XTM Tracer2206AN 20A MPPT Solar Controller

IMPORTANT SAFETY INSTRUCTIONS

Please reserve this manual for future review. This manual contains safety, installation, and operation instructions for the tracer2206AN MPPT solar controller (“controller” referred to in this manual).

• Read all the instructions and warnings carefully in the manual before installation.
• No user-serviceable components inside the controller; please do not disassemble or attempt to repair the controller.
• Mount the controller indoors. Avoid exposure to the components and do not allow water to enter the controller.
• Install the controller in a well-ventilated place; the controller’s heat sink may become very hot during operation.
• We suggest installing appropriate external fuses/breakers.
• Ensure to switch off PV array connections and the battery fuse/ breakers before controller installation and adjustment.
• Power connections must remain tight to avoid excessive heating from a loose connection.

GENERAL INFORMATION

Overview

Based on a digital control circuit, the Tracer2206AN controller contains a self-adaptive three-stage charging mode. It assists to prolong the battery lifespan and improves the system’s performance. It is also equipped with electronic protection to ensure a more reliable solar system. This controller can be widely used for camping, caravanning, and boating as well as at-home applications.

Features

• Advanced MPPT, with an efficiency no less than 99%
• Maximum DC/DC conversion efficiency of 96%
• Automatic limitation of the charging current and charging power
• Wider MPPT working voltage range
• Applicable for lead·acid and lithium batteries
• Programmable temperature compensation feature
• Multiple load work modes

Characteristics

Suppose the remote temperature sensor is not connected to the controller or is damaged. In that case, the controller will charge or discharge the battery at the default temperature setting of 25 °C (no temperature compensation).

Maximum PowerPoint Tracking Technology

Due to the nonlinear characteristics of the solar array, there is a maximum energy output point (Max PowerPoint) on its curve. Traditional controllers, equipped with switch charging technology and PWM charging technology, can’t charge the battery at the maximum power point and cannot obtain the maximum energy available from the PV array. In contrast. the solar charge controller with Maximum Power Point Tracking (MPPT) Technology can lock the point to obtain the maximum energy and deliver it to the battery. As Figure 1-2, the curve is also the array’s characteristic curve; the MPPT technology will ‘boost’ the battery charge current by tracking the MPP. Assuming 100% conversion efficiency exists in the solar system. the following formula is established:

Normally, the Vww is always higher than Ve.1. Due to the principle of energy conservation, the leat is always higher than IPv. The greater the difference between VMw & Vea1, the greater the difference between IPv & le.1. The greater the difference between the array and the battery will also decrease the system conversion efficiency. Therefore, the controller’s conversion efficiency is particularly important in the PV system. Figure 1-2 is the maximum power point curve, whose shaded area is the traditional solar charge controller (PWM Charging Mode). It is known that the MPPT mode can improve solar PV usage. According to the test, the MPPT controller can raise 20%-30% efficiency compared to the PWM controller. (Specified value may be fluctuant due to the influence of the circumstance and energy loss.)

In actual application, as shading from cloud, tree, and snow, the panel may appear Multi-MPP. However, in actuality, there is only one real Maximum Power Point. As the below Figure 1-3 shows:

Suppose the program works improperly after appearing Multi-MPP. In that case. the system will not work on the real max power point. which may waste most solar energy resources and seriously affect the system’s normal operation. The typical MPPT algorithm can track the real MPP quickly and accurately. It can improve the PV array’s utilization rate and avoid resource waste.

Battery charging stage

The controller has a three-stage battery charging algorithm, including Bulk Charging, Constant Charging, and Float Charging. Through the three-stage charging method, the system can extend the battery’s lifespan.

Bulk Charging
The battery voltage has not yet reached constant voltage (Equalize or Boost Charging Voltage). The controller operates in constant current mode, delivering its maximum current to the batteries (MPPT Charging). When the battery voltage reaches the constant voltage set point. the controller will start to operate in constant charging mode.

Constant Charging
When the battery voltage reaches the constant voltage set point, the controller will start to operate in constant charging mode. The MPPT charging stops during this process, and the charging current will drop gradually at the same time. Constant charging has two stages, namely, equalizing charging and boosting charging. These two charging processes are not repeated.

