Epever DuoRacer Series User manual

MPPT Dual Battery Solar Charge Controller
User Manual
DR1106N-DDB/DDS DR1206N-DDB/DDS
DR2106N-DDB/DDS DR2206N-DDB/DDS
DR3106N-DDB/DDS DR3206N-DDB/DDS
DR2210N-DDB/DDS DR3210N-DDB/DDS

Important Safety Instructions
Please reserve this manual for future review.
This manual contains all the safety, installation, and operation instructions for the
DuoRacer series MPPT Dual Battery Solar Charge Controller (referred to as the
controller in the next contents).
Read all the instructions and warnings carefully before installation.
No user-serviceable components exist inside the controller. Do NOT disassemble
or attempt to repair the controller.
Avoid direct sunlight and high temperature, and do NOT install the controller at
locations where water can get in.
Install the controller in well-ventilated places; the controller's heat sink may
become very hot during the system operation.
Appropriated external fuses or breakers are suggested.
Please cut off all PV array connections, and disconnect the fuses or breakers
close to the battery before the controller installation and adjustment.
Power connections must remain tight to avoid excessive overheating from the
loose connection.

CONTENTS
1 General Information 1
1.1 Overview 1
1.2 Naming Rule 3
1.3 Appearance 3
1.4 Battery charging stage 4
1.5 Starter battery BATT2 6
1.6 AES Signal Port 7
2 Installation 10
2.1 Attentions 10
2.2 PV Array Requirements 10
2.3 Wire Size 11
2.4 Mounting 13
3 Display units 17
3.1 DuoRacer Display Basic (DDB) 17
3.2 DuoRacer Display Standard (DDS) 19
4 Others 27
4.1 Protections 27
4.2 Troubleshooting 28
4.3 Maintenance 30
5 Specifications 31
Annex I Dimension Diagrams 34

1
1 General Information
1.1 Overview
DuoRacer MPPT charge controller is designed for charging two batteries (shown as
the main battery (BATT1) and starter battery (BATT2) below) at the same time in a
solar system. This controller, supporting multiple main batteries (BATT1), including
Sealed, Gel, Flooded, LiFePO4, and Li-NiCoMn, is suitable for the RV, Camper, Boat,
and so on. The device automatically recognizes the starter battery (BATT2) system
voltage and charges the battery when the conditions are satisfied.
The controller adopts the advanced MPPT control algorithm, which will minimize the
maximum power point loss rate and loss time, fast-track the maximum power point
(MPP) of the PV array, and obtain the maximum energy of the solar array under any
conditions. The energy utilization in the MPPT solar system is increased by 20-30%
compared with the PWM charging method.
When there is no operation for a long time and the charging conditions cannot be
satisfied, the controller switches to the low-power mode. It helps reduce
self-consumption and saves the battery power to enhance the product's life. The
system parameters are shown and set by LED/LCD or the MT11 remote meter
(Accessory).
The AES control signal of the car refrigerator is built into the controller, which will
supply thesurplus solar power to the refrigerator to avoid energy waste. The controller
has an IP33 protection level, which is waterproof and dustproof. Multiple protection
features, including battery overcharge protection, over-discharge protection, and
reverse connection protection of the PV and battery, ensure the solar system's safety,
stability, and lifetime.
Features：
Maximum Power Point Tracking technology with ultra-fast tracking speed and the
tracking efficiency is no less than 99.5% guaranteed
Advanced MPPT control algorithm to minimize the MPP lost rate and time
The wider range of the MPP operation voltage to improve the PV module
utilization

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Auto-control function of charging power & charging current limitation(BATT1)
High quality and low failure rate components of ST, TI, and Infineon to ensure the
product life
Digital circuit control of adaptive three-stage charging mode to enhance BATT1
life.
BATT1 type can be set via LED/LCD.
The product runs into the low-power mode when there is no manual operation for
a long time and charging conditions are not satisfied (PV<5V).
100% charging and discharging in operation environmental temperature range.
Optional LED and LCD units.
AES control signal for car refrigerators to avoid energy waste.
Standard Modbus protocol and RS485 (5V/200mA) communication port for the
customer to expand the application area.
①Main battery (BATT1) is the energy storage battery for powering the
household loads in the off-grid system, supporting Sealed, Gel, Flooded,
LiFePO4, and Li-NiCoMn batteries. The controller can NOT automatically
identify the system voltage.
②Starter battery (BATT2), built in the vehicle, is the energy storage battery for
powering systems such as RVs and boats. It only supports a lead-acid
battery, and the controller can automatically identify the system voltage.
CAUTION
The BATT1 and BATT2 must be at the same voltage level.

