Manual_iTracer_EN

Manual_iTracer_EN
EPsolar
iTracer Series
—— Maximum Power Point Tracking
Solar Charge Controller
OPERATION
MANUAL
Thank you very much for selecting our product!
This manual offers important information and suggestion about installation, use and
troubleshooting, etc. Please read this manual carefully before using the product and pay
attention to the safety recommendations in it.
iTracer Series
—— Maximum Power Point Tracking
Solar Charge Controller
Models:
IT3415ND/IT4415ND/IT6415ND
Final interpretation right of the manual belongs to EPsolar.
Any changes without prior notice!
Contents
1.0 Important Safety Information ................................................................. 1
2.0 General Information ............................................................................... 2
2.1 Overview ......................................................................................... 2
2.2 Models & Parameters ...................................................................... 3
2.3 Characteristics ................................................................................. 4
2.4 Optional Accessories ....................................................................... 7
3.0 Installation Instructions .......................................................................... 8
3.1 General Installation Notes ............................................................... 8
3.2 Mounting ......................................................................................... 9
3.3 Wiring ........................................................................................... 10
4.0 Operation .............................................................................................. 14
4.1 MPPT Technology ........................................................................ 14
4.2 Battery Charging Information ....................................................... 16
4.3 LED Indication.............................................................................. 18
4.4 LCD Display & Operation ............................................................ 19
5.0 Protections, Troubleshooting & Maintenance....................................... 30
5.1 Protections..................................................................................... 30
5.2 Troubleshooting ............................................................................ 31
5.3 Maintenance .................................................................................. 32
6.0 Other instructions ................................................................................. 33
6.1 PC software ................................................................................... 33
7.0 Warranty ............................................................................................... 36
8.0 Specifications ....................................................................................... 37
9.0 Conversion Efficiency Curves .............................................................. 39
10.0 Dimensions ......................................................................................... 45
1.0 Important Safety Information
This manual contains important safety, installation and operating instructions for the
iTracer Series MPPT solar controller. Save these instructions.
The following symbols are used throughout this manual to indicate potentially
dangerous conditions or mark important safety instructions.
WARNING: Indicates a potentially dangerous condition. Use
extreme caution when performing this task.
CAUTION: Indicates a critical procedure for safe and proper
operation of the controller.
NOTE: Indicates a procedure or function that is important for
safe and proper operation of the controller.
General Safety Information
 Read all of the instructions and cautions in the manual before installation.
 There are no user serviceable parts inside the controller. Do not disassemble or
attempt to repair the controller.
 Mount the controller indoors. Prevent exposure to the elements and do not allow
water to enter the controller.
 Install iTracer controller in well ventilated places, the iTracer controller heatsink
may become very hot during operation.
 Install external fuses/breakers as required.
 Disconnect the solar module, load and fuse/breakers near to battery before installing
or adjusting the controller.
 Power connections must remain tight to avoid excessive heating from a loose
connection.
1
2.0 General Information
2.1 Overview
Thank you for selecting the iTracer Series MPPT solar controller. The controller is a
high-end industrial class product based on multiphase synchronous rectification
technology and has the features of high efficiency and reliability. The features are listed
below:
 12V/24V/36V/48V Voltage DC systems.
 Smart tracking algorithm that finds and maintains operation at the solar array peak
power point with the tracking efficiency as high as 99.7%.
 Multiphase synchronous rectification technology ensures peak conversion efficiency
is up to 98.7%.
 High effective conversion efficiency at small power charging with multiphase power
decentralized control and improves the generated energy.
 Double processors architecture with high speed and performance improves the
response speed and optimizes the performance of the system.
 Multiphase control technology, optimizes charging current smoothness, reduces
ripple and improves the system generating efficiency.
 Excellent EMC design.
 Excellent heat dissipation. Using the integration of cast aluminum radiator shell, the
controller can be natural cooling.
 128*64 dot-matrix LCD intuitively displays data and state, 6 buttons combinations
for easy operation.
 RS-232, CAN, RS-485 ports via the open standard Modbus protocol are supported
to meet different occasion of demand.
 Support 4 charging preprogram options: Sealed, Gel, Flooded and User-defined.
 Several load control methods are supported to convenient for different demand.
 Protection: Over temperature, over charging, PV and load short, PV (battery) revered,
PV reverse current protect at night, over current protection.
 Actual Power Display and record function make convenience to check the datum
every day, every month and every year.
 Log function: work logs and alarm logs are all recorded.
 Firmware update: convenience to after-service and maintenance service.
The controller features a built-in fuzzy control algorithm that maximizes the energy
from the solar module(s) and charge the battery.
The battery charging process has been optimized for long battery life and improved
system performance. The comprehensive self-diagnostics and electronic protection
2
functions can prevent damage from installation mistakes or system faults.
Please take the time to read this operation's manual and become familiar with the
controller. This will help you make full use of all the functions and improve your PV
system.
2.2 Models & Parameters
Maximum 150 Volt dc systems**
RS-232, RS-485 and CAN port
IT3415ND