Boost Charging
The default duration of the boost charging stage is generally 2 hours. Customers can also adjust the constant time and preset value according to actual needs. When the duration is equal to the set value. the system will switch to the float charging stage.

Equalize Charging

Explosive Risk! Equalizing flooded batteries would produce explosive gases, so well ventilation of the battery box is recommended.

•  Equipment damage! •   Equalization may increase battery voltage to the level that damages sensitive DC loads. Verify that the load’s allowable input voltages are greater than the equalizing charging setpoint voltage. •  Over-charging and excessive gas precipitation may damage the battery plates and activate material shedding on them. Too high an equalize charging or for too long may cause damage. Please carefully review the specific requirements of the the battery used in the system.

Some battery types benefit from equalizing charging, stirring electrolytes, balancing battery voltage, and accomplishing chemical reactions. Equalized charging increases the battery voltage to make it higher than the standard complement voltage, gasifying the battery electrolyte. If the controller automatically controls the next charge for equalizing charging, the equalizing charging time is 120 minutes. Equalize charge and boost charge are not carried out constantly in a full charge process to avoid too much gas precipitation or overheating of the battery.

•  Due to the installation environment or load work, the system may not stabilize the battery voltage at a constant voltage. The controller will accumulate the time when the battery voltage is equal to the set value. When the accumulative time is equal to 3 hours, the system will automatically switch to float charging. •  If the controller time is not adjusted. the controller will equalize charging following the inner time.

Float Charging
After the constant charging stage, the controller will reduce the battery voltage to the float charging preset voltage by reducing the charging current. During the floating charge stage, the battery is charged weakly to ensure that the battery is maintained in a fully charged state. In the float charging stage, loads can obtain almost all power from the solar panel. Suppose the loads’ power exceeds the solar array’s power. In that case, the controller will no longer maintain the battery voltage in the float charging stage. When the battery voltage goes lower than the set value of the boost recharge voltage, the system will exit the float charging stage and enter the bulk charging stage again.

INSTALLATION

Warning

• Be careful when installing the batteries. Please wear eye protection when installing the open-type lead-acid battery and rinse with clean water in time for battery acid contact.
• Keep the battery away from any metal objects, which may cause a short circuit of the battery.
• Acid gas may be generated when the battery is charged. Confirm that the surrounding environment is well-ventilated.
• Avoid direct sunlight and rain infiltration when installing it outdoors.
• Loose power connectors and corroded wires may result in high heat that can melt wire insulation. burn surrounding materials. or even cause a fire.
• Ensure tight connections and secure cables with cable clamps to prevent them from swaying in moving applications.
• Only charge the lead-acid and lithium-ion batteries within the control range of this controller.
• The battery connector may be wired to another battery or a bank of batteries. The following instructions refer to a singular battery. Still. it is implied that the battery connection can be made to either one battery or a group of batteries in a battery bank.
• Select the system cables according to 5A/mm’ or less current density.

Requirements for the PV array
Serial connection (string) of PV modules As the core component of the solar system, the controller needs to suit various types of PV modules and maximize solar energy conversion into electricity. According to the open-circuit voltage (Voe) and the maximum power point voltage (VMPP) of the MPPT controller. the serial connection of PV modules suitable for different controllers can be calculated. The below table is for reference only.

Tracer 2206AN

The above parameters are calculated under the STC (Standard Test Condition)-module temperature 25°C, air mail.5, irradiance l0 00 W/ m 2 .)

Max. PV Array Power

• The MPPT controller has the function of current/ power-limiting. Namely, when the charging current or power exceeds the rated value, the controller will automatically reduce the actual charging current or power to the rated value. The function can effectively protect the charging parts of the controller and prevent damage to the controller due to the connection of some over-specification PV modules. The actual PV array running status shows as below:
• Condition 1: Actual charging power of the PV array $ Rated charging power of the controller
• Condition 2: Actual charging current of the PV array $ Rated charging current of the controller When the controller operates under “Condition 1″ or ” Condition 2″, it will carry out the charging as per the actual current or power; at this time, the controller can work at the maximum power point of the PV array.
• Condition 3: Actual charging power of the PV array> Rated charging power of the controller
• Condition 4: Actual charging current of the PV array> Rated charging current of the controller When the controller operates under ” Condition 3″ or ” Condition 4,” , it will carry out the charging as per the rated current or power.

