ACOPOWER HY-MPPT Series MPPT Solar Charge Controller User Manual

1.1 Overview

The Tracer AN series, based on a common-negative design and advanced MPPT control algorithm, features an LCD displaying running status. This product is artistic, economical, and practical. By improving the MPPT control algorithm, the Tracer AN series minimizes maximum power point loss rate and loss time, quickly tracks the maximum power point of the PV array, and obtains maximum energy from solar modules under any conditions. It can increase solar system energy utilization by 10%-30% compared to PWM charging methods. The integrated charging power and current limitation functions, along with automatic charging power reduction, enhance stability, even with oversized PV modules or in high temperatures. A professional protection chip for the communication port further improves reliability and meets diverse application requirements.

With an adaptive three-stage charging mode controlled digitally, Tracer AN series controllers prolong battery life, significantly improve system performance, and offer all-around electronic protection, including overcharging and over-discharging protection. This minimizes system component damage from incorrect installation or system failure, ensuring safer and more reliable operation of the solar power supply system for extended service life. This modular solar controller is suitable for various applications, such as communication base stations, household systems, and field monitoring.

Features:

• Advanced MPPT technology with efficiency no less than 99.5%
• Ultra-fast tracking speed and guaranteed tracking efficiency
• Advanced MPPT control algorithm to minimize maximum power point loss rate and loss time
• Wide MPP operating voltage range
• High-quality components for optimal system performance, with maximum conversion efficiency of 98%
• Accurate recognition and tracking of multiple-peaks maximum power point
• Utilizes high-quality components from international brands like ST and IR, ensuring a low failure rate and product service life
• Charging power and current limitation function
• Compatible with lead-acid and lithium-ion batteries
• Battery temperature compensation function
• Real-time energy statistics function
• Overheating power reduction function
• Multiple load work modes
• Communication port features a professional protection chip providing 5VDC power supply with over-current and short-circuit protection.
• Equipped with RS-485 communication bus interface and Modbus communication protocol to meet various communication needs.
• Allows parameter monitoring and setting via mobile phone APP or PC software.
• Supports full-load operation without capacity drop within the working environment temperature range.
• Features extensive electronic protection.

1.2 Characteristics

Figure 1 shows the front panel of the MPPT solar charge controller. Key components are labeled: 1. SELECT button, 2. RTS Interface, 3. PV Terminals, 4. Battery Terminals, 5. Load Terminals, 6. RS485 communication interface, 7. Mounting Hole (Φ5mm), 8. ENTER button, 9. LCD display. A note indicates that if the temperature sensor is short-circuited or damaged, the controller will charge or discharge at the default temperature setting of 25°C.

1.3 Designations of Controller Models

The model designation follows a pattern, for example, HY-MPPT 1 2 10 AN, which indicates: Common Negative System, Max. PV open circuit voltage 100V, System Voltage 12/24VDC, Charge & discharge current 10A, and Product Series.

1.4 Maximum Power Point Tracking Technology

Due to the nonlinear characteristics of solar arrays, there is a maximum energy output point (Max Power Point). Traditional controllers using switch charging and PWM charging technologies cannot charge the battery at this maximum power point, thus failing to harvest the maximum available energy from the PV array. However, MPPT technology allows the solar charge controller to lock onto this point, harvest maximum energy, and deliver it to the battery.

The company's MPPT algorithm continuously compares and adjusts operating points to locate the array's maximum power point. This tracking process is fully automatic and requires no user adjustment.

Figure 1-2 illustrates a typical Maximum Power Point (MPP) curve for a solar array, showing the relationship between voltage and current. It highlights the MPP and the traditional operating range for PWM controllers, indicating that MPPT technology captures more energy. The formula for power conversion is: Input power (P_PV) = Output power (P_Bat), where Input voltage (V_MPP) * input current (I_PV) = Battery voltage (V_Bat) * battery current (I_Bat). Typically, V_MPP is higher than V_Bat, and due to energy conservation, I_Bat is higher than I_PV. A larger discrepancy between V_MPP and V_Bat leads to a larger discrepancy between I_PV and I_Bat, resulting in reduced system conversion efficiency. Therefore, controller conversion efficiency is crucial in PV systems.

Figure 1-2 shows that the shaded area represents the charging range of traditional PWM controllers. It is evident that MPPT mode significantly improves solar energy resource utilization. Testing indicates that MPPT controllers can achieve 20%-30% higher efficiency compared to PWM controllers, though values may vary with ambient conditions and energy loss.