Rated charge/discharge current 30A

PV input Max.Power 1600W

12V/24V/36V/48V system voltage and auto work *
IT4415ND

Rated charge/discharge current 45A

PV input Max.Power 2400W

12V/24V/36V/48V system voltage and auto work *
IT6415ND

Rated charge/discharge current 60A

PV input Max.Power 3200W

12V/24V/36V/48V system voltage and auto work *
* The “auto work” setting allows the controller to detect the system voltage
automatically on start up.
** Array voltage should never exceed maximum PV input voltage. Refer to the
solar module documentation to determine the highest expected array Voc (open
circuit voltage) as defined by the lowest expected ambient temperature for the
system location.
3
2.3 Characteristics
1
3
4
5
2
6
4
12
14
13
15
16
17
18
11
10
9
8
7
Figure 2-1. iTracer features
1 – Heat Sink
Aluminum heat sink to dissipate controller heat.
2 – LCD
Display the status and data.
3 – Battery LED indicator
Three states of battery LED indicator show charging status.
4 – Charging LED indicator
Indicate that the battery is charging or not.
5 – Fault LED indicator
Indicate that controller faults.
6 – Buttons
Browse or modify all parameters.
7 – RS-232 port
Monitor controller by PC and update controller software.
5
8 – RS-485 port
Monitor controller by PC and update controller software.
9 –RTC battery
Power to RTC, battery model is CR2032.
10 – Remote Temperature Sensor port(MC1.5-5.08-2L)
Connection for a RTS (Remote Temperature Sensor, optional) to remotely
monitor battery temperature.
11 – Remote Battery Voltage Sensor port(MC1.5-5.08-2L)
Connection for RBVS (Remote Battery Voltage Sensor) to provide accurate
battery voltage measurement.
12 – CAN bus port(MC1.5-3.81-4L)
Communicate with other CAN BUS devices via our company custom protocol.
13 – Solar Positive Terminal
Power connection for Solar Positive Terminal
.
14 –Solar Negative Terminal
Power connection for Solar Negative terminal
.
15 –Load Negative Terminal
Power connection for Load Negative terminal
.
16 –Battery Negative Terminal
Power connection for Battery Negative terminal
.
17 –Battery Positive Terminal
Power connection for Battery Positive Terminal
.
18 –Load Positive Terminal
Load connection for Load Positive Terminal
6
.
2.4 Accessories
Remote Temperature Sensor (Model:RTS300R10K5.08A)
Acquiring of battery temperature for undertaking temperature compensation of control
parameters, the standard length of the cable is 3m (length can be customized). The
RTS300R10K5.08A connects to the MC1.5-5.08-2L port (10th ) on the controller.
Note: unplug the RTS, the temperature of battery will be set to a fixed value 25 ºC.
USB To RS-485 converter (Model:CC-USB-RS485-150U-3.81)
the USB To RS-485 converter is used to monitor each controller on the network using
EPsolar Station PC software and update the firmware. The length of cable is 1.5m. The
CC-USB-RS485-150U-3.81 connects to the MC1.5-5.08-2L port (8th ) on the
controller.
7
3.0 Installation Instructions
3.1 General Installation Notes
 Read through the entire installation section first before beginning installation.
 Be very careful when working with batteries. Wear eye protection. Have fresh water
available to wash and clean any contact with battery acid.
 Use insulated tools and avoids placing metal objects near the batteries.
 Explosive battery gases may be present during charging. So well ventilation of
battery box is recommended.
 Avoid direct sunlight and do not install in locations where water can enter the
controller.
 Ventilation is highly recommended if mounted in an enclosure. Never install the
iTracer in a sealed enclosure with flooded batteries! Battery fumes from vented
batteries will corrode and destroy the iTracer circuits.
 Loose power connections and/or corroded wires may result in resistive connections
that 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.
 Gel, Sealed or Flooded batteries are recommended, other kinds please refer to the
battery manufacturer.
 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 3A/mm2 or less current density.
8
3.2 Mounting
NOTE: The iTracer controller requires at least 150mm of clearance above
and below for proper air flow. Ventilation is highly recommended if
mounted in an enclosure.
WARNING: Risk of explosion! Never install the iTracer in a sealed
enclose with flooded batteries! Do not install in a confined area where
battery gas can accumulate.
Step1: Choose a Mounting Location
Place the iTracer controller on a vertical surface protected from direct sunlight, high
temperatures, and water.
Step2: Check for Clearance
Place the iTracer in the location where it will be mounted. Verify sufficient room to run
wires and sufficient room above and below the controller for air flow.
AT LEAST
WARM AIR
150mm
AT LEAST
COOL AIR
150mm
Figure3-1 Required mounting clearance for air
9
flow
Step3:Mark Holes
Mark the four (4) mounting hole locations on the mounting surface.
Step 4: Drill Holes
Remove the controller and drill four sizeable holes at the marked locations.
Step 5: Secure the Controller
Place the controller on the surface and align the mounting holes with the drilled holes in
step 4. Secure the controller in place using the mounting screws.
3.3 Wiring
NOTE: A recommended connection order has been provided for maximum
safety during installation.
NOTE: Do not entangle all wiring together. Communication cable and
power wires should be as far as possible to avoid interfering
communication signal transmission.
NOTE: The iTracer is a negative ground controller. Any negative
connection of solar, load 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.
Step 1: Remote Temperature Sensor Connection (RTS300R10K5.08A)
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 RTS300R10K5.08A and the battery will be
damaged.
The included remote temperature sensor RTS300R10K5.08A is recommended for
effective temperature compensated charging. Connect the RTS300R10K5.08A to
the10th port (MC1.5-5.08-2L) on the controller (see figure 2-1). The cable standard
length is 3 meters and could be customized. There is no polarity, so either wire (+ or -)
10
can be connected to either screw terminal. No damage will result if connect the
RTS300R10K5.08A to the remote battery voltage sense port, but the connection will
not be recognized.
Step 2: Remote Battery Voltage Sensor Connection
NOTE: When connecting Remote Battery Voltage Sensor, please pay
attention to ‗+‘ and ‗-‘ (see figure 2-1).
CAUTION: Be careful when installation. Please never plug the voltage
sensor wires into to the RTS300R10K5.08A terminals (10th 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 length as required. 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 11th port (MC1.5-5.08-2L) on the controller
(see figure 2-1). A twin-cord cable is recommended but not required.
Please be careful to ‗+‘ 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 RTS300R10K5.08A terminals (10th Port) will cause an alarm
or damage the controller
Step 3: Communicate Connection
WARNING: Shock Hazard! Should not be any communication cables and
power lines intertwined. Separate them as far as possible to void electric
shock.
There are three kinds of communication: RS-232, RS-485 and CAN BUS. Please use
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matching communication cables and make sure the cables are connected firmly during
data transmitting: the below features are supported with communication interface:
1)
Monitor each controller on the network using EPsolar Station PC software; update
the firmware;
2)
Communicate with other module(s) made by EPsolar company with CAN bus;
·
RS-232,RS-485 Connection:
The series port on iTracer controller is a standard 3.81-4P port. See figure 2.1 for the
port location. The RS-232 port is 7th port and the RS-485 port is 8th port on the
controller.
· CAN connection:
The CAN bus port is a standard MC1.5-3.81-4L connector. Refer to 12th port on the
controller in the figure 2-1.
Step 4: Connect the Power Wires
CAUTION: Risk of electric shock! Use fuses or breakers in solar, load 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
100 Vdc when in sunlight. Pay more attention for it.
WARNING: Risk of explosion or fire! Never short circuit battery