The controller may be damaged when: The PV array’s maximum open-circuit voltage is more than 60.

According to the “Peak Sun Hours diagram,” if the PV array’s power exceeds the controller’s rated charging power, the charging time as per the rated power is prolonged. The controller can obtain more energy. However, in the practical application, the maximum power of the PV array shall be not higher than 1.5 times the rated charging power of the controller. Suppose the maximum power of the PV array exceeds the rated charging power of the controller too much. In that case, it causes the waste of the PV array and increases the PV array’s open-circuit voltage, which may increase the probability of damage to the controller. For the recommended maximum power of the PV array. please refer to the table below:

Wire size
The wiring and installation methods conform to the national and local electrical code requirements.

PV wire size
The PV array’s output current varies with its size. connection method, and sunlight angle. The minimum wire size can be calculated by its ISC (short circuit current). Please refer to the ISC value in the PV module’s specifications. When the PV modules are connected in series, the total ISC equals any PV module’s ISC. When the PV modules are connected in parallel, the total ISC equals the sum of the PV module’s ISC. The PV array’s ISC must not exceed the controller’s maximum PV input current. For max. PV input current and max. PV wire size, please refer to the table as below:

When the PV modules are connected in series, the total voltage must not exceed the max. PV open circuit voltage 46V at 25°C environment temperature.

Battery and Load Wire Size
The battery and load wire size conform to the rated current, the reference size as below:

•  The wire size is only for reference. Suppose there is a long distance between the PV array and the controller or between the controller and the battery. In that case, larger wires can be used to reduce the voltage drop and improve performance. •  The recommended wire is selected for the battery according to the conditions that its terminals are not connected to any additional inverter.

Mounting

	•   Risk of explosion! Never install the controller in a sealed enclosure with flooded batteries! Do not install the controller in a confined area where battery gas can accumulate. •   Risk of electric shock! When wiring the PV modules, the PV array may generate a high open-circuit voltage. Turn off the breaker or fuse firstly, and be careful when wiring.
	The controller requires at least 150mm of clearance above and below for proper airflow. Ventilation is highly recommended if mounted in an enclosure.

Installation procedures

Step 1: Determine the installation location and heat-dissipation space

Step 2: Connect the system in the order of battery following Figure 2-2,” Schematic Wiring Diagram,” and disconnect the system in the reverse order.

Technical Specifications

Step 3: Grounding

Tracer2206AN is the common-negative controller. Negative terminals of the PV array, the battery, and the load can be grounded simultaneously, or any negative terminal is grounded. However. according to the practical application, the negative terminals of the PV array, battery, and load can also be ungrounded. However, the grounding terminal on its shell must be grounded. It shields electromagnetic interference and avoids electric shock to the human body.

Step 4: Connect accessories

• Connect the temperature sensor

Connect one end of the remote temperature sensor to the interface.

OPERATION

Buttons

Interface

• Status Description

Name	Icon	Status
PV array		Day
		Night
		No Charge
		Charging
	PV	PV array’s vo lta ge , current, and generate energy
Battery		Battery capacity, In charging
	BATT.	Battery Voltage, Current, Temperature
	BATT. TYPE	Battery type
Load		Load ON
		Load OFF
	LOAD	Current/ Consumed energy/Load mode

Error codes

Status	Icon	Instruction
Battery over-discharged		Battery level shows empty, battery frame blink, fault icon blink
Battery over voltage		Battery level shows full. battery frame blink, fault icon blink
Battery overheating		Battery level shows current value, battery frame blink, fault icon blink
Load failure		Overload ©, Load short circuit

When the load current reaches.02·1.05 times, 1.05-1.25 times, 1.25-1.35 times, and 1.35·1.5 times more than the rated value, the controller will automatically turn off the loads in 50 seconds, 30 seconds,10 seconds, and 2 seconds respectively.

Browse interface
Press the SELECT button to cycle display the following interfaces.

Setting

1. Clear the generated energy
   Step 1: Press the ENTER button and hold 5s under the PV-generated energy interface, and the value will be flashing.
   Step 2: Press the ENTER button to clear the generated energy.
2. Switch the battery temperature unit
   Press the ENTER button and hold 5s under the battery temperature interface.
3. Battery type

Support battery types

• Set the battery type via the LCD

Operation

Step 1: Press the SELECT button to browse the battery voltage interface.
Step 2: Press and hold the ENTER button until the battery-type interface flashes.
Step 3: Press the SELECT button to change the battery type, shown as below.

