Epever iTracer-ND Series User manual

MPPT Solar Charge Controller
User Manual
Model：IT6415ND

Important Safety Instructions
Please reserve this manual for future review. This manual contains all
instructions for safety, installation, and operation for the Maximum Power Point
Tracking (MPPT) controller in iTracer6415ND ("the controller" is referred to in
this manual).
General Safety Information
Read all the instructions and warnings carefully in the manual before
installation.
No user-serviceable component exists inside the controller. DO NOT
disassemble or attempt to repair the controller.
Mount the controller indoors. Avoid direct sunlight and high temperatures,
and do not install in locations where water can enter the controller.
Install the controller in well-ventilated places; the controller's heat sink may
become very hot during operation.
It is suggested to install appropriate external fuses/breakers.
Disconnect all PV array connections and the battery fuse/breakers before
installation and adjustment.
Power connections must remain tight to avoid excessive heating from a
loose connection.

Contents
1 General Information 1
1.1 Overview 1
1.2 Characteristics 3
1.3 Accessories Instructions 4
1.4 Maximum Power Point Tracking Technology 5
1.5 Battery Charging Stage 6
2 Installation 10
2.1 General Installation Notes 10
2.2 PV Array Requirements 11
2.3 Mounting 11
2.4 Wiring 12
2.5 Power ON 17
3 LED Indication 18
4 LCD Display & Operation 19
4.1 Button operation 19
4.2 LCD Display & Operation 19
5 Protections, Troubleshooting & Maintenance 28
5.1 Protections 28
5.2 Troubleshooting 29
5.3 Maintenance 31
6 PC Software 32
7 Specifications 34
8 Disclaimer 35

Annex I Conversion Efficiency Curves 36
Annex II Dimensions 38

1
1 General Information
1.1 Overview
Appreciate you for choosing our MPPT solar charge controller, iTracer6415ND.
Based on the multiphase synchronous rectification technology (MSRT),
common negative design, dual-core processor architecture, and advanced
MPPT control algorithm, the products own the features of high response speed,
high reliability, high industrial standards, etc.
With the MPPT control algorithm, in any situation, products of this series can
fast and accurately track out the best maximum power point (MPP) of the PV
array. To obtain the maximum solar energy in time, MSRT can guarantee high
conversion efficiency in any charging power. It sharply improves the energy
efficiency of the solar system. The Modbus communication protocol interface
makes it convenient to expand applications and monitor various fields. Like
telecommunication base stations, household systems, wilderness monitoring
systems, etc.
All-round electronic fault self-test and enhanced electronic protection function
could prevent damage to system components from installation errors or
system failures.
Features:
Advanced Maximum Power Point Tracking (MPPT) technology, with no
less than 99.5% efficiency.
High-quality components, perfecting system performance, with a maximum
conversion efficiency of 98% and full load efficiency of 97%.
MSRT, realizing high conversion efficiency in the situation of low charge
power.
Ultra-fast tracking speed and guaranteed tracking efficiency.
Multiple power point recognizing and tracking accuracy.
Reliable automatic limit function of maximum PV input power, ensuring no

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overload.
Wide MPP operating voltage range.
High-speed and high-powered dual-core processor architecture, improving
system response speed, optimizing system performance.
Die-cast aluminum case for heat-dissipating, ensuring excellent heat
dissipation characteristics.
12/24/36/48VDC auto-identifying system voltage or user-defined working
voltage.
Concise human-computer interactive interface, convenient multiple
combination keys, dynamically displaying system operating data and
working conditions.
Multiple load control modes: manual control, light ON/OFF, light on+timer,
and time control.
Support 4 charging options: Sealed, Gel, Flooded, and User.
Battery temperature compensation function.
Real-time energy statistics function.
With RS-485, RS-232 communication bus interface, and Modbus
communication protocol, it can meet various communication requirements
in different situations.
Available for PC monitoring and external display unit connecting like MT50
and so on, realizing real-time data checking and parameters setting.