Positive (+) and negative (-) or cables. Pay more attention for it
· 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 of the rated current. Keep OFF before connection.
Connect battery positive (+) and negative (-) to battery terminals on the controller in the
figure 2-1. 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 2-1. Please
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pay much attention to ‗+‘ and ‗-‘.
Solar array short circuit protection and the reversed polarity connection will trigger
automatically.
· Load Connection
Connecting a breaker in series in the load circuit is recommended, and the breaker must
be 1.25 to 2 times of the rated current. Make it keep OFF state before connection.
Connect load positive (+) to 18th port and negative (-) to 15th port on the controller in the
figure 2-1. Please pay much attention to ‗+‘‗-‘ and confirm the cable is connected
tightly and right.
Load short circuit protection and the reversed polarity connection will trigger
automatically.
Step 5: Power-Up
NOTE: The controller is only powered by battery, so it will not work when
only connecting to solar input.
 Confirm that all connections are correct especially the Solar, Battery and load
polarities.
 Turn the battery disconnect switch on first. Observe that the LED‘s indicate a
successful start-up (refer to section 4.0).
 Turn the solar disconnect on. If the solar array is in full 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 5.0 for
troubleshooting.
WARNING: Disconnect the battery will produce interference to the load
when the controller is work at charging.
WARNING: Don‘t do the battery reversed polarity test within 10 minutes
after power off.
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4.0 Operation
4.1 MPPT Technology
The iTracer utilizes Maximum Power Point Tracking technology to extract maximum
power from the solar array. The tracking algorithm is fully automatic and does not
require user adjustment. iTracer technology will track the array maximum power point
voltage (Vmp) as it varies with weather conditions, ensuring that maximum power is
harvested from the array through the course of the day.
·
Current Boost
In many cases, iTracer MPPT technology will ‗boost‘ the solar charge current. For
example, a system may have 8 Amps of solar current flowing into the iTracer and 10
Amps of charge current flowing out to the battery. The iTracer does not create current!
Rest assured that the power into the iTracer is the same as the power out of the iTracer.
Since power is the product of voltage and current (Volts×Amps), the following is true*:
(1)
Power Into the iTracer =Power Out of the iTracer
(2) Volts In×Amps In=Volts Out×Amps Out
* Assuming 100% efficiency. Actually, the losses in wiring and conversion exist.
If the solar module’s Vmp is greater than the battery voltage, it follows that the battery
current must be proportionally greater than the solar input current so that input and
output power are balanced. The greater the difference between the maximum power
voltage and battery voltage, the greater the current boost. Current boost can be
substantial in systems where the solar array is of a higher nominal voltage than the
battery.
·
An Advantage Over Traditional Controllers
Traditional controllers connect the solar module directly to the battery when recharging.
This requires that the solar module operate in a voltage range that is below the module‘s
Vmp. In a 12V system for example, the battery voltage may range from 11 to 15Vdc but
14
the module‘s Vmp is typically around 16 or 17V.
Figure 4-1 shows a typical current VS. voltage output curve for a nominal 12V off-grid
module.
Current vs Voltage in 12V system
Output power in 12V system
Figure 4-1 Nominal 12V solar module I-V curve and output power graph
The array Vmp is the voltage where the product of current and voltage (Amps×Volts) is
greatest, which falls on the ‗knee‘ of the solar module I-V curve as shown in Figure4-1.
Because Traditional controllers do not operate at the Vmp of the solar modules(s),
energy is wasted that could otherwise be used to charge the battery and power system
loads. The greater the difference between battery voltage and the Vmp of the module,
the more energy is wasted.
iTracer MPPT technology will always operate at the Vmp resulting in less wasted
energy compared to traditional controllers.
·
Conditions That Limits the Effectiveness of MPPT
The Vmp of a solar module decreases as the temperature of the module increases. In
very hot weather, the Vmp may be close or even less than battery voltage. In this
situation, there will be very little or no MPPT gain compared to traditional controllers.
However, systems with modules of higher nominal voltage than the battery bank will
15
always have an array Vmp greater than battery voltage. Additionally, the savings in
wiring due to reduced solar current make MPPT worthwhile even in hot climates.
4.2 Battery Charging Information
The iTracer has a 4 stages battery charging algorithm for rapid, efficient, and safe
battery charging.
Figura4-2 iTracer charging algorithm
·Bulk Charge
In this stage, the battery voltage has not yet reached boost voltage and 100% of
available solar power is used to recharge the battery.
·Boost Charge
When the battery has recharged to the Boost voltage setpoint, constant-voltage
regulation is used to prevent heating and excessive battery gassing. The Boost stage
remains for some time and then goes to Float Charge. Every time when the controller is
powered on, if it detects neither over discharged nor overvoltage, the charging will
enter into boost charging stage.
·Float Charge
After the Boost voltage stage, iTracer will reduce the battery voltage to float voltage
setpoint. When the battery is fully recharged, there will be no more chemical reactions
and all the charge current transmits into heat and gas at this time. Then the iTracer
16
reduces the voltage to the floating stage, charging with a smaller voltage and current. It
will reduce the temperature of battery and prevent the gassing and charge 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.
Once in Float stage, loads can continue to draw power from the battery. In the event that
the system load(s) exceed the solar charge current, the controller will no longer be able
to maintain the battery at the Float setpoint. Should the battery voltage remain below
the Boost Return Voltage; the controller will exit Float stage and return to Bulk
charging.
·Equalize
WARNING: Risk of explosion!
Equalizing flooded battery would produce explosive gases, so well
ventilation of battery box is recommended.
NOTE: Equipment damage!
Equalization may increase battery voltage to the level damaging to
sensitive DC loads. Verify that all load allowable input voltages are greater
11% than the equalizing charging set point voltage.
NOTE: Equipment damage!
Over-charging and excessive gas precipitation may damage the battery
plates and activate material shedding on them. Too high and equalizing
charge or for too long may cause damage. Please carefully review the
specific requirements of the battery used in the system.
Certain types of batteries benefit from periodic equalizing charge, which can stir the
electrolyte, balance battery voltage and complete chemical reaction. Equalizing charge
increases the battery voltage, higher than the standard complement voltage, which
gasifies the battery electrolyte.
The controller will equalize the battery on 28th each month. The constant equalization
17
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 battery.
NOTE: When the sunshine is weak and Charging current is less than 1.5Amps, the
controller couldn‘t fully follow the maximum power tracking. Therefore, don‘t evaluate
in that condition.
4.3
LED Indication
Charging LED
Indicator
Status
Green Blink
Charging
Green OFF
No charging
Battery LED
Indicator
Status
Green ON
Normal
Green slow blink
Full
Orange ON
Under voltage warning
Red ON
Low voltage disconnect
Red Blink
Battery over temperature
Green fast blink
High volt disconnect
Fault LED
Indicator
Status
Red OFF
Normal
Red Blink
Current abnormal
Overload load short
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All Indicator
4.4