Step 4: Press the ENTER button to confirm.

Operation

Step 1: On the battery voltage interface, press and hold the ENTER button to enter the battery type interface.
Step 2: Press the SELECT button to change the battery type, such as selecting the “GEL”‘; and then press the ENTER button to confirm and back to the battery voltage interface automatically.
Step 3: On the battery voltage interface, press and hold the ENTER button to enter the battery type interface again.
Step 4: Press the SELECT button to change the battery type to “USE”. Under the “USE” battery type, the battery parameters that can be set via the LCD are shown in the table below:

The SYS value can only be modified under the non-lithium “USE” type. That is, if the battery type is Sealed, Gel, or Flooded before entering the “USE” type, the SYS value can be modified; if it is lithium battery type before entering the “USE” type, the SYS value cannot be modified. Only the above battery parameters can be set on the local controller and the remaining battery parameters follow the following logic (the voltage level of the 12V system is 1, and the voltage level of 24V system is 2).

Battery voltage parameters

Measure the parameters in the condition of 12V/25°C. Please double the values in the 24V system.

When the default battery type is selected, the battery voltage parameters cannot be modified. To change these parameters, select the “USE” type.

When the battery type is “USE.” the battery voltage parameters follow the following logic:

• A. Over Voltage Disconnect Voltage> Charging Limit Voltage > Equalize Charging Voltage > Boost Charging Voltage > Float Charging Voltage > Boost Reconnect Charging Voltage.
• B. Over Voltage Disconnect Voltage> Over Voltage Reconnect Voltage
• C. Low Voltage Reconnect Voltage > Low Voltage Disconnect Voltage > Discharging Limit Voltage.
• D. Under Voltage Warning Reconnect Voltage>Under Voltage Warning Voltage> Discharging Limit Voltage;
• E. Boost Reconnect Charging voltage >Low Voltage Reconnect Voltage.

Lithium Battery voltage parameters

The battery parameters under the “User” battery type is 9-17V for LFP4S. They should x 2 for LFPSS.

When the battery type is “USE,” the Lithium battery voltage parameters follow the following logic:

• A. Over Voltage Disconnect Voltage>Over Charging Protection Voltage(Protection Circuit Modules(BMS))+0.2V;
• B. Over Voltage Disconnect Voltage>Over Voltage Reconnect Voltage=Charging Limit Voltage;. Equalize Charging Voltage=Boost Charging Voltage;. Float Charging Voltage>Boost Reconnect Charging Voltage;
• C. Low Voltage Reconnect Voltage > Low Voltage Disconnect Voltage;. Discharging Limit Voltage.
• D. Under Voltage Warning Reconnect Voltage>Under Voltage Warning Voltage> Discharging Limit Voltage;
• E. Boost Reconnect Charging voltage> Low Voltage Reconnect Voltage;
• F. Low Voltage Disconnect Voltage;;. Over Discharging Protection Voltage (BMS)+0.2V

The required accuracy of BMS is no higher than 0.2V. We will not assume responsibility for the abnormal when the accuracy of BMS is higher than 0.2 v.

Local load mode setting

When the LCD shows the above interface, operate as follows

Operation

Step 1: Press the SELECT button to jump to the load type interface.
Step 2: Press and hold the ENTER button until the load type interface flashes.
Step 3: Press the SELECT button to modify the load type.
Step 4: Press the ENTER button to confirm.

Load mode

When selecting the load mode as the Light ON/OFF mode, Test mode, and Manual mode, only the Timer I can be set; and the Timer 2 is disabled and display ” 2 n “.

OTHERS

Protection

When the controller’s internal temperature reaches 8 1°C, the charging power automatic reduction function is enabled. Temperature increases by 1°C, the charging power is reduced by 5%, 10%, 20%, and 40%. If the internal temperature is higher than 85°C, the controller stops charging the battery.
When the internal temperature is not more than 75°C, the controller resumes charging per the rated charging power.