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1.2 Characteristics
2
3
4
5
6
1
Figure 1-1 Controller Characteristics
14
13
16
15
11
10
9
12
2
17
8
7

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Item
Name
Item
Name
1
Heat Sink
10
RTS Port②
2
LCD
11
RBVS Port③
3
Battery LED indicator
12
Solar Positive Terminal(+)
4
Charging LED indicator
13
Solar Negative Terminal(-)④
5
Fault LED indicator
14
Load Negative Terminal(-)
6
Buttons
15
Battery Negative Terminal(-)
7
RS-232 port
16
Battery Positive Terminal(+)
8
RS-485 port①
17
Load Positive Terminal(+)
9
RTC battery (model:CR2032)
①Monitor controller by PC via RS485 or RS232.
②Connect an RTS (Remote Temperature Sensor) to detect battery
temperature remotely.
③Connect an RBVS (Remote Battery Voltage Sensor) to detect battery
voltage accurately.
④The PV negative, battery negative, and load negative are common.
1.3 Accessories Instructions
1. Remote Temperature Sensor (Model: RTS300R10K5.08A)
The standard cable length is 3m (it can be customized) to
acquire battery temperature for undertaking temperature
compensation of control parameters. The
RTS300R10K5.08Aconnects to the RTS port (10th ) on the
controller.
CAUTION
Unplug the RTS, and the battery's temperature will be set to a
fixed value of 25℃.
2. USB to RS-485 Converter (Model: CC-USB-RS485-150U-3.81)
The USB to RS-485 converter monitors each controller
on the network using Solar Station PC software and
updates the firmware. The cable length is 1.5m. The
CC-USB-RS485-150U-3.81 connects to the
MC1.5-5.08-2L port (8th ) on the controller.

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3. CD （PC Software）
Solar Station PC software is used to monitor each controller on the network
1.4 Maximum Power Point Tracking Technology
Due to the nonlinear characteristics of the solar array, there is a maximum
energy output point (Max Power Point) on its curve. Traditional controllers,
adopting the switch charging technology and PWM charging technology, can't
charge the battery at the maximum power point. They can't harvest the
maximum energy available from the PV array. While the solar charge controller
with Maximum Power Point Tracking (MPPT) Technology can lock on the point
to harvest the maximum energy and deliver it to the battery.
The MPPT algorithm of our company continuously compares and adjusts the
operating points to locate the array's maximum power point. The tracking
process is fully automatic and does not need user adjustment.
As shown in Figures 1-2, the curve is the characteristic curve of the array. The
MPPT technology will boost the battery charge current by tracking the MPP.
Assuming the conversion efficiency of the solar system is 100%, the following
formula is established:
Input power (PPV)= Output power (PBat)
Input voltage (VMp) *input current (IPV) =Battery voltage (VBat) *battery current (IBat)
Normally, the VMp is always higher than VBat. Due to the principle of energy
conservation, the IBat is always higher than IPV. The greater the discrepancy
between VMp &VBat, the greater the discrepancy between IPV& IBat. The greater
the discrepancy between array and battery, the bigger reduction of the
conversion efficiency of the system. Thus the controller's conversion efficiency
is particularly important in the PV system.
Figure 1-2 is the maximum power point curve, and the shaded area is the
charging range of a traditional solar charge controller (PWM Charging Mode).
It can diagnose that the MPPT mode can improve the usage of solar energy
resources. According to our test, the MPPT controller can raise 20%-30%
efficiency compared to the PWM controller. (Value may fluctuate due to the
ambient circumstance's influence and energy loss.)

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Figure 1-2 Maximum Power Point Curve
The panel may appear Multi-MPP as shading from cloud, tree, or snow in
actual application. However, there is only one real Maximum Power Point. As
the Figure 1-3 show:
Figure 1-3 Mutil-MPP Curve
If the program works improperly after appearing Multi-MPP, the system will not
work on the real max. power point. It may waste most solar energy resources
and affect the system's normal operation. The typical MPPT algorithm,
designed by our company, can track the real MPP quickly and accurately,
improve the array's utilization rate and avoid wasting resources.
1.5 Battery Charging Stage
The controller has a three-stage battery charging algorithm (Bulk Charging,
Constant Charging, and Float Charging) for rapid, efficient, and safe battery
charging.