Figure 1-3 displays characteristic curves for solar arrays that may exhibit multiple power peaks (Multi-MPP) due to conditions like shading (cloud, tree, snow). It shows how MPPT technology can accurately track the real MPP, unlike simpler algorithms that might get stuck on a suboptimal peak, thus wasting solar energy and affecting system operation. The company's MPPT algorithm quickly and accurately tracks the real MPP, improving array utilization and preventing resource waste.

1.5 Battery Charging Stage

The controller employs a 3-stage battery charging algorithm (Bulk Charging, Constant Charging, and Float Charging) for rapid, efficient, and safe battery charging.

Figure 1-4 illustrates the three-stage battery charging process: Bulk Charging (constant current, MPPT), Constant Charging (constant voltage, including Boost and Equalize stages), and Float Charging (maintaining battery voltage). The graphs show battery voltage and current over time for each stage.

• A) Bulk Charging: In this stage, the battery voltage has not yet reached the constant voltage setpoint (Equalize or Boost Voltage). The controller operates in constant current mode, delivering maximum current to the batteries (MPPT Charging).
• B) Constant Charging: When the battery voltage reaches the constant voltage setpoint, the controller switches to constant charging mode. This is no longer MPPT charging, and the charging current gradually decreases. Constant Charging includes two stages: Equalize and Boost. These stages are not continuously active during a full charge cycle to prevent excessive gas precipitation or battery overheating.
  • Boost Charging: The Boost stage defaults to 2 hours but can be adjusted by the user for constant time and preset boost voltage. It helps prevent heating and excessive battery gassing.
  • Equalize Charging: WARNING: Explosive Risk! Equalizing flooded batteries can produce explosive gases; ensure good ventilation of the battery box. CAUTION: Equipment damage! Equalization may increase battery voltage to a level that damages sensitive DC loads. Verify that all load allowable input voltages are 11% greater than the equalizing charging set point voltage. Over-charging and excessive gas precipitation can damage battery plates and cause material shedding. High or prolonged equalizing charges may cause damage. Consult specific battery requirements. Equalizing charge increases battery voltage, which can gasify the electrolyte. The controller equalizes the battery on the 28th of each month for 0-180 minutes. If not completed in one session, the time accumulates. Equalize and boost charges are not constant to avoid gas precipitation or overheating. NOTE: 1) Due to ambient conditions or load, battery voltage may fluctuate. The controller accumulates constant voltage working time; after 3 hours, it switches to Float Charging. 2) If the controller time is not adjusted, equalization occurs monthly based on internal time.
• C) Float Charging: After the Constant voltage stage, the controller reduces charging current to the Float Voltage setpoint. This stage involves minimal chemical reactions. The voltage is reduced to the floating stage, charging with lower voltage and current to minimize battery temperature and gassing, while maintaining full battery storage capacity. Loads can draw power directly from the solar panel. If loads exceed available power, the controller may not maintain battery voltage. If battery voltage drops below the Recharge Voltage, the system exits Float charging and returns to Bulk charging.

2.1 General Installation Notes

• Read all installation instructions before proceeding.
• Exercise caution when installing batteries, especially flooded lead-acid types. Wear eye protection and have fresh water available for cleaning battery acid contact.
• Keep batteries away from metal objects to prevent short circuits.
• Ensure good ventilation, as explosive battery gases may be released during charging.
• Ventilation is highly recommended for enclosed installations. Never install the controller in a sealed enclosure with flooded batteries, as fumes can corrode circuits.
• Loose or corroded power connections can cause high heat, melting insulation, burning materials, or fire. Ensure tight connections and use cable clamps to secure wires, especially in mobile applications.
• Lead-acid and lithium batteries are recommended; consult the battery manufacturer for other types.
• Battery connections can be to a single battery or a bank. Instructions apply to both.
• Multiple controllers can be paralleled on the same battery bank for higher charging current, with each controller requiring its own solar module(s).
• Select system cables according to 5A/mm² or less current density, conforming to Article 690 of the National Electrical Code, NFPA 70.

2.2 PV Array Requirements

As a core component of the PV system, the controller is suitable for various PV modules. The series number of PV modules can be calculated based on the open circuit voltage (Voc) and maximum power point voltage (V_MPP) of the MPPT controller. The following tables provide reference values.

NOTE: Parameter values are calculated under standard test conditions (STC: Irradiance 1000W/m², Module Temperature 25°C, Air Mass 1.5).

