Epever Tracer-AN Series User manual

Tracer-AN series
——MPPT Solar Charge Controller
User Manual
Model:
Tracer5415AN/Tracer6415AN
Tracer8415AN/Tracer10415AN
Tracer5420AN/Tracer6420AN
Tracer8420AN/Tracer10420AN

Important Safety Instructions
Please reserve this manual for future review. This manual contains all
instructions of safety, installation and operation of Tracer-AN series ("the
controller" is referred in this manual).
General Safety Information
Read carefully all the instructions and warnings in the manual before
installation.
No user serviceable component inside controller. DO NOT disassemble or
attempt to repair the controller.
Avoid direct sunlight, 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.
Installing appropriate external fuses/breakers is suggested.
Make sure switching off all connections with PV array and the fuse/breakers
close to battery before controller 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.....................................................................................2
1.3 Accessories (Included)........................................................................3
1.4 Designations of Controller Models.......................................................3
2 Installation................................................................................................................4
2.1 General Installation Notes...................................................................4
2.2 PV Array Requirements.......................................................................4
2.3 Wire Size.............................................................................................8
2.4 Mounting .............................................................................................9
3 Operation ...............................................................................................................13
3.1 Indicator ............................................................................................13
3.2 Button................................................................................................13
3.3 LCD Display ......................................................................................13
3.4 Setting...............................................................................................15
4 Protections, Troubleshooting & Maintenance...................................................17
4.1 Protections ........................................................................................17
4.2 Troubleshooting.................................................................................18
4.3 Maintenance......................................................................................18
5 Specifications ........................................................................................................20
Annex I Dimensions.................................................................................................22

1
1 General Information
1.1 Overview
Tracer-AN series controller, based on multiphase synchronous rectification technology (MSRT)
and advanced MPPT control algorithm, with dual-core processor architecture and common
negative design, has the features of high response speed, high reliability and high industrial
standard. MSRT can guarantee very high conversion efficiency in any charge power, which
sharply improves the energy efficiency of solar system; Advanced MPPT control algorithm
minimize the maximum power point loss rate and loss time, to ensure the tracking efficiency,
corresponding speed as well as high conversion efficiency under high or low power, so that in
any situation, Tracer-AN products can rapidly track the maximum power point(MPP) of PV
array to obtain the maximum energy of the panel. The limitation function of the charging power
and current, and automatic power reduction function fully ensure the stability when works with
oversize PV modules and operate under high temperature environment.
With the adaptive three-stage charging mode based on digital control circuit, Tracer-AN series
controllers can effectively prolong the life-cycle of battery and significantly improve the system
performance. The load, utility and generator auto-control relay output make it easy to connect
other equipment. All-around electronic protections, including overcharging, over discharging,
and PV reverse polarity protection, effectively ensure the safer and more reliable operation of
the solar system for a longer service time. The isolated RS485 interface with standard
MODBUS communication protocol makes it easy for customer to expand the application,
greatly meet with different monitoring requirements, so that can be widely used for various
applications, e.g. solar RV, household system and field monitoring, etc.
Features:
High quality and low failure rate components of ST and IR ensure the product’s service life
100% charging and discharging in working environment temperature range
Maximum DC/DC transfer efficiency as high as 98.7%
Advanced MPPT technology & ultra-fast tracking speed guarantee tracking up to 99.5%
Advanced MPPT control algorithm minimize the MPP loss rate and loss time
Accurate recognition and tracking of multiple-peaks maximum power point
Wide MPP operating voltage range
Limit the charging power and current over rated value
Support 4 charging options: Sealed, Gel, Flooded and User.
Battery temperature compensation function
Real-time energy statistics function
Automatic over-temperature power reduction function
Load relay control to realize diversified load work modes
Auto-control of utility and generator relay design
Remote temperature sensor and remote voltage sensor design, collect more accurate data
of battery temperature and voltage value