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A) Bulk Charging
In this stage, the battery voltage has not yet reached constant voltage
(Equalize or Boost Voltage). The controller operates in constant current mode,
delivering its maximum current to the batteries (MPPT Charging).
B) Constant Charging
When the battery voltage reaches the constant voltage setpoint, the controller
will start to operate in constant charging mode. This process is no longer
MPPT charging. In the meantime, the charging current will drop gradually. The
process is not the MPPT charging. Constant charging has two stages, equalize
and boost. These two stages are not carried out constantly in a full charge
process to avoid too much gas precipitation or overheating of the battery.
Boost Charging
The Boost stage maintains 2 hours in default. Users can adjust the constant
time and preset value of boost voltage according to demand.
The stage is used to prevent heating and excessive battery gassing.
Equalize Charging
WARNING
Explosive Risk!
Equalizing flooded batteries would produce explosive
gases, so well ventilation of the battery box is
recommended.
Figure 1-4 Battery changing stage Curve

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CAUTION
Equipment damage!
Equalization may increase battery voltage high enough to
damage sensitive DC loads. Verify that all load allowable
input voltages are 11% greater than the equalizing
charging set point voltage.
Equipment 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.
Some batteries benefit from equalizing charge regularly, which can stir
electrolytes, balance battery voltage, and accomplish chemical reactions.
Equalizing charge increases battery voltage, higher than the standard
complement voltage, which gasifies the battery electrolyte.
The controller will equalize the battery on the 28th of each month. The
constant equalization period is 0~180 minutes. Suppose the equalization isn't
accomplished at one-time. In that case, the equalization recharge time will be
accumulated until the set time is finished. 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.
NOTE:
1) The battery voltage can't be steady in constant voltage due to ambient
circumstances or load working. The controller will accumulate and
calculate the time of constant voltage working. When the accumulated
time reaches 3 hours, the charging mode will turn to Float Charging.
2) If the controller time is not adjusted, the controller will charge the
battery in equalized charging mode once a month following the inner
time.
C) Float Charging
After the Constant voltage stage, the controller will reduce the charging current
to the Float Voltage set point. This stage will have no more chemical reactions,
and all the charge current transforms into heat and gas at this time. Then the
controller reduces the voltage to the floating stage, charging with a smaller
voltage and current. It will reduce the battery's temperature and prevent the

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battery's gassing and charging simultaneously. The purpose of the 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 the Float charging stage, loads can obtain almost all power from solar
panels. If loads exceed the power, the controller can no longer maintain battery
voltage in the Float charging stage. Suppose the battery voltage remains
below the Recharge Voltage. In that case, the system will leave the Float
charging stage and return to the Bulk charging stage.

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2 Installation
2.1 General Installation Notes
Before installation, please read through the instructions to familiarize
yourself with the installation steps.
Be very careful when installing the batteries, especially flooded lead-acid
batteries. Please wear eye protection, and have fresh water available to
wash and clean 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
ensure the ventilation condition is good.
Gel, Sealed, or Flooded batteries are recommended. For other batteries,
please refer to the battery manufacturer.
Ventilation is highly recommended if mounted in an enclosure. Never install
the controller in a sealed enclosure with flooded batteries! Battery fumes
from vented batteries will corrode and destroy the controller circuits.
Loose power 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 mobile applications.
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
batteries in a battery bank.
Multiple models of controllers can be installed in parallel on the same
battery bank to achieve a higher charging current. Each controller must

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have its solar module(s).
Select the system cables according to 5A/mm2or less current density
following Article 690 of the National Electrical Code, NFPA 70.
2.2 PV Array Requirements
Serial connection (string) of PV modules
As the core component of the PV system, the controller could be suitable for
various types of PV modules and maximize converting solar energy into
electrical energy. The series number of 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.
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
6
3
4
2
4
2
3
2
48V
6
5
4
3
4
3
3
3
System
voltage
72cell Voc＜46V
96cell Voc＜62V
Thin-Film
Module
Voc＞80V
MAX.
Best
MAX.
Best
12V
2
1
1
1
1
24V
3
2
2
1
1
48V
3
2
2
2
1
NOTE: The above parameter values are calculated under standard test
conditions (STC (Standard Test Condition): Irradiance 1000W/m2, Module
Temperature 25℃, Air Mass1.5.)
2.3 Mounting
WARNING
Explosive Risk!
Never install the controller with flooded batteries in a sealed
enclosure! Do not install the battery in a confined area where
battery gas can accumulate.
CAUTION
When mounting the controller, ensure at least 150mm of
clearance above and below the controller for proper airflow. If

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mounted in an enclosure, ensure good ventilation condition of
the box.
150mm of clearance is required around the controller for proper airflow.
Secure the controller in place using proper mounting screws.
2.4 Wiring
※Please remove the terminal protective cover before wiring.
Figure 2-1 Installation Diagram