NOTE: Parameter values are calculated under standard test conditions (STC: Irradiance 1000W/m², Module Temperature 25°C, Air Mass 1.5).

Maximum PV array power: The MPPT controller limits current/power if it exceeds the rated value during charging, protecting the controller and preventing damage from over-specified PV modules. Actual PV array operation is as follows:

• Condition 1: Actual charging power of PV array ≤ Rated charging power of controller
• Condition 2: Actual charging current of PV array ≤ Rated charging current of controller

Under Conditions 1 or 2, the controller charges according to actual current/power, operating at the PV array's maximum power point.

WARNING: If PV power is not greater than rated charging power, but the maximum open-circuit voltage (V_OC) of the PV array exceeds 50V (Tracer**06AN) or 96V (Tracer**10AN) 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

Under Conditions 3 or 4, the controller charges according to the rated current or power.

WARNING: If PV module power exceeds the rated charging power, and the PV array's maximum open-circuit voltage (V_OC) exceeds 50V (Tracer**06AN) or 96V (Tracer**10AN) at the lowest environmental temperature, the controller may be damaged.

If the PV array power exceeds the controller's rated charging power, charging time at rated power will be extended, allowing more energy capture. However, in practice, the maximum PV array power should not exceed 1.5 times the controller's rated charging power. Exceeding this limit can waste PV modules and increase V_OC due to temperature, potentially damaging the controller. Proper system configuration is essential. Refer to the table below for recommended maximum PV array power:

¹At 25°C environment temperature
²At minimum operating environment temperature
³At 25°C environment temperature

2.3 Wire Size

Wiring and installation must comply with national and local electrical codes.

PV Wire Size

PV array output varies with module size, connection method, and sunlight angle. Minimum wire size is calculated using the PV array's short-circuit current (I_SC). Refer to PV module specifications for I_SC values. For series connections, I_SC equals a single module's I_SC. For parallel connections, I_SC is the sum of module I_SCs. The array's I_SC must not exceed the controller's maximum PV input current. All PV modules in an array are assumed to be identical.

*These are the maximum wire sizes that fit the controller terminals.

CAUTION: When connecting PV modules in series, the open circuit voltage (V_OC) of the PV array must not exceed 46V (Tracer**06AN) or 92V (Tracer**10AN) at 25°C environment temperature.

Battery and Load Wire Size

Battery and load wire sizes must conform to the rated current. Reference sizes are provided below:

CAUTION: Wire size is for reference only. For long distances between the PV array and controller, or controller and battery, larger wires can reduce voltage drop and improve performance.

CAUTION: For batteries, recommended wire size depends on terminal conditions and whether an inverter is connected.

2.4 Mounting

WARNING: Risk of explosion! Never install the controller in a sealed enclosure with flooded batteries. Do not install in a confined area where battery gas can accumulate.

WARNING: Risk of electric shock! When wiring solar modules, the PV array can produce open circuit voltages exceeding 100V in sunlight.

CAUTION: The controller requires at least 150mm clearance above and below for proper airflow. Ventilation is highly recommended if mounted in an enclosure.

Installation Procedure:

Figure 2-1 shows the controller with recommended mounting clearances of 150mm above and below for proper airflow.

Figure 2-2 provides a schematic wiring diagram showing the connections between the battery (1), load (2), and PV array (3). It specifies connecting the system in the order 1 -> 2 -> 3 and disconnecting in the reverse order 3 -> 2 -> 1.

CAUTION: While wiring, do not close the circuit breaker or fuse. Ensure correct polarity (+ and -) connections.

CAUTION: Install a fuse rated 1.25 to 2 times the controller's rated current on the battery side, no more than 150mm from the battery.

CAUTION: If the controller is used in an area prone to frequent lightning strikes or unattended, install an external surge arrester.

CAUTION: If connecting an inverter, connect it directly to the battery, not to the controller's load side.

Step 3: Grounding

The Tracer AN series is a common-negative controller. All negative terminals (PV array, battery, load) can be grounded simultaneously or individually. Alternatively, negative terminals can be ungrounded, but the controller's shell grounding terminal must be grounded to shield against electromagnetic interference and prevent electric shock.

CAUTION: For common-negative systems (e.g., motorhomes), a common-negative controller is recommended. If common-positive equipment is used in a common-negative system and the positive electrode is grounded, the controller may be damaged.