3
1.2 Naming Rule
1.3 Appearance
❶
Mounting hole sizeΦ5mm
❻
BATT1 terminals
❷
LCD(Refer to chapter 3)
❼
BATT2 terminals
❸
Grounding Terminal
❽
RS485 Communication port⑵
❹
Remote temperature sensor⑴
port
❾
AES (signal) output port⑵
❺
PV terminals
❿
Terminal protection cover
⑴The controller charges the BATT1 as default (25℃) when it's not connected
to the remote temperature sensor or the temperature sensor is damaged.

4
The temperature compensation is ONLY designed for the lead-acid battery.
For lithium batteries, there is no temperature compensation.
⑵For DR1106/2106/3106N models, AES port (outputs 12V/200mA) and RS485
port(outputs 5V/200mA) are independent. The 12V output voltage is the
battery voltage.
For DR1206/2206/3206/2210/3210N models, the AES port and RS485 port
share the power of 5VDC/Max. 200mA.
The AES signal port is designed for car refrigerators supporting the AES
signal. It is built into a power switching device.
1.4 Battery charging stage
Note: The following instructions for the battery charging stage are suitable for
the main battery (BATT1). Charging instructions for the starter battery (BATT2)
refer to chapter 1.5.
The controller has a three-stage battery charging algorithm, including Bulk Charging,
Constant Charging, and Float Charging. The system can extend the battery's lifespan
through the three-stage charging method.
Figure 1-4 Battery charging stage curve
a) Bulk Charging
The battery voltage has not yet reached the constant voltage (Equalize or Boost
Charging Voltage). The controller operates in constant current mode, delivering its

5
maximum current to the batteries (MPPT Charging). When the battery voltage
reaches the constant voltage set point, the controller will start to operate in constant
charging mode.
b) Constant Charging
When the battery voltage reaches the constant voltage set point, the controller will
start to operate in constant charging mode. The MPPT charging stops during this
process, and the charging current will drop gradually simultaneously. Constant
charging has two stages, namely, equalize charging and boost charging. These two
charging processes are not repeated. Among them, equalized charging starts on the
28th of each month.
Boost Charging
The default duration of the boost charging stage is generally 2 hours. Customers can
adjust the constant time and preset value according to actual needs. The system will
switch to the float charging stage when the duration equals the set value.
Equalize Charging
WARNING
Explosive Risk! Equalizing flooded batteries would produce
explosive gases, so well ventilation of the battery box is
recommended.
CAUTION
Equipment damage!
Equalization may increase battery voltage to the level that
damages sensitive DC loads. Verify that the load's allowable
input voltages are greater than the equalizing charging voltage.
Over-charging and excessive gas precipitation may damage
the battery plates and activate material shedding on them. Too
high an equalized charging or for too long may cause damage.
Please carefully review the specific requirements of the battery
used in the system.
Some battery types benefit from equalizing charging, stirring electrolytes, balancing
battery voltage, and accomplishing chemical reactions. Equalize charging increases
the battery voltage to make it higher than the standard complement voltage, gasifying
the battery electrolyte.
If the controller automatically controls the next charge for equalizing charging, the
equalizing charging time is 120 minutes. Equalize and boost charges are not carried
out constantly in a full charge process to avoid too much gas precipitation or
overheating of the battery.