Indicator
Fault Status
Blink(Battery LED in Red)
Work voltage error
Blink(Battery LED in Orange)
Controller over temperature
LCD Display & Operation
Initialization
Efficient Power
LCD will paint the picture as shown on the left as soon
as it is powered on. It indicates that initialization is
normal when the interface goes automatically to the
Rated Info interface.

Rated Info
Rated Para.
Rat.Volt
Rated info of the controller will be displayed. Monitor
interface will be switched after 3 seconds.
48.0V
Chrg.Cur 60.0A
Disc.Curr 60.0A

Main Menu
Click ESC button to return main menu in any monitoring interface.
There are 9 interfaces for monitoring, as shown in the below picture.
Press ↑
↓ button to move inverse cursor among 9 menus.
Press OK to enter corresponding interface.
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1.Monitoring
5.Load Set
2.Log Info
6.Control Para
3.Clock Set
7.Sys Password
4.Local Para Set
8.Default Set
9.Dev Msg
设备参数

Monitor
There are 11 interfaces for monitoring, as shown below:
Load State
ON
Local Temp
25.5 ºC
Load Volt.
12.4V
Load Cur.
2.2A
Total Generated
7.50kWh
Total Consumed
5.50kWh
Batt.Volt
12.4V
Batt Curr
2.2A
Consumed Energy
1.1kWh/D
Load Power
30.5W
Batt Day‘Max
13.5V
Batt Day‘ Min
11.7V
Batt State
Normal
Batt SOC
51%
Batt Temp
21ºC
Temp Coefficient
-3mV/ºC/2V
Charge State
Float
PV Volt.
25.4V
Generated Energy
1.5kWh/D
PV Power
85.5W
Press OK to enter the monitoring interface when the inverse cursor point to monitor
item.
The parameters in monitoring interface are only for browse.
Press ↑
↓ button to browse the parameters interfaces in turns. There are 5
battery status: Normal, UVW(Under voltage warning), LVD(Low voltage disconnect),
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Over Voltage, Over Temperature and 4 charging stages: no charging, equalized, boost,
float. The load status has only ON or OFF status.

