Epever Tracer AN series User manual

Tracer AN series
——MPPT Solar Charge Controller
User Manual
Models:
Tracer5210AN/Tracer6210AN
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 controller
("the controller" is referred in this manual).
General Safety Information
Read all the instructions and warnings carefully 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 the controller at
locations where water can get in.
Install the controller at well ventilated places, the controller’s heat sink will be
very hot during operation.
Installing appropriate external fuses/breakers is suggested.
Please make sure to switch off all connections of the PV array and the
fuse/breakers which close to the battery before the controller installation and
adjustment.
Power connections must remain tight to avoid excessive heating from the
loose connection.

Contents
1 General Information.......................................................................................1
1.1 Overview .............................................................................................1
1.2 Characteristics.....................................................................................2
1.3 Designations of Controller Models.......................................................3
1.4 Accessories (Included)........................................................................3
1.5 Accessories (optional).........................................................................4
2 Installation.....................................................................................................5
2.1 General Installation Notes...................................................................5
2.2 PV Array Requirements.......................................................................5
2.3 Wire Size.............................................................................................8
2.4 Relay instruction..................................................................................9
2.5 Mounting ...........................................................................................11
3 Operation.....................................................................................................16
3.1 Indicator ............................................................................................16
3.2 Button................................................................................................16
3.3 LCD Display ......................................................................................17
3.4 Setting...............................................................................................18
4 Protections, Troubleshooting & Maintenance..............................................20
4.1 Protections ........................................................................................20
4.2 Troubleshooting.................................................................................21
4.3 Maintenance......................................................................................22
5 Specifications ..............................................................................................23
Annex I Dimensions........................................................................................25

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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 or generator auto-control relays make it easy to compose the
hybrid power system. 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 and 5V power supply makes it easy for customer
to expand the application, it support up to 8 charging in parallel to expand system and 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:
CE certification(LVD EN/IEC62109,EMC EN61000-6-1/3)
High quality & low failure rate components of ST and Infineon to ensure the product’s life
Advanced MPPT technology & ultra-fast tracking speed, with tracking efficiency no less than
99.5%
Maximum DC/DC transfer efficiency is as high as 98.6%★, full load efficiency is up to 98%★
Advanced MPPT control algorithm will minimize the MPP loss rate and loss time
The accuracy of the recognition and tracking at the highest point of multiple-peaks MPP
The wider range of MPP operating voltage.
Auto control system to limit the charging power & current go over the rated value.
Support 4 charging options: Sealed, Gel, Flooded and User.
Battery temperature compensation function
Real-time energy recording and statistical function
Automatic over-temperature power reduction function
Hundred percent full load operation in working environment temperature range within
charging & discharging
Support up to 8 units in parallel to expand system

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Load relay control external load switch signal to realize diversified load work modes
The first and the second disconnection of load control, contain two relay’s contact.
Auto-control of utility and generator relay design
Utility or generator auto-control relays make it easy to compose the hybrid power system
The remote temperature and the voltage sensor design will collect accurate data of battery
temperature and voltage
Isolated RS485 with 5VDC/200mA to protect output for no power devices with MODBUS
protocol
To monitor or set the parameters by using the phoneApps or PC software.
★Tracer10415AN@48V system
1.2 Characteristics
❶-Charging LED indicator
❿-Utility/Generator relay ON
❷-SELECT button
➀-RBVS Port(3)
❸-Fuse
➁-Load control relay(4)
❹-Grounding Terminal
➂-Utility/Generator relay OFF
❺-Cover screw holes M4
➃-PV Terminals(5)
Figure 1 Characteristics

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❻-PV reverse polarity alarm indicator
➄-Battery Terminals(5)
❼-Generator and load relay enable⑴
➅-ENTER button
❽-RTS Port(2)
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 disabled when the switch is OFF.
(2) Connect for a RTS (Remote Temperature Sensor) to remotely detect battery temperature,
sample distance less than 20m.
CAUTION: If the temperature sensor is short-circuited or damaged, the controller
will charge or discharge at the default temperature setting of 25 ºC.
(3) Connect for RBVS (Remote Battery Voltage Sensor) to detect accurate battery voltage,
sample distance less than 20m.
(4) Low Voltage Disconnect Voltage(VLVD) make the relay turn off;
Low Voltage Reconnect Voltage(VLVR) make the relay turn on.
(5) Common negative design, with the same terminal of the PV and battery.
1.3Designations of Controller Models
Example:
1.4 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: The Battery Voltage Sensor Terminal and Load Control Delay Terminal
should not mix, otherwise the controller may be damaged.

