Epever Tracer-AN Series User manual

Tracer-AN series
——MPPT Solar Charge Controller
User Manual
Models：
Tracer8415AN
Tracer10415AN

Important Safety Instructions
Please reserve this manual for future review. This manual contains all
instructions of safety, installation and operation for Maximum Power Point
Tracking (MPPT) controller in 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.
Mount the controller indoors. 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.
Suggested to install appropriate external fuses/breakers.
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 Maximum Power Point Tracking Technology ......................................3
1.5 Battery Charging Stage.......................................................................5
2 Installation................................................................................................................8
2.1 General Installation Notes...................................................................8
2.2 PV Array Requirements.......................................................................8
2.3 Mounting ...........................................................................................10
2.4 Wiring................................................................................................11
2.5 Power Up...........................................................................................15
3 Operation ...............................................................................................................15
3.1 Indicator ............................................................................................16
3.2 Button Function.................................................................................16
3.3 LCD Display ......................................................................................16
3.4 Battery Type......................................................................................18
4 Protections, Troubleshooting & Maintenance...................................................20
4.1 Protections ........................................................................................20
4.2 Troubleshooting.................................................................................21
4.3 Maintenance......................................................................................21
5 Specifications ........................................................................................................23
6 Disclaimer ..............................................................................................................24
Annex I Dimensions.................................................................................................25

1
1 General Information
1.1 Overview
Appreciate you for choosing our MPPT solar charge controller, Tracer-AN
series. Based on multiphase synchronous rectification technology (MSRT) and
common negative design, with dual-core processor architecture and advanced
MPPT control algorithm, the products in this series have the features of high
response speed, high reliability, high industrial standards, etc.
With MPPT control algorithm, in any situation, products of this series can fast
and accurately track out the best maximum power point (MPP) of PV array, in
order to obtain the maximum solar energy in time, MSRT can guarantee very
high conversion efficiency in any charge power, which sharply improves the
energy efficiency of solar system. With Modbus communication protocol
interface, it is convenient for customers to expand applications and monitor in
various fields like telecommunication base station, household system,
wilderness monitoring system, etc.
All-round electronic fault self-test function and enhanced electronic protection
function could furthest avoid damages on system components resulting from
installation errors or system failures.
Features:
Advanced Maximum Power Point Tracking (MPPT) technology, with
efficiency no less than 99.5%.
High quality components, perfecting system performance, with maximum
conversion efficiency of 98.7% and full load efficiency of 98%.
MSRT, realizing high conversion efficiency in the situation of low charge
power.
Ultra-fast tracking speed and guaranteed tracking efficiency.
Accurately recognizing and tracking of multiple power points.
Reliable automatic limit function of maximum PV input power, ensuring no
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

2
dissipation characteristic.
12/24/36/48VDC automatically identifying system voltage or user-defined
working voltage.
Concise human-computer interactive interface, convenient multiple
combination keys, dynamically displaying system operating data and working
condition.
Support 4 charging options: Sealed, Gel, Flooded and User.
Battery temperature compensation function.
Real-time energy statistics function.
With RS-485 communication bus interface and Modbus communication
protocol, it is available to 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.
Support software upgrade.
1.2 Characteristics

3
Item
Name
Item
Name
1
Charging LED indicator
9
PV reverse polarity alarm indicator
2
LCD
10
Diesel generator relay enable
Load control relay enable
3
SELECT button
11
RS485 port②
4
Fuse
12
Diesel generator relay
5
Battery Terminals
13
RBVS Port③
6
PV Terminals
14
ENTER button
7
RTS Port①
15
Fault LED indicator
8
Load control relay
16
Cover screw holes
①Connect for a RTS (Remote Temperature Sensor) to remotely detect battery
temperature.
②Monitor controller by PC and update controller software via RS485
③Connect for RBVS (Remote Battery Voltage Sensor) to detect accurate
battery voltage.
1.3 Maximum Power Point Tracking Technology
Due to the nonlinear characteristics of solar array, there is a maximum energy
output point (Max Power Point) on its curve. Traditional controllers, with switch
charging technology and PWM charging technology, can‟t charge the battery at
the maximum power point, so can‟t harvest the maximum energy available
from PV array, but 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.
Figure 1-1 Tracer-AN Series Characteristics