Log Info
There are two items of log record as shown blew.
<1>Work Log
<2>Alarm Log
<1>Work Log
<2>Alarm Log
Work Log Query
From 2012-01-01
To 2012-06-08
Total:79
No. 1/79
2012-01-01 00:00
Batt Volt 13.3V
Batt Cur 0.0A
Alarm Log Query
From 2012-01-01
To 2012-06-08
Total:10
No. 1/10
Batt OVD/Begin
2012-01-04 14:20
Para 17.20V
Press OK to enter the monitoring interface when the inverse cursor point to monitor
item. Press ESC button to exit. Work Log and Alarm Log could be browsed in this
interface, the operation is as follows:
Press OK to enter the Work Log or Alarm Log interface respectively when the item is
chosen in inverse. Press OK again to enter the Edit Mode. Use ↑
move the cursor between the time parameters and data bit. Use +
or
↓
button to
- button to
modify the value and set the period of log for browse. When the period is set, press OK
to enter the corresponding details.
Log Number, time, the voltage and current of battery are included in every work log
item and are shown in the Work Log interface.
warning event sequence number, warning event, start or end time, the fault status and
values are all included in every event log item and are shown in the Alarm Log
interface.
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
Clock Set
The interface of Clock Set is shown as follow:
Press OK to enter the Clock Set interface when the inverse cursor
Clock Set
Jan-16-2014
17:12:28
point to Clock Set item. Press ESC button to exit.
Date and Time can be adjusted in this interface. Press OK and
input the 6 digit user password and then Date and Time could be
adjusted. The format of date is YYYY-MM-DD; the one of time is HH-MM-SS. When
the set is over, press OK to save or press ESC button to cancel. ―save success!‖ will
be promoted if adjusted and save operated successfully.
Input Password
Save Cancel
Save success!
000000
NOTE:The log after the current time will be erased when the clock has be adjusted.

Device Parameter
There are 3 interfaces about device parameter as shown blew:
Local ID
T03-0001
Backlight Time
60 s
Storage Interval
10min
Press OK to enter the Device Parameter interface when the inverse cursor point to
Device Para item. Press ESC button to exit.
You should input the user password (see above) before setting the parameters.
The first interface shows the 4-digit controller‘s ID in networking and keeps the ID
number unique in the networking or PC software or other device(s) couldn‘t search it.
The 2nd interface shows the backlight time. The range is from 1 to 90 seconds
(60seconds default). ―–―means that the backlight is never off. The interval log is from 1
to 30 minutes (10minutes default).
22

Load Mode
Press OK to enter the Load Mode interface when the inverse cursor points to Load
Mode item. Press ESC button to exit. Load Mode can be set through each menu item
respectively.
Manual(default)
the default load output can be
√ Manual
◎ Light On/Off
Manual Control
set ON/OFF in this interface.
ON
Parameters in the table below:
◎ Light On+Timer
◎ Time
Parameter
Detail
The load will open automatically after the controller is
ON
initialized. If the battery power is enough and the controller
works well, load will keep open
The load will keep off after the controller is initialized. Only
when open load manually, load can be output. If the battery
OFF
power is enough and the controller works well, load will keep
open
23
Light On/Off
Load control mode can be set
Light On/Off
to light control in this interface.
◎ Light On/Off
On 05.0V T 10 M
Parameters in the table below:
◎ Light On+Timer
Off 06.0V T 10 M
◎ Manual
◎ Time
Parameter
Detail
When solar module voltage goes below the point of NTTV (Night Time
Night Time Threshold
Voltage
Threshold Voltage), the solar controller will recognize the starting voltage
and turn on the load after pre-set time delay when the battery power is
enough and the controller works well
When solar module voltage goes above the point of DTTV (Day Time
Day Time Threshold
Threshold Voltage), the solar controller will recognize the starting voltage
Voltage
and turn off the load after pre-set time delay
Solar energy confirms delay time. If the solar energy meets the condition to
Delay time
the action, it will be execute. The range of delay time value is 0 to 99
minutes
24
Light On+Timer
◎ Manual
Light On+Timer
Light On+Timer
◎ Light On/Off
On 05.0V T 10 m
On T1 01H:00M
◎ Light On+Timer
Off 06.0V T 10 m
On T2 01H:00M
◎ Time
NightTime 12:00
Load control mode can be set to light + time control in this interface. Parameters in the
table below:
Parameter
Detail
Working Time 1
The open time of load in the light mode after dusk
Working Time 2
The open time of load in the light mode before dawn
The controller calculated the total length of the night by self-learning.
Night time
The time should be more than 3 hours
25
Time
◎ Manual
Time Control 1
Time Control 2
◎ Light On/Off
On Time 19 : 00
On Time 05 : 00
◎ Light On+Timer
Off Time 02 : 00
Off Time 06 : 00
◎ Time
Single Double
Load control mode can be set to time control in this interface. Parameters in the table
below:
Parameter
Detail
Time Control 1
Set the begin and end time 1 of the load output
Time Control 2
Set the begin and end time 2of the load output
Single
The load output according to time1
Double
The load output according to time1 and time2
26