2
Isolated RS-485 with 5VDC/200Ma protected output for no power devices, with MODBUS
protocol
Monitor and set the parameters via mobile phone APP or PC software
1.2 Characteristics
❶-Charging LED indicator
❿-Utility/Diesel generator relay ON
❷-SELECT button
➀-RBVS Port(2)
❸-Fuse
➁-Load control delay(4)
❹-Grounding Terminal
➂-Utility/Diesel generator relay OFF
❺-Cover screw holes M4
➃-PV Terminals(4)
❻-PV reverse polarity alarm indicator
➄-Battery Terminals(3)
❼-Generator and load relay enable⑴
➅-ENTER button
❽-RTS Port(3)
➆-LCD
❾-RS485 port(5VDC/200mA)
➇-Fault LED indicator
(1) Generator and load relay enabled when the switch is ON;
Generator and load delay is abled when the switch is OFF.
(2) Connect for RBVS (Remote Battery Voltage Sensor) to detect accurate battery voltage.
Figure 1 Characteristics

3
(3) Connect for a RTS (Remote Temperature Sensor) to remotely detect battery temperature.
If the temperature sensor is short-circuited or damaged, the controller will charge or
discharge at the default temperature setting of 25 ºC.
(4) Common negative design, with the same terminal of the PV and battery.
1.3 Accessories (Included)
Item
Accessory
Model
Number
Picture
1
Local Temperature Sensor
RT-MF58R47K3.81A
(2P-3.81mm)
1Pcs
2
Battery Voltage Sensor Terminal
2P-3.81mm
1Pcs
3
Load control delay Terminal
2P-3.81mm
1Pcs
4
Diesel generator relay Terminal
2P-3.5mm
2Pcs
WARNING: DO NOT insert the same model terminals into different interface,
or the controller may be damaged.
1.4Designations of Controller Models
Example:

4
2 Installation
2.1 General Installation Notes
Before installation, please read through the entire installation instructions to get familiar with
the installation steps.
Be very careful when installing the batteries, especially flooded lead-acid battery. 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 short circuit of the battery.
Explosive battery gases may come out from the battery during charging, so make sure
ventilation condition is good.
Lead-acid battery and lithium battery are recommended, other kinds 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 result in high heat that can 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.
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.
Multiple same models of controllers can be installed in parallel on the same battery bank to
achieve higher charging current. Each controller must have its own solar module(s).
Select the system cables according to 5A/mm2or less current density in accordance with
Article 690 of the National Electrical Code, NFPA 70.
2.2 PV Array Requirements
(1)Serial connection (string) of PV modules
As the core component of PV system, Controller could be suitable for various types of PV
modules and maximize converting solar energy into electrical energy. According to the open
circuit voltage (Voc) and the maximum power point voltage (Vmpp) of the MPPT controller, the
series number of different types PV modules can be calculated. The below table is for
reference only.
Tracer5415/6415/8415/10415AN:
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

5
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.)
Tracer5420/6420/8420/10420AN:
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
3
1
2
1
2
1
24V
6
3
4
2
4
2
3
2
48V
8
5
5
4
5
3
4
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
4
3
2
2
2
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) PV array maximum power
The MPPT controller has the function of current/power-limiting, that is, during the charging
process, when the charging current or power exceeds the rated charging current or power, the
controller will automatically limit the charging current or power to the rated charging current or
power, which can effectively protect the charging parts of controller, and prevent damages to
the controller due to the connection of some over-specification PV modules. The actual
operation of PV array is as follows:
Condition 1:
Actual charging power of PV array ≤Rated charging power of controller
Condition 2:
Actual charging current of PV array ≤Rated charging current of controller
When the controller operates under “Condition 1”or“Condition 2”, it will carry out the charging
as per the actual current or power; at this time, the controller can work at the maximum power
point of PV array.
WARNING: When the power of PV module is greater than the rated charging
power, and the maximum open-circuit voltage of PV array is more than
150V(Tracer**15AN)/200V(Tracer**20N) (at the lowest environmental temperature),
the controller may be damaged.