Step 4: Connect accessories

Connect the remote temperature sensor cable (model: RTS300R47K3.81A) to interface ③, placing the other end near the battery. If the sensor is short-circuited or damaged, the controller defaults to 25°C for charging/discharging temperature compensation.

Connect accessories for RS485 communication as described in section 3.3 "Setting".

Step 5: Powered on the controller

Close the battery fuse to power on the controller. Check the battery indicator; a green light signifies normal operation. Close the load and PV array fuses/breakers to start the system in its preprogrammed mode.

CAUTION: If the controller operates abnormally or the battery indicator shows an issue, refer to section 4.2 "Troubleshooting".

3.1 Button

3.2 Interface

1) Icon

The LCD displays various icons indicating system status:

2) Fault Indication

Faults are indicated by specific icons and display patterns:

¹When load current exceeds nominal value by 1.02-1.05x, 1.05-1.25x, 1.25-1.35x, or 1.35-1.5x, loads are automatically turned off after 50s, 30s, 10s, and 2s respectively.

3) Browse interface

The browse interface figures show how the LCD display changes when cycling through different parameters like PV voltage (e.g., 39.8V), PV power (e.g., 890W), load type (e.g., 206), battery voltage (e.g., 13.8V), battery temperature (e.g., 4.0°C), and accumulated energy (e.g., 890kWh).

3.3 Setting

1) Clear the generated energy

Operation: Step 1: Press and hold the "ENTER" button for 5 seconds on the PV power interface until the value flashes. Step 2: Press the "ENTER" button to clear the generated energy.

2) Switch the battery temperature unit

Press and hold the "ENTER" button for 5 seconds on the battery temperature interface.

3) Battery type

Select the appropriate battery type:

CAUTION: When a default battery type is selected, control parameters are set automatically and cannot be changed. To modify parameters, select the "User" battery type.

Operation: Step 1: Press and hold "ENTER" for 5s on the battery voltage interface. Step 2: Press "SELECT" when the battery type interface flashes. Step 3: Press "ENTER" to confirm.

CAUTION: Refer to chapter 3 for battery control voltage settings when the battery type is User.

Battery Voltage Control Parameters

The following parameters are for a 12V system at 25°C; double values for a 24V system:

CAUTION: Due to the diversification of lithium battery types, its control voltage shall be confirmed with the engineer.

User settings

(1)PC setting

• Connection: Connect the controller to a PC via RJ45 and USB cable.
• Download software: http://www.acopower.com (PC Software for the Solar Charge Controller)

(2)APP software setting

• Connection: Connect the controller to a mobile device via RJ45, USB, and OTG cable.
• Download software (for lead-acid battery): http://www.acopower.com (Android APP for the Solar Charge Controller)
• Download software (for lithium battery): http://www.acopower.com (Android APP for the Li-Battery Solar Charge Controller)

(3)Setting the control voltage value

The following rules must be observed when modifying parameter values in User mode for lead-acid battery:

1. Over Voltage Disconnect Voltage > Charging Limit Voltage ≥ Equalize Charging Voltage ≥ Boost Charging Voltage ≥ Float Charging Voltage > Boost Reconnect Charging Voltage.
2. Over Voltage Disconnect Voltage > Over Voltage Reconnect Voltage
3. Low Voltage Reconnect Voltage > Low Voltage Disconnect Voltage ≥ Discharging Limit Voltage.
4. Under Voltage Warning Reconnect Voltage > Under Voltage Warning Voltage ≥ Discharging Limit Voltage.
5. Boost Reconnect Charging voltage > Low Voltage Disconnect Voltage.

The following rules must be observed when modifying parameter values in User mode for lithium battery:

1. Over Voltage Disconnect Voltage > Over charging protection voltage (PCM) + 0.2V;
2. Over Voltage Disconnect Voltage > Over Voltage Reconnect Voltage = Charging Limit Voltage ≥ Equalize Charging Voltage = Boost Charging Voltage ≥ Float Charging Voltage > Boost Reconnect Charging Voltage;
3. Low Voltage Reconnect Voltage > Low Voltage Disconnect Voltage ≥ Discharging Limit Voltage;
4. Under Voltage Warning Reconnect Voltage > Under Voltage Warning Voltage ≥ Discharging Limit Voltage;
5. Boost Reconnect Charging voltage > Low Voltage Disconnect Voltage.;
6. Low Voltage Disconnect Voltage ≥ Over discharging protection voltage (PCM) + 0.2V;

WARNING: PCM accuracy must be at least 0.2V. Deviations higher than 0.2V may void manufacturer liability for system malfunction.