6
CAUTION
Due to the installation environment or load work, the system may
not stabilize the battery voltage at a constant voltage. The
controller will accumulate the time when the battery voltage is
equal to the set value. When the accumulative time equals 3
hours, the system will automatically switch to float charging.
If the controller time is not adjusted, the controller will equalize
charging following the inner time.
c) Float Charging
After the constant charging stage, the controller will reduce the battery voltage to the
float charging preset voltage by reducing the charging current. During the floating
charge stage, the battery is charged weakly to ensure that the battery is maintained in
a fully charged state. In the float charging stage, loads can obtain almost all power
from the solar panel. Suppose loads' power exceeds the solar array's power. In that
case, the controller will no longer maintain the battery voltage in the float charging
stage. When the battery voltage goes lower than the boost voltage reconnect voltage,
the system will exit the float charging stage and enter the bulk charging stage again.
1.5 Starter battery BATT2
1) Working principle
The controller trickle charges the BATT2 at 1A constant current. When the voltage
reaches the "Full voltage" during the BATT2 charging process, the controller will stop
charging and exit from the constant voltage charging mode.
2) Voltage parameters
Item
Default
Modify range
Full voltage
13.8V/12V; 27.6V/24V
9~17V(24V×2)
Charge return voltage
13V/12V; 26V/24V
9~17V(24V×2)
CAUTION
Please follow the logic of Full Voltage > Return Voltage when
modifying the voltage point.
3) Start charging conditions
CAUTION
BATT2 ONLY supports lead-acid battery types. Before starting the
BATT2 charging, please connect the BATT1 first.

7
Condition1: BATT2 starts charging when BATT1 reaches the float charging stage,
and the BATT2 voltage is lower than the "Charging Return Voltage.
Condition 2: BATT2 starts charging when the battery's total charging current is
higher than 3A and the BATT2 voltage is lower than the "Charging Return Voltage.
4) Stop Charging Conditions
Condition 1: BATT2 stops charging when the PV voltage is no higher than 2Vof the
BATT1.
Condition 2:BATT2 stops charging when BATT1 is not in the float charging stage and
the total charging current for the battery is less than 2.5A.
Condition 3: BATT2 stops charging when BATT2 reaches the "Full Voltage."
CAUTION
After the BATT2 charging is turned off, it will be recharged only when
the start charging conditions are satisfied.
5) Starter Battery (BATT2) Charging indication
1.6 AES Signal Port
1) AES port working principle
The AES signal is turned on after the BATT1 voltage reaches the Boost Charging
Voltage or Equalize Charging Voltage for 5 minutes.
The controller checks if the BATT1 charges in the boost, equalize, or float stage
every 5 minutes. The interval is the delay time for turning off the AES signal, set via
PC software (default 5 minutes, ranging from 0 to 999 minutes). The AES signal
control is turned off if the BATT1 is not in the charging stage five times.

8
2) AES port of DR1106/2106/3106N-DDB/DDS
The AES port and the RS485 port are independent. The AES port output is
12V/200mA, and the voltage is the battery voltage. Connect the refrigerator. Refer to
the below picture.
3) AES signal port of DR1206/2206/3206/2210/3210N-DDB/DDS
The AES signal port and RS485 port share the power of 5VDC/Max.200mA. Connect the
accessories (AES-ADP adapter) when connecting the refrigerator; refer to the below
picture.
CAUTION
The AES signal port and RS485 port share the power of
5VDC/Max.200mA. The MT11 power consumption is 13mA when it
is ON and 4mA when it's off.
4) (Optional) AES-ADP adapter
The AES-ADP adapter converts the 5V-AES signal of the solar controller into a
12V-AES signal for the refrigerator. AN AES-ADP ADAPTER IS NECESSARY when
DR1206/2206/3206/2210/3210N-DDB/ DDS connects the refrigerator.
Appearance

9
No.
Interface
Instructions

Input terminal
Connect to the controller's AES Sig.
terminal and the BATT1 output terminal

Output terminal
Connect to the refrigerator's AES signal
terminal

Power indicator
Indicate BATT1 power ON

AES signal indicator
Light on with an AES signal
Light off without an ASE signal
Main Parameters
Applicable
DR1206/2206/3206/2210/3210N-DDB/DDS
Input Voltage
8.5V-35V
Output Voltage
12V/200mA
Self-consumption
1mA@12V; 1.5mA@24V
Environment
temperature
-30℃~ +60℃
Features
Support output short-circuit, BATT1 input terminal reversed
polarity, andAES signal reversed connection