6
Condition 3:
Actual charging power of PV array＞Rated charging power of controller
Condition 4:
Actual charging current of PV array＞Rated charging current of controller
When the controller operates under “Condition 3”or“Condition 4”，it will carry out the charging
as per the rated current or power.
WARNING: When the power of PV module is greater than the rated charging
power, and the maximum open-circuit voltage of PV array is more than
150V(Tracer**15AN)/200V(Tracer**20N) (at the lowest environmental temperature)
, the controller may be damaged.
According to “Peak Sun Hours diagram”, if the power of PV array exceeds the rated charging
power of controller, then the charging time as per the rated power will be prolonged, so that
more energy can be obtained for charging the battery. However, in the practical application,
the maximum power of PV array shall not be greater than 1.5 x the rated charging power of
controller. If the maximum power of PV array exceeds the rated charging power of controller
too much, it will not only cause the waste of PV modules, but also increase the open-circuit
voltage of PV array due to the influence of environmental temperature, which may increase the
probability of damage to the controller rise. Therefore, it is very important to configure the
system reasonably. For the recommended maximum power of PV array for this controller,
please refer to the table below:

7
Item
Rated Charge
Current
Rated Charge
Power
Max. PV Power
Max. PV Open Circuit
Tracer5415AN
50A
625W/12V
1250W/24V
1875W/36V
2500W/48V
937.5W/12V
1875W/24V
2812.5W/36V
3750W/48V
150V
(At Min. operating environment Tem.)
138V
(At 25℃environment Tem.)
Tracer6415AN
60A
750W/12V
1500W/24V
2250W/36V
3000W/48V
1125W/12V
2250W/24V
3375W/36V
4500W/48V
Tracer8415AN
80A
1000W/12V
2000W/24V
3000W/36V
4000W/48V
1500W/12V
3000W/24V
4500W/36V
6000W/48V
Tracer10415AN
100A
1250W/12V
2500W/24V
3750W/36V
5000W/48V
1875W/12V
3750W/24V
5625W/36V
7500W/48V
Tracer5420AN
50A
625W/12V
1250W/24V
1875W/36V
2500W/48V
937.5W/12V
1875W/24V
2812.5W/36V
3750W/48V
200V
(At Min. operating environment Tem.)
180V
(At 25℃environment Tem.)
Tracer6420AN
60A
750W/12V
1500W/24V
2250W/36V
3000W/48V
1125W/12V
2250W/24V
3375W/36V
4500W/48V
Tracer8420AN
80A
1000W/12V
2000W/24V
3000W/36V
4000W/48V
1500W/12V
3000W/24V
4500W/36V
6000W/48V
Tracer10420AN
100A
1250W/12V
2500W/24V
3750W/36V
5000W/48V
1875W/12V
3750W/24V
5625W/36V
7500W/48V

8
2.3 Wire Size
The wiring and installation methods must conform to all national and local electrical code
requirements.
PV Wire Size
Since PV array output can vary due to the PV module size, connection method or sunlight
angle, the minimum wire size can be calculated by the Isc＊of PV array. Please refer to the
value of Isc in the PV module specification. When PV modules connect in series, the Isc is
equal to a PV modules Isc. When PV modules connect in parallel, the Isc is equal to the sum of
the PV module’s Isc. The Isc of the PV array must not exceed the controller’s maximum PV
input current. Please refer to the table as 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＊
Tracer5415AN
Tracer5420AN
50A
16mm2/6AWG
Tracer6415AN
Tracer6420AN
60A
16mm2/5AWG
Tracer8415AN
Tracer8420AN
80A
25mm2/4AWG
Tracer10415AN
Tracer10420AN
100A
35mm2/2AWG
＊These are the maximum wire sizes that will fit the controller terminals.
CAUTION: When the PV modules connect in series, the open circuit voltage of the
PV array must not exceed 138V (Tracer**15AN) or 180V (Tracer**20AN) at 25℃
environment temperature.
Battery Wire Size
The battery wire size must conform to the rated current, the reference size as below:
Model
Rated charge current
Battery wire size
Tracer5415AN
Tracer5420AN
50A
16mm2/6AWG
Tracer6415AN
Tracer6420AN
60A
16mm2/5AWG
Tracer8415AN
Tracer8420AN
80A
25mm2/4AWG
Tracer10415AN
Tracer10420AN
100A
35mm2/2AWG
CAUTION: The wire size is only for reference. If there is a long distance between
the PV array and the controller or between the controller and the battery, larger
wires can be used to reduce the voltage drop and improve performance.
CAUTION: The battery wire size recommended is for battery terminal without
inverter.