4) Local load mode

Operation: Step 1: Press and hold "ENTER" for 5s on the load mode interface. Step 2: Press "SELECT" when the load mode interface flashes. Step 3: Press "ENTER" to select the load mode. Refer to section 4.2 for load working modes.

CAUTION: Set Light ON/OFF, Test mode, and Manual mode via Timer 1. Timer 2 will be disabled and display "2 n ".

②Load working mode settings

(1) PC setting

• Connection: Connect the controller to a PC via RJ45 and USB cable.
• Download software: http://www.acopower.com (PC Software for the Solar Charge Controller)

(2) APP software setting

• Connection: Connect the controller to a mobile device via RJ45, USB, and OTG cable.
• Download software: http://www.acopower.com (Android APP for the Solar Charge Controller)

(3) MT50 Setting

• Connect the controller to the MT50 via RJ45 cable.

4.1 Protection

The controller offers various protections:

When the internal temperature reaches 81°C, a reducing power charging mode is activated, decreasing charging power by 5%, 10%, 20%, or 40% for each 1°C increase. Charging stops if the internal temperature exceeds 85°C, but resumes when it drops below 75°C.

4.2 Troubleshooting

Troubleshooting common issues:

4.3 Maintenance

Recommended maintenance tasks (at least twice per year):

• Ensure the controller is firmly installed in a clean, dry environment.
• Verify no airflow blockage around the controller; clear any dirt or fragments from the radiator.
• Inspect all exposed wires for insulation damage due to solarization, wear, dryness, insects, or rodents. Repair or replace wires as needed.
• Tighten all terminals. Check for loose, broken, or burnt wire connections.
• Confirm LED indicators are consistent with requirements. Note any troubleshooting or error indications and take corrective action.
• Verify all system components are tightly and correctly grounded.
• Check terminals for corrosion, insulation damage, or signs of high temperature/discoloration. Tighten terminal screws to the recommended torque.
• Check for dirt, nesting insects, and corrosion. Clean promptly if found.
• Ensure the lightning arrester is in good condition. Replace it to prevent damage to the controller and other equipment.

WARNING: Risk of electric shock! Ensure all power is turned off before performing maintenance, then follow the specified inspections and operations.

Annex I Conversion Efficiency Curves

These curves illustrate conversion efficiency versus charging power for different system voltages and solar module MPP voltages under Illumination Intensity: 1000W/m² and Temp: 25°C.

Model: Tracer1206AN

• 12V Conversion Efficiency Curves: Shows efficiency for 17V and 34V module MPP voltages.
• 24V Conversion Efficiency Curves: Shows efficiency for 34V and 45V module MPP voltages.

Model: HY-MPPT10

• 12V Conversion Efficiency Curves: Shows efficiency for 17V and 34V module MPP voltages.
• 24V Conversion Efficiency Curves: Shows efficiency for 34V, 51V, and 68V module MPP voltages.

Model: Tracer2206AN

• 12V Conversion Efficiency Curves: Shows efficiency for 17V and 34V module MPP voltages.
• 24V Conversion Efficiency Curves: Shows efficiency for 34V and 45V module MPP voltages.

Model: HY-MPPT20

• 12V Conversion Efficiency Curves: Shows efficiency for 17V and 34V module MPP voltages.
• 24V Conversion Efficiency Curves: Shows efficiency for 34V, 45V, and 68V module MPP voltages.

Model: HY-MPPT30

• 12V Conversion Efficiency Curves: Shows efficiency for 17V and 34V module MPP voltages.
• 24V Conversion Efficiency Curves: Shows efficiency for 34V, 45V, and 68V module MPP voltages.

Model: HY-MPPT40

• 12V Conversion Efficiency Curves: Shows efficiency for 17V and 34V module MPP voltages.
• 24V Conversion Efficiency Curves: Shows efficiency for 34V, 45V, and 68V module MPP voltages.

Annex II Dimensions

Dimension drawings provide physical specifications for each controller model series in millimeters (mm).

• Tracer1206/HY-MPPT10: Includes top and front views with dimensions.
• Tracer2206AN/HY-MPPT20: Includes top and front views with dimensions.
• HY-MPPT30: Includes top and front views with dimensions.
• HY-MPPT40: Includes top and front views with dimensions.

Version number: 1.0. Any changes without prior notice!