10
2 Installation
2.1 Attentions
Be very careful when installing the batteries, especially flooded lead-acid
batteries. Wear eye protection, and have fresh water to rinse if there is any
contact with battery acid.
Keep the battery away from any metal objects, which may cause a short circuit of
the battery.
Explosive battery gases may come out from the battery during charging, so make
sure the ventilation condition is good.
For outdoor installation, keep out of the direct sunshine and rain infiltration.
Loose connections and corroded wires may produce high heat that can melt wire
insulation, burn surrounding materials, or even cause a fire. Ensure tight
connections, use cable clamps to secure cables, and prevent them from swaying
in the mobile application.
The controller can work with lead-acid and lithium batteries within its control
scope.
The battery connection may be wired to one battery or a bank of batteries. The
following instructions refer to a singular battery. However, it is implied that the
battery connection can be made to either one battery or a group of the battery
bank.
Select the system connection cables according to the current density no greater
than 5A/mm2.
2.2 PV Array Requirements
Serial connection (string) of PV modules
As the core component of the solar system, the controller could be suitable for various
types of PV modules and maximize converting solar energy into electrical energy. The
series number of different PV modules can be calculated according to the open-circuit
voltage (Voc) and the maximum power point voltage (Vmpp) of the MPPT controller.
The below table is for reference only.

11
DR1106/2106/3106/1206/2206/3206N-DDB/DDS:
System
voltage
36cell
Voc＜23V
48cell
Voc＜31V
54cell
Voc＜34V
60cell
Voc＜38V
Max.
Best
Max.
Best
Max.
Best
Max.
Best
12V
2
2
1
1
1
1
1
1
24V
2
2
-
-
-
-
-
-
System
voltage
72cell Voc＜46V
96cell Voc＜62V
Thin-Film
module
Voc＞80V
Max.
Best
Max.
Best
12V
1
1
-
-
-
24V
1
1
-
-
-
NOTE: The above parameter values are calculated under standard test conditions
(STC(Standard Test Condition): Irradiance 1000W/m2, Module Temperature 25℃, Air
Mass 1.5.)
DR2210/3210N-DDB/DDS:
System
voltage
36cell
Voc＜23V
48cell
Voc＜31V
54cell
Voc＜34V
60cell
Voc＜38V
Max.
Best
Max.
Best
Max.
Best
Max.
Best
12V
4
2
2
1
2
1
2
1
24V
4
3
2
2
2
2
2
2
System
voltage
72cell Voc＜46V
96cell Voc＜62V
Thin-Film
module
Voc＞80V
Max.
Best
Max.
Best
12V
2
1
1
1
1
24V
2
1
1
1
1
NOTE: The above parameter values are calculated under standard test conditions
(STC(Standard Test Condition): Irradiance 1000W/m2, Module Temperature 25℃, Air
Mass 1.5.)
2.3 Wire Size
The wiring and installation methods must conform to national and local electrical code
requirements.

12
PV Wire Size
Since the PV output current varies with the PV module's size, connection method, or
sunlight angle, the minimum wire size can be calculated by the PV Isc . Please refer
to the value of Isc in the PV module specification. When PV modules are connected in
series, the Isc equals each PV module's Isc. When PV modules are connected in
parallel, the Isc equals the sum Isc of the PV modules. The Isc of the PV array must not
exceed the controller's maximum PV input current. Please refer to the table below:
NOTE: All PV modules in a given array are assumed to be identical.
Isc =Short circuit current (amps) Voc= Open circuit voltage
Model
Max. PV input
current
Max. PV wire size
DR1106N-DDB/DDS
DR1206N-DDB/DDS
10A
4mm2/12AWG
DR2106N-DDB/DDS
DR2206N-DDB/DDS
DR2210N-DDB/DDS
20A
6mm2/10AWG
DR3106N-DDB/DDS
DR3206N-DDB/DDS
DR3210N-DDB/DDS
30A
10mm2/8AWG
CAUTION
When the PV modules are connected in series, the open-circuit
voltage of the PV array must not exceed
46V(DR**06N-DDB/DDS),92V
(DR**10N-DDB/DDS).
Battery and load wire size
The battery and load wire size must conform to the rated current. The reference size
is as below:
Model
Rated Charge
Current
Battery wire size
DR1106N-DDB/DDS
DR1206N-DDB/DDS
10A
4mm2/12AWG
DR2106N-DDB/DDS
DR2206N-DDB/DDS
DR2210N-DDB/DDS
20A
6mm2/10AWG
DR3106N-DDB/DDS
30A
10mm2/8AWG