4
The MPPT algorithm of our company continuously compares and adjusts the
operating points to attempt to locate the maximum power point of the array.
The tracking process is fully automatic and does not need user adjustment.
As the Figure 1-2, the curve is the characteristic curve of the array, the MPPT
technology will boost the battery charge current through tracking the MPP.
Assuming 100% conversion efficiency of the solar system, in that way, the
following formula is established:
Normally, the VMpp is always higher than VBat, Due to the principle of
conservation of energy, the IBat is always higher than IPV. The greater the
discrepancy between VMpp &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, the shaded area is charging
range of traditional solar charge controller (PWM Charging Mode), it can
obviously diagnose that the MPPT mode can improve the usage of the solar
energy resource. According to our test, the MPPT controller can raise 20%-30%
efficiency compared to the PWM controller. (Value may be fluctuant due to the
influence of the ambient circumstance and energy loss.)
Figure 1-2 Maximum Power Point Curve
In actual application, as shading from cloud, tree and snow, the panel may
Input power (PPV)= Output power (PBat)
Input voltage (VMpp) *input current (IPV) =Battery voltage (VBat) *battery current (IBat)

5
appear Multi-MPP, but in actually there is only one real Maximum Power Point.
As the below Figure 1-3 shows:
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, which may waste most solar energy
resources and seriously affect the normal operation of the system. The typical
MPPT algorithm, designed by our company, can track the real MPP quickly
and accurately, improve the utilization rate of the array and avoid the waste of
resources.
1.5 Battery Charging Stage
The controller has a 3 stages battery charging algorithm (Bulk Charging,
Constant Charging and Float Charging) for rapid, efficient, and safe battery
charging.
Figure 1-4 Battery changing stage
Curve

6
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, and in the meantime the charging current will drop gradually, the
process is not the MPPT charging. The Constant Charging has 2 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 battery.
Boost Charging
The Boost stage maintain 2 hours in default, user 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 battery would produce explosive gases, so well
ventilation of battery box is recommended.
CAUTION: Equipment damage!
Equalization may increase battery voltage high enough so as to
damage sensitive DC loads. Verify that all load allowable input
voltages are 11% greater than the equalizing charging set point
voltage.
CAUTION: 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 types of batteries benefit from equalizing charge on a regular basis,
which is able to stir electrolyte, balance battery voltage and accomplish
chemical reaction. 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 each month. The constant
equalization period is 0~180 minutes. If the equalization isn‟t accomplished in
one-time, the equalization recharge time will be accumulated until the set time
is finished. Equalize charge and boost charge are not carried out constantly in
a full charge process to avoid too much gas precipitation or overheating of

7
battery.
NOTE: 1) Due to the influence of ambient circumstance or load working,
the battery voltage can’t be steady in constant voltage, controller will
accumulate and calculate the time of constant voltage working. When the
accumulated time reach to 3 hours, the charging mode will turn to Float
Charging.
2) If the controller time is not adjusted, the controller will equalize charge
battery once every month following the inner time.
C) Float Charging
After the Constant voltage stage, the controller will reduce charging current to
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 temperature of the battery and prevent
the gassing and charging the battery slightly at the same time. The purpose of
Float stage is to offset the power consumption caused by self consumption and
small loads in the whole system, while maintaining full battery storage
capacity.
In Float charging stage, loads are able to obtain almost all power from solar
panel. If loads exceed the power, the controller will no longer be able to
maintain battery voltage in Float charging stage. If the battery voltage remains
below the Recharge Voltage, the system will leave Float charging stage and
return to Bulk charging stage.

8
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.
Gel, Sealed or Flooded batteries 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

9
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.
Tracer8415AN：
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) PV array maximum power
This MPPT controller has a limiting function of charging current, the charging
current will be limited within rated range, therefore, the controller will charge
the battery with the rated charging power even if the input power at the PV
exceeds.
The actual operation power of the PV array conforms to the conditions below:
1）PV array actual power ≤ controller rated charge power, the controller
charge battery at actual maximum power point.
2）PV array actual power > controller rated charge power, the controller
charge battery at rated power.
If the PV array higher than rated power, the charging time at rated power to
battery will be longer, more energy to battery yields.
WARNING: Controller will be damaged when the PV array straight
polarity and the actual operation power of the PV array is three times
greater than the rated charge power!
WARNING: Controller will be damaged when the PV array reverse
polarity and the actual operation power of the PV array is 1.5 times
greater than the rated charge power!

10
When the PV array straight polarity, the actual operation of the PV array must
NOT exceed three times of rated charge power；When the PV array reverse
polarity, the actual operation must NOT exceed 1.5 times. For real application
please refer to the table below:
Model
Rated
Charge
Current
Rated Charge
Power
Max. PV
Array Power
Max. PV
open circuit
voltage
Tracer8415AN
80A
1050W/12V
2100W/24V
3150W/36V
4200W/48V
3150W/12V
6300W/24V
9450W/36V
12600W/48V
150V①
138V②
Tracer10415AN
100A
1325W/12V
2650W/24V
4000W/36V
5300W/48V
3975W/12V
7950W/24V
12000W/36V
15900W/48V
①At minimum operating environment temperature
②At 25℃environment temperature
2.3 Mounting
CAUTION: When mounting the controller, ensure at least 150mm of
clearance above and below the controller for proper air flow. If
mounted in an enclosure, ensure good ventilation condition of the
box.
WARNING: Risk of explosion!
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.