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1.5 Accessories (optional)
Remote Temperature Sensor
(RTS300R47K3.81A)
Acquisition of battery temperature for undertaking temperature compensation of
control parameters, the standard length of the cable is 3m (length can becustomized).
The RTS300R47K3.81A connects to the port (4th) on the controller.
NOTE: The temperature sensor short-circuited or damaged, the controller will
be charged or discharged at the default temperature 25 ºC.
USB to RS485 cable
CC-USB-RS485-150U
USB to RS485 converter is used to monitor each controller using Solar Station PC
software. The length of cable is 1.5m. TheCC-USB-RS485-150U connects to the
RS485 Port on the controller.
Remote Meter
MT50
MT50 can display various operating data and fault info the system. The information
can be displayed on a backlit LCD screen, the buttons are easy-to-operate, and the
numeric display is readable.
WIFI Serial Adapter
eBox-WIFI-01
After thecontroller is connected with the eBox-WIFI-01 through the standard Ethernet
cable (parallel cable), the operating status and related parameters of the controller
can be monitored by the mobile APP software through WIFI signals.
RS485 to Bluetooth Adapter
eBox-BLE-01
After the controller is connected with the eBox-BLE-01 through the standard Ethernet
cable (parallel cable), the operating status and related parameters of the controller
can be monitored by the mobile APP software through Bluetooth signals.
Logger
eLOG01
After the controller is connected with the eLOG-01 throughthe RS485 communication
cable, it can record the operating data of the controller or monitor the real-time
operating status of the controller via PC software.
PT Adapter
PT-ADP
Manage to work and communicate with the 2 to 8 pcs controllers in parallel
NOTE: For setting and operation of accessory, please refer to accessory’s user manual.

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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 if 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 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, burning surrounding materials, or even causing 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.
Tracer5210/6210AN:
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

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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 Mass1.5.)
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
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:

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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
100V(Tracer**10AN)/150V(Tracer**15AN)/200V(Tracer**20N) (at the lowest environmental
temperature), the controller may be damaged.
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
100V(Tracer**10AN)/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:
Item
Rated Charge
Current
Rated Charge
Power
Max. PV
Power
Max. PV Open
Circuit
Tracer5210AN
50A
625W/12V
1250W/24V
937.5W/12V
1875W/24V
100V①
92V②
Tracer6210AN
60A
750W/12V
1500W/24V
1125W/12V
2250W/24V
Tracer5415AN
50A
625W/12V
1250W/24V
1875W/36V
2500W/48V
937.5W/12V
1875W/24V
2812.5W/36V
3750W/48V
150V①
138V②
Tracer6415AN
60A
750W/12V
1500W/24V
2250W/36V
3000W/48V
1125W/12V
2250W/24V
3375W/36V
4500W/48V

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Tracer8415AN
80A
1000W/12V
2000W/24V
3000W/36V
4000W/48V
1500W/12V
3000W/24V
4500W/36V
6000W/48V
150V①
138V②
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
200V①
180V②
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
①At minimum operating environment temperature
②At 25℃environment temperature
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, connectionmethod orsunlight angle,
the minimum wire size can be calculated by the Isc＊of PV array. Please refer to the value ofIsc
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.

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Model
Max. PV input current
Max. PV wire size＊
Tracer5210AN
Tracer5415AN
Tracer5420AN
50A
16mm2/6AWG
Tracer6210AN
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 72V (Tracer**10AN)/138V(Tracer**15AN)/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
Tracer5210AN
Tracer5415AN
Tracer5420AN
50A
16mm2/6AWG
Tracer6210AN
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.
2.4 Relay instruction
Utility/Generator Relay and Load Parameter：
Rated Value：5A/30VDC
Maximum Value：0.5A/60VDC
1) Control the utility/generator ON/OFF via the utility/generator relay
Utility/Generator start-up Voltage (VON)=Under Voltage Warning Voltage
Utility/Generator stop Voltage (VOFF)= Under Voltage Warning Recover Voltage
Low Voltage Disconnect Voltage (VLVD)

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Battery Voltage (VBAT)
Charging current (Ic)
Discharging current (Id)
Start-up the Utility/Generator working:
VBAT＜VON.
Stop the Utility/Generator working:
VBAT＜VON
CAUTION: The VON and VOFF can be set via the PC software，the Battery Control
Voltage Parameters refer to the chapter 3.4 Setting.
2) Control the load first disconnection and second disconnection.
Battery Voltage (VBAT)
Under Voltage Warning Voltage (VUVW)
Under Voltage Warning Recover Voltage (VUVWR)
Low Voltage Disconnect Voltage(VLVD)
Low Voltage Reconnect Voltage(VLVR)
Utility/Generator Relay normally closed contact:
VBAT≤VUVW: The Utility/Generator Relay normally closed contact OFF control the load ❶first
disconnection;
VBAT≥VUVWR: The Utility/Generator Relay normally closed contact ON control the load❶first
connection.
Load Relay：
VBAT≤VLVD:The Load Relay OFF control the load❷second disconnection;
VBAT≤VLVR:The Load Relay ON control the load❷second connection;
CAUTION: The Battery Control Voltage Parameters refer to the chapter 3.4
Setting.
WARNING: When the system power off, the utility/generator relay normally
closed contact is closed, please check the system in time.

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Refer to the below the diagram:
2.5 Mounting
WARNING: Do not reverse the polarity of the batteries. Reverse polarity will damage
the charge controller permanently. Damage caused by reverse polarity, is not covered by
warranty.
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! The solar array high voltage can cause serious
shock or injury. Make use of fuses/breaker or cover the entire solar array, prior to performing
any work on change controller.
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.

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Step 2：Remove the terminal protective cover
Step3：Connect the battery❶(Left) and PV❷(Right)
NOTE: Disconnect the system in the reverse order.
WARNING: Do not reverse the polarity of the batteries. Reverse polarity will damage the
charge controller permanently. Damage caused by reverse polarity, is not covered by warranty.
CAUTION: While wiring the controller do not turn on the breaker or fuse and make sure
that the leads of "+" and "-" poles are connected correctly.
CAUTION: A fuse 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.

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One controller：

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Multiple controllers