintenance 5.1 Protections ·PV Short Circuit When PV short circuit occurs, the controller will stop charging. Clear it to resume normal operation. ·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.
  • Page 37 protection will start automatically. After five automatic load reconnect attempt, the fault must be cleared by restarting controller or pressing the - button . NOTE: Overload fault and load short fault will be cleared every day, so the faults which aren’t caused by hardware can be solved intelligently. 5.2 Troubleshooting ...
  • Page 38 serial COM port has been mapped.
  • Page 39 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 is not blocked. Clear all dirt or fragments on the heat sink.
  • Page 40 6.1 PC Software iTracer controller can be connected to a common PC monitoring software by supporting USB communication cable developed by the EPsolar company. Monitoring software can remote single or more controllers to modify the parameters, configure load mode and others in the PV system management (username: administrator, password: 111111 as default).
  • Page 41 Figure6-2 Real Time Monitoring...
  • Page 42 Figure6-3 Control Parameter Figure6-4 Load Configuration...
  • Page 43 If the products failure is caused by customers’ misuse or not following the manual, EPsolar won’t be responsible for the free maintenance. We will ask for the raw material cost. And please refer to above procedure.
  • Page 44 8.0 Specifications Electrical Parameters IT3415ND T4415ND IT6415ND Nominal System Voltage 12Vdc/24Vdc/36Vdc/48Vdc/ Auto Nominal Battery Current Maximum Solar Input Voltage 150Vdc Battery Voltage Range 8～72Vdc Maximum Input Power 12V： 400W 600W 800W 24V： 800W 1200W 1600W 36V： 1200W 1800W 2400W 48V： 1600W 2400W 3200W...
  • Page 45 Enclosure IP20 Protection Solar input short protection Solar input reversed polarity protection Solar input reverse current protect at night Battery reversed polarity protection Battery over voltage disconnect protection Battery over voltage reconnect protection Battery over temperature disconnect protection Load short disconnect protection Load overload disconnect protection Controller over temperature disconnect protection Abbreviation...
  • Page 46 9.0 Conversion Efficiency Curves Test model: IT3415ND 1. Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(12V) 12V Conversion Efficiency Curves 115V Charging Power(W) 2. Solar MPPT Voltage(33V, 66V, 98V, 115V) / System Voltage(24V)
  • Page 47 24V Conversion Efficiency Curves 115V Charging Power(W) 3. Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(36V) 36V Conversion Efficiency Curves 115v 1000 1100 Charging Power(W) 4. Solar MPPT Voltage(17V,34V,68V) / System Voltage(48V)
  • Page 48 48V Conversion Efficiency Curves 98.5 97.5 115v 96.5 95.5 1000 1200 1400 Charging Power(W)
  • Page 49 Test model: IT4415ND 1. Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(12V) 12V Conversion Efficiency Curves 115v Charging Power(W) 2. Solar MPPT Voltage(33V, 66V, 98V, 115V) / System Voltage(24V) 24V Conversion Efficiency Curves 115v 1000 1100 1200 Charging Power(W) 3. Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(36V)
  • Page 50 36V Conversion Efficiency Curves 115v 1000 1200 1400 1600 1800 Charging Power(W) 4. Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(48V) 48V Conversion Efficiency Curves 115v 1000 1200 1400 1600 1800 2000 2200 2400 Charging Power(W)
  • Page 51 Test model: IT6415ND 1. Solar MPPT Voltage(17V,34V,68V) / System Voltage(12V) 12V Conversion Efficiency Curves Charging Power(W) 2. Solar MPPT Voltage(34V,68V,115V) / System Voltage(24V) 24V Conversion Efficiency Curves 115v 1000 1200 1400 1600 Charging Power(W)
  • Page 52 3. Solar MPPT Voltage(68V,115V) / System Voltage(36V) 36V Conversion Efficiency Curves 115v 800 1000 1200 1400 1600 1800 2000 2200 2400 2400 2600 Charging Power(W) 4. Solar MPPT Voltage(68V,115V) / System Voltage(48V) 48V Conversion Efficiency Curves 115v 1200 1500 1800 2100 2400 2700 3000...
  • Page 53 10.0 Dimensions IT3415ND Dimensions（Unit：mm）...
  • Page 54 IT4415ND Dimensions（Unit：mm）...
  • Page 55 IT6415ND Dimensions（Unit：mm） Version：V2.2...
  • Page 59 BEIJING EPSOLAR TECHNOLOGY CO., LTD. Tel：010-82894112 / 82894962 Fax：010-82894882 E-mail：info@epsolarpv.com Website: www.epsolarpv.com...

This manual is also suitable for:

Itracer it3415ndItracer it4415ndItracer it6415nd