EP Solar Tracer-3215RN User manual

Tracer-3215RN
—— Maximum Power Point Tracking Solar Charge Controller
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.
EPSOLAR
INSTRUCTION
MANUAL
Utility model patent NO.
201120064092.1

Tracer-3215RN
—— Maximum Power Point Tracking Solar Charge Controller
System Voltage 12 / 24VDC
Rated Charge Current 30A
Rated Discharge Current 20A
Max. PV Input Voltage** 150VDC
Max. PV Input Power
12V System 390W
24V System 780W
**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...............................................1
2 General Information.............................................................2
2.1 Overview..................................................................2
2.2 Optional Accessories................................................4
3 Installation Instructions........................................................5
3.1 General Installation Notes........................................5
3.2 Mounting..................................................................5
3.3 Wiring......................................................................6
4 Operation..............................................................................9
4.1 MPPT Technology...................................................9
4.2 Battery Charging Information................................10
4.3 LED Indications.....................................................12
4.4 Setting Operation...................................................15
5 Protections, Troubleshooting and Maintenance .................19
5.1 Protection...............................................................19
5.2 Troubleshooting.....................................................20
5.3 Maintenance...........................................................21
6 Warranty ............................................................................22
7 Technical Specifications ....................................................23

1
1 Important Safety Information
Save These Instructions
This manual contains important safety, installation and operating instructions for
Tracer
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 critical 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.
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 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
Install external fuses/breakers as required
Do not allow water to enter the controller
Confirm that power connections are tightened to avoid excessive heating from loose
connection

2
2 General Information
2.1 Overview
Thank you for selecting the Tracer controller which represents advanced technology of
our company The features are listed below:
12V / 24V auto recognition
Advanced maximum power point tracking technology to optimize using the solar
system
Peak conversion efficiency of 97 %, high Tracking efficiency of 99%
Very fast sweeping of the entire I-V curve, several seconds tracking speed
Widely used, automatic recognize day/night
Timer function with 1-15 hours option for street light
Unique dual timer function, enhance the flexibility of street light system
Sealed, Gel and Flooded battery option
Adopting temperature compensation and correcting the charging and discharging
parameters automatically, improving the battery lifetime
Electronic protection: over charging, over discharging, overload, short circuit
Reverse protection: any combination of solar module and battery, without causing
damage to any component
Excellent thermal design and nature air cooling
RJ45 interface with remote meter MT-5, convenient to check operating parameters of
controllers
The Tracer series controller is for off-grid solar system and control the charging
and discharging of the battery, especially suitable for the street light system The
controller features a smart tracking algorithm inside 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 Tracer controller 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 controller has a RJ45 interface to allow communication with a
meter for remote monitoring
Although the Tracer 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

3
The features of Tracer controller:
Figure 2-1 Tracer Characteristics
5
6
7
8
9
10
RJ45
4
3
1
2

4
1 –Charging Status LED Indicator
An LED indicator that shows charging status and overvoltage of battery
2 –Battery Status LED Indicator
An LED indicator that shows battery status or system errors
3 –Temperature Sensor
Measure ambient temperature and make temperature compensation for charging and
discharging
4 –Setting Indicators
Corresponding indicator will be on when set timer1, timer2 and battery type
5 –LED Digital Display
Display the load work mode and status
6 –Setting Button (in manual mode used for load ON/OFF)
Set load work mode and select battery type
7 –Solar Module Terminals
Connect solar modules
8 –Battery Terminals
Connect batteries
9 –Load Terminals
Connect loads
10 –RJ45 Communication Interface
Communicate with remote meter MT-5
2.2 Optional Accessories
Remote Meter(Model：MT-5)
The digital remote meter displays system operating information, error indications,
and self-diagnostics read-out Information is displayed on a backlit LCD display The
large numerical display and icons are easy to read and large buttons make navigating
the meter menus easy The meter can be flush mounted in a wall or surface mounted
using the mounting frame (included) The MT-5 is supplied with 2m of cable and a
mounting frame The MT-5 connects to the RJ45 port on the Tracer

5
3 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
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 to release the gasses
Avoid direct sunlight and do not install in locations where water can enter the
controller
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 Gel, Sealed or Flooded batteries only
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/mm2current density
3.2 Mounting
NOTE: When mounting the Tracer, ensure free air through the controller heat
sink fins. There should be at least 150mm of clearance above and below the
controller to allow for cooling. If mounted in an enclosure, ventilation is highly
recommended.
WARNING: Risk of explosion! Never install the Tracer in a sealed enclose with
flooded batteries! Do not install in a confined area where battery gas
can accumulate.
Step 1: Choose Mounting Location
Locate the Tracer on a vertical surface protected from direct sun, high
temperature, and water
Step 2: Check for Clearance
Place the Tracer in the location where it will be mounted Verify that there is
sufficient room to run wires and that there is sufficient room above and below the
controller for air flow
Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole locations on the mounting
surface