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CAUTION
The following connection order is recommended for optimal
safety.
Do not entangle all wiring together. Communication cable
and power wires should be as far as possible to avoid
interfering with the communication signal transmission.
The iTracer-ND controller is a negative ground controller.
Any negative PV, load, or battery connection can be earth
grounded as required.
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. Unsecured
cables create loose and resistive connections, which may
lead to excessive heating or fire.
①Remote Temperature Sensor Connection (RTS300R10K5.08A)
WARNING
Equipment Damage! Never place the temperature sensor
inside a battery. Both the RTS300R10K5.08A and the battery
will be damaged.
CAUTION
Unplug the RTS, and the battery's temperature will be set to a
fixed value of 25ºC.
The included remote temperature sensor (RTS300R10K5.08A) is
recommended for effective temperature compensated charging. Connect the
RTS300R10K5.08A to the10th port on the controller (Check Figure 1-1). 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 connecting the RTS300R10K5.08A to the remote battery
voltage sense port, but the connection will not be recognized.
②Remote Battery Voltage Sensor Connection
CAUTION
When connecting the Remote Battery Voltage Sensor,
please pay attention to '+' and '-' (Check Figure 1-1).
Be careful when installing. Please never plug the voltage
sensor wires into the RTS300R10K5.08A terminals (10th
Port). It will 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

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battery voltage 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 required length. The wire can
range from 0.25 to 1.0 mm2(24 to 18 AWG). The maximum size is 3m.
Connect the remote battery voltage sensor wires to the 11th port on the
controller (Check Figure 1-1). A twin-cord cable is recommended but not
required.
Please spot the '+' 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 the RTS300R10K5.08A terminals (10th Port) will
cause an alarm or damage to the controller.
③Communicate Connection
WARNING
Shock Hazard!
There should not be any communication cables and power
lines intertwined. Separate them as far as possible to void
electric shock.
There are two kinds of communication: RS-232 and RS-485. Please use
matching communication cables and make sure the cables are connected
firmly during data transmission: the below features are supported by the
communication interface:
Monitor each controller on the network using Solar Station PC software;
update the firmware.
RS-232, RS-485 Connection
The controller is a standard 3.81-4P port. Check Figure 1-1 for the port location.
The RS-232 port is the 7th port, and the RS-485 port is the 8th port on the
controller.
④Power Wires Connection
PV Wire Size
Since the PV array output varies with the PV module size, connection method,
or sunlight angle, the minimum wire size can be calculated by the ISC of the PV
array. Please refer to the value of ISC in the PV module specification. When the
PV modules are connected in series, the ISC equals the PV module's ISC. When

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the PV modules are connected in parallel, the ISC equals the sum of the PV
module's ISC. The ISC of the PV array must not exceed the maximum PV input
current. Please refer to the table below:
Model
Max. PV input current
Max. PV wire size
IT6415ND
60A
16mm2/5AWG
NOTE: When the PV modules are connected in series, the open-circuit voltage
of the PV array must not exceed 138V (25℃)
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
Load wire size
IT6415ND
60A
16mm2/5AWG
16mm2/5AWG
NOTE: The wire size is only for reference. Suppose there is a long distance
between the PV array, the controller, and the battery. In that case, larger wires
can be used to reduce the voltage drop and improve performance.
WARNING
Risk of electric shock!
Adopt fuses or breakers in solar and battery circuits is
recommended, and disconnect them before installation.
Exercise caution when handling solar wiring. The solar PV
array can produce open-circuit voltages over 150 V in
sunlight. Pay more attention to it.
Risk of explosion or fire!
Never short circuit battery positive (+) and negative (-) or
cables. Pay more attention to it.

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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 the rated current. Disconnect it
before installation. Connect battery positive (+) and negative (-) to battery
terminals on the controller in figure 1-1. Please pay much attention to '+' and '-.'
Load Connection
Connect a breaker in series for the load circuit, and the breaker must be 1.25
to 2 times the rated current. Disconnect it before installation. Connect load
positive (+) to the 17th port and negative (-) to the 14th port on the controller in
figure 2-1. Please pay attention to '+"-' and confirm that the cable is connected
tightly and correctly.
PV Array Connection
Connect a breaker in series for the solar circuit, and the breaker must be 1.25
to 2 times the rated current. Disconnect it before installation. Connect solar
positive (+) and negative (-) to solar terminals on the controller in figure 1-1.
Please pay much attention to '+' and '-.'
Solar array short circuit protection and the reversed polarity connection will
trigger automatically.
Figure 2-2 Connection Diagram