9
2.4 Mounting
WARNING：The controller doesn’t have battery reverse polarity protection. DO NOT
reversely connect the battery wires, the controller may be damaged.
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.
WARNING: Risk of electric shock! When wiring the solarmodules, the PV array can
produce open circuit voltages in excess of 100V when in sunlight.
CAUTION：The controller requires at least 150mm of clearance above and below
for proper air flow. Ventilation is highly recommended if mounted in an enclosure.
Installation steps:
Step 1: Determination of Installation Location and Heat-dissipation Space
Determination of installation location: The controller shall be installed in a place with sufficient
air flow through the radiators of the controller and a minimum clearance of 150 mm from the
upper and lower edges of the controller to ensure natural thermal convection. Please see
Figure 2-1: Mounting
CAUTION: If the controller is to be installed in an enclosed box, it is important
to ensure reliable heat dissipation through the box.
Figure2-1 Mounting

10
Step 2：Remove the terminal protective cover
Step3：Connect the battery and PV
NOTE: Disconnect the system in the reverse order

11
WARNING：The controller doesn’t have battery reverse polarity protection. DO NOT
reversely connect the battery wires, the controller may be damaged.
CAUTION: While wiring the controller do not close the circuit breaker or fuse and
make sure that the leads of "+" and "-" poles are connected correctly.
CAUTION: Afuse which 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 150 mm.
CAUTION: If an inverter is to be connected to the system, connect the inverter
directly to the battery, not to the load side of the controller.
Step 4：Grounding
Tracer AN series is a common-negative controller, where all the negative terminals of PV array
and battery can be grounded simultaneously or any one of them will be grounded. However,
according to the practical application, all the negative terminals of PV array, battery and load
can also be ungrounded, but the grounding terminal on its shell must be grounded, which may
effectively shield the electromagnetic interference from the outside, and prevent some electric
shock to human body due to the electrification of the shell.
CAUTION: For common-negative system, such as motorhome, it is recommended
to use a common-negative controller; but if in the common-negative system, some
common-positive equipment are used, and the positive electrode is grounded, the
controller may be damaged.
Step 5：Control the utility/generator ON/OFF via the utility/generator relay
Conditions of switching ON/OFF of the utility/generator:
Utility/generator start voltage(VON)=Under Voltage Warning Voltage
Utility/generator stop voltage(VOFF)=Under Voltage Warning Recover Voltage
Battery Voltage (VBAT)
When VBAT is lower than VON, utility/generator relay’s normally open contact
close and normally closed contact open, the utility/generator starts to work.
When VBAT is higher than VOFF, utility/generator relay’s normally open contact
open and normally closed contact close, the utility/generator stops working.
NOTE：The utility/ generator start/stop voltage can be set via the PC software
Step 6：Connect accessories
Connect the remote temperature sensor cable (Model:RTS300R47K3.81A)
Connect the remote temperature sensor cable to the interface ➀and place
the other end close to the battery.
CAUTION: If the remote temperature sensor is not connected to the controller,, the
default setting for battery charging or discharging temperature is 25 °C without
temperature compensation.
Connect Remote Battery Voltage Sensor (Model:RVBS300B3.81)
Connect the remote battery voltage sensor cable to the interface ❿and connect the other end
to the battery terminals.

12
Connect the accessories for RS485 communication, refer to the accessories list.
Step 7：Powered on the controller
Turn on the battery fuse to power on the controller, then check the LCD is OFF or the fault
indictor is ON when the controller is normal.
CAUTION: If the controller is not operating properly or the battery indicator on the
controller shows an abnormality, please refer to 4.2 “Troubleshooting”.