Control Parameter
Press OK to enter the Device Parameter interface when the inverse cursor point to
Control Para item. Press ESC button to exit. There are 10 interfaces for ‗Control
Parameters‘ as shown below.
Batt Type
SEALED
Batt AH
200AH
Temp Coefficient
Over Volt. Disc.
32.0V
Charge Limit
30.0V
-3mV/℃/2V
Rated Volt
AUTO
Batt. Manag.
Char.SOC: 100%
Disc.SOC: 30%
Vol.Com. SOC
Equalize Time
60 min
Boost Time
60 min
Over Volt. Rect
31.0V
Equalize Charge
29.2V
Boost Charge
28.8V
Float Charge
27.6V
Under Volt Rect
24.4V
Under Volt Warn
24.0V
Low Volt Disc
22.2V
Discharge Limit
21.6V
Boost Rect Volt
26.4V
Low Volt Rect
25.2V
You should input the user password(see above) before setting the parameters. In
setting mode, all the parameters can be modified. And will immediately effect when
saved. The detail and value range of control parameter are shown in the tables below:
Battery Charging Setting
Battery Type
Note
Sealed (default)
GEL
flooded
Constant value
Constant value
Constant value
User
Defined by user
27
Battery Charging Mode
Charging Mode
Voltage Compensate
SOC
Note
Controlled by voltage(default)
SOC mode, controlled by SOC charging or discharging value
Others
Parameter
Battery capacity
Temperature compensate
coefficient
Rated system voltage
Default value
200Ah
Range
1~9999Ah
-3mV/ºC/2V
-9~0mV
Auto
Auto/12V/24V/36V/48V
Precent of charging
100%
100% constant value(SOC charging mode)
Precent of discharging
30%
10~80% (SOC charging mode)
Battery Control Parameters
All the coefficient is referred to 25℃, and twice in 24v system rate, triple in 36v
system rate and quadruple in 48v system rate.
Battery Type
High Volt Disconnect
Charging limit voltage
Over Voltage Reconnect
Equalization voltage
Boost voltage
Float voltage
Boost return voltage
Low voltage reconnect
Under voltage recover
Under voltage warning
Low voltage disconnect
Discharging limits voltage
Equalize duration
Boost duration
Gel
16V
15V
15V
——
14.2V
13.8V
13.2V
12.6V
12.2V
12V
11.1V
10.6V
——
120min
Sealed
16V
15V
15V
14.6V
14.4V
13.8V
13.2V
12.6V
12.2V
12V
11.1V
10.6V
120min
120min
Flooded
16V
15V
15V
14.8V
14.6V
13.8V
13.2V
12.6V
12.2V
12V
11.1V
10.6V
120min
120min
User
9~17V
9~17V
9~17V
9~17V
9~17V
9~17V
9~17V
9~17V
9~17V
9~17V
9~17V
9~17V
0~180min
10~180min
The following rules must be observed when modify the parameters value in user
battery type(factory default value is the same as sealed type):
Rule1: High Volt Disconnect > Charging limit voltage ≥ Equalization voltage ≥ Boost
voltage ≥ Float voltage > Boost return voltage;
Rule2: High Volt Disconnect > Over Voltage Reconnect;
Rule3: Low voltage reconnect > Low voltage disconnect ≥ Charging limit voltage;
28
Rule4: Under voltage recover > Under voltage warning ≥ Charging limit voltage;
Rule5: Boost return voltage > Low voltage reconnect;

Password
Press OK to enter the Password Set interface when the inverse cursor points to
Password Para item. Press ESC button to exit.
Sys Password
Note: The factory default password is “000000”.
Old PSW 000000
New PSW 000000

Default Set
Under the main menu interface, when the inverse cursor to restore the default option,
press the OK button to enter to restore the default interface.
Default Set
No
Yes
Clr Log Record
Retain clear
Under the main menu interface, when the inverse cursor
points to restore the default option, press the OK button to
enter to restore the default interface and clear all logs
including work log and event log. Note: all parameters will be
set to factory default and couldn‘t be recovery.