11
2.4 Wiring
CAUTION: The following connection order is recommended for
optimal safety.
CAUTION: Do not entangle all wiring together. Communication
cable and power wires should be as far as possible to avoid
interfering communication signal transmission.
CAUTION: The controller is a negative ground controller. Any
negative connection of solar or battery can be earth grounded as
required.
CAUTION: 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 and/or fire.
①Remote Temperature Sensor Connection
CAUTION: The controller will perform temperature compensation
for charging parameters according to the device temperature.
CAUTION: Equipment Damage! Never place the temperature
sensor inside a battery. Both the RTS and the battery will be
damaged.
※Please remove the terminal
protective cover before wiring.

12
The included remote temperature sensor is recommended for effective
temperature compensated charging. Connect the RTS to the7th 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 connect the RTSto the remote
battery voltage sense port, but the connection will not be recognized.
②Remote Battery Voltage Sensor Connection
CAUTION: When connecting Remote Battery Voltage Sensor,
please pay attention to „+‟ and „-‟(Check Figure 1-1).
CAUTION: Be careful when installation. Please never plug the
voltage sensor wires into to the RTS terminals (7th Port). This 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
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 size
can range from 0.25 to 1.0 mm2(24 to 16 AWG). Maximum length is 3m.
Connect the remote battery voltage sensor wires to the 13th port on the
controller (Check Figure 1-1). A twin-cord cable is recommended but not
required.
Please be careful to 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 to the RTS terminals (7th Port)
will cause an alarm or damage the controller.
③Power Wires Connection
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 PV module specification. When the PV
modules connect in series, the ISC is equal to the PV module‟s ISC. When the
PV modules connect in parallel, the ISC is equal to the sum of PV module‟s ISC.
The ISC of PV array must not exceed the maximum PV input current, please
refer to the table as below:

13
Model
Max. PV input current
Max. PV wire size
Tracer8415AN
80A
25mm2/4AWG
Tracer10415AN
100A
35mm2/2AWG
NOTE: When the PV modules connect in series, the open circuit voltage of the
PV array must not exceed 138V under the 25℃condition.
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
Tracer8415AN
80A
25mm2/4AWG
Tracer10415AN
100A
35mm2/2AWG
NOTE: 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.
Figure 2-1 Stand-alone Wiring Diagram

14
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 to the rated current. Keep OFF
before connection. Connect battery positive (+) and negative (-) to battery
terminals on the controller in the figure 1-1. Please pay much attention to „+‟
and „-‟.
Solar Module(s) Connection
Connecting a breaker in series in the solar circuit is recommended, and the
breaker must be 1.25 to 2 times of the rated current. Keep OFF before
connection. Connect solar positive (+) and negative (-) to solar terminals on
the controller in the figure 1-1. Please pay much attention to „+‟ and „-‟.
Solar array short circuit protection and the reversed polarity connection will
trigger automatically.
WARNING: Risk of electric shock!
Use fuses or breakers in solar and battery circuits is recommended,
and make them keep OFF state before connection.
WARNING: Risk of electric shock!
Exercise caution when handling solar wiring. The solar PV array can
produce open-circuit voltages in excess of 150 V when in sunlight.
Pay more attention to it.
Figure 2-2Multi-machine Wiring Diagram

15
WARNING: Risk of explosion or fire!
Never short circuit battery positive (+) and negative (-) or cables.
Pay more attention to it
2.5 Power Up
CAUTION: The controller is only powered by battery, so it will not
work when connected only to solar input.
Before switching on, recheck the step of ①～④and make sure all wirings
correct, especially ④connected with battery and PV array.
Turn on the battery Fuse firstly. Observe if battery indicator light and
startup interface work fine or not (Refer to section 4). Always connect the
battery firstly, in order to allow the controller to recognize the system
voltage.
After battery works fine with power on, switch on the breaker of PV array.
With enough sunlight, the charging LED will blink and the controller will
begin charging.
If the battery LED error exists or LCD interface alarms, refer to section 5 for
troubleshooting. When disconnecting the system, the order will be
reserved.
3Operation

16
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
Fault LED
indicator
Red
OFF
Normal
Red
Flashing
Over discharged
Battery Overheating
All indicator is fast flashing
System voltage error
All indicator is slowly flashing
Controller Overheating
3.2 Button Function
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
PV array
Day
Night
No charging
Charging