6
Step 4: Drill Holes
Remove the controller and drill four sizeable holes in the marked locations
Step 5: Secure 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
NOTE: A recommended connection order has been provided for maximum
safety during installation.
NOTE: The Tracer is a negative ground controller. Any negative connection of
solar module, battery or load can be earth grounded as required. Grounding is
recommended.
CAUTION: Don’t connect the loads with surge power exceeding the ratings of
the controller.
CAUTION: For mobile applications, be sure to secure all wiring. Use cable
clamps to prevent cables from swaying when the vehicle is in motion. Unsecured
cables create loose and resistive connections which may lead to excessive heating
and/or fire.
Step 1: Battery Wiring
WARNING: Risk of explosion or fire! Never short circuit battery positive (+)
and negative (-) or cables
Figure 3-1 Battery wiring
Fuse
Battery

7
Before connecting the battery, measure the battery voltage It must be over 9V to
power the controller For 24V, the voltage must be greater than 18V to properly detect
a 24V battery The 12/24V battery detection is automatic and the check is only
performed at start-up
Wire an in-line fuse holder no more than 150mm from the battery positive
terminal Do not insert a fuse at this time Confirm the connection correct and then
turn on the power
Step 2: Load Wiring
The Tracer load output can connect DC electronic devices of which rated voltage
is same as battery’s Tracer will provide battery voltage to the loads See Section 4 4
Setting Operation for more details about the load control
Figure 3-2 Load wiring
Connect load positive (+) and negative (-) to the Tracer load output as shown in
figure 3-2 The load terminals may exist voltage, connect carefully to avoid short
circuit
An in-line fuse holder should be wired in series in the load positive (+) or
negative (-) wire as shown Do not insert a fuse at this time Confirm the connection
correct and then turn on the power
If wiring the load connection to a load distribution panel, each load circuit should
be fused separately The total load draw should not exceed the 20A load rating
Step 3：Solar Module Wiring
WARNING: Risk of electric shock! Exercise caution when handling solar wiring.
The solar module(s) high voltage output can cause severe shock or injury. Cover
the solar module(s) from the sun before installing solar wiring.
Fuse
Load

8
The Tracer can accept 12V, 24V nominal off-grid solar module arrays Grid –tie
solar module(s) may be used if the open circuit voltage does not exceed the maximum
solar input rating The solar module(s) nominal voltage must be equal to or greater
than the nominal battery voltage
Figure3-3 Solar Module wiring
Step 4: Accessories (option)
Install Remote Meter (purchased separately) if required Refer to the instructions
provided for detailed installation procedures
Step 5: Confirm Wiring
Double-check the wiring in step1 through 4 Confirm correct polarity at each
connection Verify that all six power terminals are tightened
Step 6: Confirm Power-up
When battery power is applied and the Tracer powers up, the battery led indicator
will be green
If the Tracer does not power up or battery status LEDs error exists, refer to
Section 5 Troubleshooting
Solar Module

9
4 Operation
4.1 MPPT Technology
The Tracer 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 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 MPPT technology will ―boost‖ the solar charge current
For example, a system may have 8 Amps of solar current flowing into the Tracer and
10 Amps of charge current flowing out to the battery The Tracer does not create
current! Rest assured that the power into the Tracer is the same as the power out of the
Tracer Since power is the product of voltage and current (Volts×Amps), the following
is true*:
(1) Power Into the Tracer =Power Out of the Tracer
(2) Volts In×Amps In=Volts Out×Amps 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 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
11-15Vdc 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

11
Figure 4-2 Tracer 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 charging stage
Float Charge
After the Boost voltage stage, Tracer 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 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 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

13
Charging Indicator
The green LED indicator will light whenever sunlight is available for battery
charging, the green charging LED will stay on in normal charging The charging LED
indicator flashes when battery over voltage Please refer to Chapter 5 for
troubleshooting
Charging LED indicator Table4-1
Color
Indication
Operating State
Green
On Solid
Charging
Green
Flashing
Battery over-voltage
Battery Indicator
GREEN ON when battery voltage in normal range
GREEN FLASHING when battery full
ORANGE ON when battery under voltage
RED ON when battery over discharged
Please refer to Chapter 5 for troubleshooting
Battery LED indicator Table 4-2
Color
Indication
Operating State
Green
On solid
Normal (battery)
Green
Flashing
Full (battery)
Orange
On solid
Under voltage(battery)
Red
On solid
Over discharged(battery)
PV Overvoltage Display
If the solar input open circuit voltage (Voc) exceeds the maximum rating, the
array will remain disconnected until the Voc falls safely below the maximum rating
PV Overvoltage LED Display Table 4-3
Color
Indication
Operating State
Red
LED digital tube displays ―P‖
PV Overvoltage

14
PV Overcurrent Display
If the solar input current exceeds the maximum rating, the array will be
disconnected automatically
PV Overcurrent LED Display Table 4-4
Color
Indication
Operating State
Red
LED digital tube displays ―C‖
PV Overcurrent
Load indicator
When the load amp is 1 25times of rated current for 60 seconds, or the load amp
is 1 5 times of rated current for 5 seconds (overload); or load short circuit, the Battery
Indicator RED FLASHING Please refer to section 5 for troubleshooting
Load LED indicator Table 4-5
Color
Indication
Load status
Red
battery indicator red flashing
Overload or Short circuit