Troubleshooting

Fault s	Faults	Troubleshooting
PV array open-circuit	When there is plenty of direct sunlight on the PV array, the LCD shows	Confirm whether the connection of the PV array is correct and tight
The battery voltage is lo we r than av	The wire connection is correct: the controller is not working	Please check the voltage of the battery (at least av voltage to activate the controller)
Battery over voltage	Battery frame blink	Check whether the battery voltage is higher than (over-voltage disconnect voltage) and disconnect the PV array connection
Battery over-discharged	Battery frame blink	(1) When the battery voltage is restored to or above LVR (low voltage reconnect voltage). the load will recover. (2) Takeother ways to recharge the battery
Battery overheating	Battery frame blink	While the temperature decline to be below 55 •c, the controller will resume
Overload	1.    Load off   2.                Load and fault	(!)Please reduce the number of electric devices. start the controller or pressthe button to clear faults
Load short-circuit		(!)Check carefully the load’s connection, clear the fault, ®Restart the controller or press the button to clear faults

When the load current goes higher than 1.02-1.05 times, 1.05-1.25 times, 1.25-1.35 times, and 1.35-1.5 times the rated value, the controller may automatically turn offloads in 50 seconds, 30 seconds,10 seconds, and 2 seconds r respectively.

Maintenance

The following inspections and maintenance tasks are recommended at least two times per year for good performance.

• Make sure no block on airflow around the controller. Clear up any dirt and fragments on the radiator.
• Check all the naked wires to ensure insulation is not damaged by sun exposure, frictional wear, dryness, insects or rats, etc. Repair or replace some wires if necessary.
• Verify the indicator display is consistent with the actual operation. Pay attention to any troubleshooting or error conditions. Take necessary corrective action.
• Confirm that terminals have no corrosion, insulation damage, high temperature, or burnt/discolored sign, and tighten terminal screws to the suggested torque.
• Clear up dirt, nesting insects, and corrosion in time.
• Check and confirm that the lightning arrester is in good condition. Replace a new one in time to avoid damaging the controller and even other equipment.

SPECIFICATIONS

Electrical Parameters

1. When a lithium battery is used, the system voltage can’t be identified automatically.
2. At minimum operating environment temperature
3. At 25°C environment temperature
4. When a lithium battery is used, the temperature compensation coefficient will be 0 and can’t be changed.

Environmental Parameters

The controller can full load working in the working environment temperature. When the internal temperature reaches 81°C, the reducing charging power mode is turned on. Refer to Chapter 4.1 Protection.

Mechanical parameters

ANNEX I CONVERSION EFFICIENCY CURVES

Test condition: Illumination Intensity: I000W/m2 Temperature: 25 Model: Tracer2206AN

1. PV array Max. power point voltage (17V, 34VJ/system voltage (12V)
2. PV array Max. power point voltage (34V, 45VJ/system voltage (24V)

WARRANTY

Our product is guaranteed to be free from quality and manufacturing defects for a period of 12 months. If your product becomes defective during this period, SRGS PTY LTD will offer you either a replacement. credit or refund where a product is faulty; wrongly described; different from the sample shown to you or do not do what they are supposed to do. This warranty will not cover substantially modified products; misuse or abuse of the product contrary to user instructions or packaging label; change of mind and normal wear and tear. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and failure does not amount to a major failure. To claim the warranty, take the product to the front Service Desk of your nearest store of purchase. You will need to show a receipt or other proof of purchase. Additional information may be required to process your claim. Should you not be able to provide proof of purchase with a receipt or bank statement, or identification showing your name. address and signature may be required to process your claim. Any expenses relating to the return of your product to the store will normally have to be paid by you. For online store purchases, SRGS PTY LTD will pay for the return freight for any product assessed as having a major failure. The benefits to the customer given by this warranty are in addition to other rights and remedies of the Australian Consumer Law in relation to the goods or services to which this warranty relates. This warranty is provided by SRGS PTY LTD, 6 Coulthards Avenue, Strathpine QLD 4500, Australia. Phone: 1300 880 764.

PLU: 613766 CODE: TRACER2206AN
Manufactured & packaged for SRGS PTY LTD

• ABN 23 113 230 050
• 6 Coulthards Avenue
• Strathpine QLD 4500, Australia
• MADE IN CHINA

Documents / Resources

XTM Tracer2206AN 20A MPPT Solar Controller [pdf] User Manual Tracer2206AN 20A MPPT Solar Controller, Tracer2206AN, 20A MPPT Solar Controller, Solar Controller

References

• User Manual