13
3 Operation
3.1 Indicator
Indicator
Color
Status
Instruction
Charging
LED indicator
Green
On Solid
PV connection normal but low
voltage(irradiance) from PV,
no charging
Green
OFF
No PV voltage(night time) or
PV connection problem
Green
Slowly Flashing
In charging
Green
Fast Flashing
PV over voltage
3.2 Button
Button
Function
SELECT button
Browse interface
Setting parameter
ENTER button
Load ON/OFF
Clear error
Enter into Set Mode
Save data
3.3 LCD Display
Status Description
Item
Icon
Status
Day

14
PV array
Night
No charging
Charging
PV Voltage, Current, Power
Battery
Battery capacity, In Charging
Battery Voltage, Current, Temperature
Battery Type
Load
Load control delay turn ON
Load control delay turn OFF
Load control delay control the load voltage,
current, energy and work mode
Browse interface
NOTE: When no operation, the interface will be automatic cycle, but the follow two interfaces
not be display.
Fault Indication
Status
Fault
indicator
charging
indicator
Icon
Description
Battery over
discharged
Red
on solid
——
Battery level shows empty,
battery frame blink, fault
icon blink.
Battery over
voltage
Red
slowly
flashing
——
Battery level shows full,
battery frame blink, fault
icon blink.

15
Battery over
temperature
Red
slowly
flashing
——
Battery level shows current
value, battery frame blink,
fault icon blink.
Controller over
temperature
Red
slowly
flashing
Green
slowly
flashing
Battery level shows current
value, battery frame blink,
fault icon blink.
System voltage
error
Red
slowly
flashing
Green
fast flashing
Battery level shows current
value, battery frame blink,
fault icon blink.
3.4 Setting
(1)Clear the generated energy
Operating:
Step 1: Press the “ENTER”button and hold 5s under the PV power interface and the value
is flashing.
Step 2: Press the “ENTER”button to clear the generated energy..
(2)Switch the battery temperature unit
Press the “ENTER”button and hold 5s under the battery temperature interface.
(3)Battery type
Battery Type
①Sealed (Default) ②Gel ③Flooded
④User(Apply to “MT50” and “PC software “Solar Station Monitor”）
Operating Steps
Under Battery Voltage interface, long press ENTER button enter into the interface of Battery
type setting. After choosing the battery type by pressing SELECT button, waiting for 5
seconds or pressing ENTER button again to modify successfully.
Battery Voltage Parameters
The parameters is in 12V system at 25℃, please use double value in 24V
Battery charging setting
Sealed
Gel
Flooded
User
Over Voltage Disconnect Voltage
16.0V
16.0V
16.0V
9~17V
Charging Limit Voltage
15.0V
15.0V
15.0V
9~17V
Over Voltage Reconnect Voltage
15.0V
15.0V
15.0V
9~17V
Equalize Charging Voltage
14.6V
——
14.8V
9~17V

16
Battery charging setting
Sealed
Gel
Flooded
User
Boost Charging Voltage
14.4V
14.2V
14.6V
9~17V
Float Charging Voltage
13.8V
13.8V
13.8V
9~17V
Boost Reconnect Charging
Voltage
13.2V
13.2V
13.2V
9~17V
Low Voltage Reconnect Voltage
12.6V
12.6V
12.6V
9~17V
Under Voltage Warning
Reconnect Voltage
12.2V
12.2V
12.2V
9~17V
Under Volt. Warning Volt.
12.0V
12.0V
12.0V
9~17V
Low Volt. Disconnect Volt.
11.1V
11.1V
11.1V
9~17V
Discharging Limit Voltage
10.6V
10.6V
10.6V
9~17V
Equalize Duration (min.)
120
——
120
0~180
Boost Duration (min.)
120
120
120
10~180
NOTE:
1) When the battery type is sealed, gel, flooded, the adjusting range of equalize duration is 0
to180min and boost duration is 10 to180min.
2) The following rules must be observed when modifying the parameters value in user battery
type (factory default value is the same as sealed type):
a. Over Voltage Disconnect Voltage > Charging Limit Voltage ≥ Equalize Charging Voltage ≥
Boost Charging Voltage ≥ Float Charging Voltage > Boost Reconnect Charging Voltage.
b. Over Voltage Disconnect Voltage > Over Voltage Reconnect Voltage
c. Low Voltage Reconnect Voltage > Low Voltage Disconnect Voltage ≥ Discharging Limit
Voltage.
d. Under Voltage Warning Reconnect Voltage > Under Voltage Warning Voltage ≥
Discharging Limit Voltage.
e. Boost Reconnect Charging voltage > Low Voltage Disconnect Voltage.
CAUTION: Please refer to user guide or contact with the sales for the detail of
setting operation.