13
DR3206N-DDB/DDS
DR3210N-DDB/DDS
CAUTION
The wire size is only for reference. Suppose a longdistance exists
between the PV array and the controller or between the controller
and the battery. Larger size wires can be used to reduce the
voltage drop and improve performance.
The battery cable size recommendations assume that the charge
controller is the only device connected to this cable (no inverter
connected to the same cable etc.).
2.4 Mounting
WARNING
Risk of explosion. Never install the controller in a sealed enclose
with flooded batteries. Do not install in a confined area where
battery gas can accumulate.
Risk of electric shock. Disconnect the breaker before wiring
because the PV array may generate a high open-circuit voltage.
CAUTION
The controller requires at least 150mm of clearance above and
below for proper airflow. Ventilation is highly recommended if
mounted in an enclosure.
Installation steps:

14
Step1: Determine the installation location and heat-dissipation space
The controller shall be installed with sufficient airflow through the controller's radiators.
The minimum clearance is 150mm from the upper and lower edges to ensure natural
thermal convection.
CAUTION
Ensure that the controller can dissipate heat if installed in a closed
area. Suppose the controller is to be installed in an enclosed box. In
that case, ensuring reliable heat dissipation through the box is
important.
Step2: Wiring❶❷❸
Connect the system in the order of ❶Starter batteryBATT2 ❷Main battery
BATT1 ❸PV array by the above diagram and disconnect the system in
the reverse order❸❷❶.
CAUTION
The BATT1 and BATT2 must be set at the same voltage level, and
other situations are not supported for the moment.
Follow the above instruction for wiring. Otherwise, it may cause

15
the BATT2 system voltage identification error.
While wiring the controller, do NOT connect the breaker or fuse.
Ensure that the electrode polarity is correctly connected.
A fuse whose current is 1.25 to 2 times the rated current of the
controller must be installed on the battery side with a distance
from the battery not greater than 150mm.
If an inverter is connected to the system, connect the inverter
directly to the battery.
Step3：Grounding❹
DR N series is a common-negative controller. All the negative terminals of the PV
array and battery can be grounded simultaneously, or any one of the negative will be
grounded. However, according to the practical application, all the negative terminals
of the PV array and battery needn't be grounded. However, the grounding terminal on
the controller's shell must be grounded. It may effectively shield the electromagnetic
interference from the outside and prevent electric shock to the human body.
CAUTION
A common-negative controller for common-negative systems, such
as a motorhome, is recommended. However, the controller may be
damaged if some common-negative equipment is used and its
positive electrode is grounded in the common-negative system.
Step4: Connect the remote temperature sensor cable❺
(Model:RT-MF58R47K3.81A) （Model:RTS300R47K3.81A）
Connect the remote temperature sensor cable to the port ❹and place the other end
close to the BATT1.
CAUTION
Suppose the remote temperature sensor is not connected to the
controller. In that case, the default temperature for battery charging or
discharging is 25℃without temperature compensation.
Step5: Connect the remote meter MT11❻and AES signal of the refrigerator❼
DR1106/2106/3106N-DDB/DDS:
Temperature sensor
Remoter temperature sensor

16
DR1206/2206/3206/2210/3210N-DDB/DDS:
❶RS485 Communication cable
CC-RS485-RS485-3.81-4P-150 (Included)
CC-RS485-RS485-3.81-4P-1000 (Optional)
CC-RS485-RS485-3.81-4P-2000 (Optional)
The remote meter operations refer to the MT11 user manual.
The controller only provides one AES signal control. A practical consideration is
needed for the specific application (Check the "1.5 AES Signal output port instruction"
for more information).
Step6: Power on the controller
1) Firstly, turn on the BATT2 safety switch and check the BATT2 charging indicator
status.
2) Then, turn on the BATT1 safety switch and check the BATT1 charging indicator
status (Check the "3. Display Units" for more information).
3) Lastly, connect the PV array circuit breaker.
CAUTION
If the controller is not operating properly or the battery indicator on
the controller shows an abnormality, please refer to 4.2
"Troubleshooting."