Device Message
Under the main menu interface, when the inverse cursor to the Dev Msg , press the
OK button to enter to Device Info interface.
ARM Msg.
DSP Msg.
Type: IT6415ND
Type: IT6415ND
Ver:v01.00+v02.60
Ver:v01.00+v02.60
SN:0420131210000001
SN: 0420131210000001
The Model, software and hardware version and SN number are shown in this interface.
29
5.0 Protections, Troubleshooting & Maintenance
5.1 Protections
·PV Short Circuit
When PV short circuit occurs, the controller will stop charging. Clear it to resume
normal operation.
·PV Over Voltage
If PV voltage is larger than maximum input open voltage 150V, PV will remain
disconnected and warning until the voltage falls safely below 145V. PV voltage cannot
be too high, otherwise it may damage the controller, please verify the PV parameter.
·PV Over Current
The iTracer controller will limit battery current to the Maximum Battrery Current
rating. An over-sized solar array will not operate at peak power.
·PV or/and Battery Polarity Reversed
Fully protection against PV or/and Battery reverse polarity, no damage to the controller
will result. Correct the miswire to resume normal operation.
·Over Temperature Protection
If the temperature of the controller heat sinks exceeds 85℃, the controller will
automatically start the overheating protection and recover below 75℃.
·Load Over Load
If the load current exceeds the maximum load current rating 1.05 times, the controller
will disconnect the load. Overloading must be cleared up through reducing the load and
then press the - button.
·Load Short Circuit
Fully protected against load wiring short-circuit. Once the load short, the load short
protection will start automatically. After five automatic load reconnect attempt, the
fault must be cleared by restarting controller or pressing the - button .
NOTE: Overload fault and load short fault will be cleared every day, so
the faults which aren’t caused by hardware can be solved intelligently.
30
5.2 Troubleshooting
 Charging LED indicator off during daytime when sunshine falls on solar modules
properly
Solution: Confirm that PV and battery wire connections are correct and tight.
 Battery LED indicator green fast blink and LCD displaying ‗OVD‘
Probable Cause: Battery voltage is larger than over voltage disconnect voltage (OVD).
Solution: Check if battery voltage too high, and disconnect solar modules.
 Fault LED indicator blink, LCD displaying ‗Current Err‘
Probable Cause: Charging current in three phases is unbalanced.
Solution: Disconnect solar modules and restart the iTracer; if the fault still exists, please
contact the supplier to make maintenance.
 Fault LED indicator blink, LCD displaying ‗Over Volt‘
Probable Cause: solar modular output is too high.
Solution: Check solar component parameters matching; the controller will disconnect
the input if the voltage is over 150v and will Recovery below 145v.
 Fault LED indicator blink, LCD displaying ‗Over Temp‘
Probable Cause: Heat sinks operational temperature is quite high to 85 ºC
or above.
Solution: The controller will automatically stop working. When the temperature is
below 75 ºC, the controller will resume to work.
 Cannot connect to the controller via RS-485 or RS-232
Probable Cause:RS-485 serial baud rate setting error or serial-USB adapter incorrect
configuration.
Solution: Check serial baud rate is set to 115200bps or not and choose the right COM
port ;If using a serial-USB adapter, verify that the adapter software is installed and a
serial COM port has been mapped.
31
5.3
Maintenance
The following inspections and maintenance tasks are recommended at least two times
per year for best controller performance.
 Check that the controller is securely mounted in a clean and dry environment.
 Check that the air flow and ventilation around the controller is not blocked. Clear all
dirt or fragments on the heat sink.
 Check all the naked wires to make sure insulation is not damaged for serious
solarization, frictional wear, dryness, insects or rats etc. Maintain or replace the wires if
necessary.
 Tighten all the terminals. Inspect for loose, broken, or burnt wire connections.
 Check and confirm that LED or LCD is consistent with required. Pay attention to any
troubleshooting or error indication .Take necessary corrective action.
 Confirm that all the system components are ground connected tightly and correctly.
 Confirm that all the terminals have no corrosion, insulation damaged, high
temperature or burnt/discolored sign, tighten terminal screws to the suggested torque.
 Inspect for dirt, insects and corrosion, and clear up.
 Check and confirm that lightning arrester is in good condition. Replace a new one in
time to avoid damaging of the controller and even other equipments.
Warning:Risk of electric shock!
Make sure that all the power is turned off before above operations, and
then follow the corresponding inspections and operations.
32
6.0 Other instructions
6.1 PC Software
iTracer controller can be connected to a common PC monitoring software by supporting
USB communication cable developed by the EPsolar company. Monitoring software
can remote single or more controllers to modify the parameters, configure load mode
and others in the PV system management (username: administrator, password: 111111
as default). See the specific instructions related software user guide. Software
interfaces are shown below:
Figure6-1 Globe Monitoring
33
Figure6-2 Real Time Monitoring
34
Figure6-3 Control Parameter
Figure6-4 Load Configuration
35
7.0 Warranty
The iTracer charge controller is warranted to be free from defects for a period of TWO
(2) years from the date of shipment to the original end user.
• Claim Procedure
Before requesting warranty service, check the operation manual to be certain that there
is a problem with the controller. Return the defective product to us with shipping
charges prepaid if problem cannot be solved. Provide proof of date and place of
purchase. To obtain rapid service under this warranty, the returned products must
include the model, serial number and detailed reason for the failure, the module type
and size, type of batteries and system loads. This information is critical to a rapid
disposition of your warranty claim.
If the products failure is caused by customers‘ misuse or not following the manual,
EPsolar won‘t be responsible for the free maintenance. We will ask for the raw material
cost. And please refer to above procedure.
36
8.0 Specifications
Electrical Parameters
Nominal System Voltage
Nominal Battery Current
Maximum Solar Input Voltage
Battery Voltage Range
Maximum Input Power
12V:
24V:
36V:
48V:
Self Consumption
Grounding
IT3415ND
T4415ND
IT6415ND
12Vdc/24Vdc/36Vdc/48Vdc/ Auto
30A
45A
60A
150Vdc
8~72Vdc
400W
800W
1200W
1600W
600W
800W
1200W
1600W
1800W
2400W
2400W
3200W
1.4~2.2W
Common Negative Grounding
Mechanical Parameters
IT3415ND
LxWxH
L:
W:
H:
Net Weight:
Terminal:
Mounting Hole:
358mm
219mm
102mm
3.7kg
25mm2
IT4415ND
IT6415ND
382mm
231mm
107mm
4.6kg
35mm2
Φ10
440mm
231mm
110mm
5.9kg
35mm2
Environmental Parameters
LCD Temp
-20℃ ~ +70℃
Ambient Temp
-25℃ ~ +55℃
Storage Temp
-30℃ ~ +85℃
Humidity
95% N.C.
Enclosure
IP20
Protection
37
Solar input short protection
Solar input reversed polarity protection
Solar input reverse current protect at night
Battery reversed polarity protection
Battery over voltage disconnect protection
Battery over voltage reconnect protection
Battery over temperature disconnect protection
Load short disconnect protection
Load overload disconnect protection
Controller over temperature disconnect protection
Abbreviation
HVD
High voltage disconnect
LVD
Low voltage disconnect
OVT
over temperature
UVW
Under voltage warning
38
9.0 Conversion Efficiency Curves
Test model: IT3415ND
1.
Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(12V)
12V Conversion Efficiency Curves
95
94
66V
Conversion Efficiency(%)
93
92
98V
91
115V
90
89
88
87
86
85
50
150
200
250
Charging Power(W)
300
350
400
Solar MPPT Voltage(33V, 66V, 98V, 115V) / System Voltage(24V)
24V Conversion Efficiency Curves
99
98
33V
Conversion Efficiency(%)
2.
100
97
66V
96
98V
95
115V
94
93
92
91
90
100
200
300
400
500
Charging Power(W)
39
600
700
800
3.
Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(36V)
36V Conversion Efficiency Curves
99
Conversion Efficiency(%)
98
66v
97
98v
115v
96
95
94
93
92
100
300
400
500
600
700
Charging Power(W)
800
900
1000
1100
Solar MPPT Voltage(17V,34V,68V) / System Voltage(48V)
48V Conversion Efficiency Curves
99
98.5
Conversion Efficiency(%)
4.
200
98
66v
97.5
115v
97
98v
96.5
96
95.5
95
0
200
400
600
800
Charging Power(W)
40
1000
1200
1400
Test model: IT4415ND
1.
Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(12V)
12V Conversion Efficiency Curves
96
95
66v
Conversion Efficiency(%)
94
98v
93
92
115v
91
90
89
88
87
86
0
200
300
400
Charging Power(W)
500
600
Solar MPPT Voltage(33V, 66V, 98V, 115V) / System Voltage(24V)
24V Conversion Efficiency Curves
99
98
33v
66v
97
Conversion Efficiency(%)
2.
100
96
98v
95
115v
94
93
92
91
90
89
100
200
300
400
500
600
700
800
Charging Power(W)
41
900
1000
1100
1200
3.
Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(36V)
36V Conversion Efficiency Curves
99
Conversion Efficiency(%)
98
66v
97
98v
96
115v
95
94
93
92
91
0
400
600
800
1000
1200
Charging Power(W)
1400
1600
1800
Solar MPPT Voltage(66V, 98V, 115V) / System Voltage(48V)
48V Conversion Efficiency Curves
99
98
66v
Conversion Efficiency(%)
4.
200
98v
97
115v
96
95
94
93
92
91
90
0
200
400
600
800
1000 1200 1400 1600 1800 2000 2200 2400
Charging Power(W)
42
Test model: IT6415ND
1.
Solar MPPT Voltage(17V,34V,68V) / System Voltage(12V)
12V Conversion Efficiency Curves
98
96
34v
Conversion Efficiency(%)
17v
94
92
68v
90
88
86
84
82
0
200
300
400
500
600
Charging Power(W)
700
800
900
1400
1600
Solar MPPT Voltage(34V,68V,115V) / System Voltage(24V)
24V Conversion Efficiency Curves
100
98
Conversion Efficiency(%)
2.
100
34v
96
68v
94
115v
92
90
88
86
0
200
400
600
800
1000
Charging Power(W)
43
1200
3.
Solar MPPT Voltage(68V,115V) / System Voltage(36V)
36V Conversion Efficiency Curves
98
Conversion Efficiency(%)
96
68v
94
115v
92
90
88
86
84
400
600
800 1000 1200 1400 1600 1800 2000 2200 2400 2600
Charging Power(W)
Solar MPPT Voltage(68V,115V) / System Voltage(48V)
48V Conversion Efficiency Curves
100
98
Conversion Efficiency(%)
4.
200
96
68v
94
115v
92
90
88
86
0
300
600
900
1200
1500 1800 2100
Charging Power(W)
44
2400
2700
3000
3300
10.0 Dimensions
IT3415ND Dimensions(Unit:mm)
45
IT4415ND Dimensions(Unit:mm)
46
IT6415ND Dimensions(Unit:mm)
Version:V2.2
47
48
49
50
BEIJING EPSOLAR TECHNOLOGY CO., LTD.
Tel:010-82894112 / 82894962
Fax:010-82894882
E-mail:[email protected]
Website: www.epsolarpv.com
51
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