Saturday, July 4, 2020

Epever , Epsolar technology

What is DuoRacer?

Posted On : Tuesday, November 5, 2019

Introduction of EPEVER DuoRacer MPPT charge controller

Charge controllers were discussed in detail in our previous articles, and the importance and widespread applications of the EPEVER MPPT and PWM charge controllers were emphasized by scientific studies. In a standalone PV system, the charge controller manages the energy flow to system, batteries, and loads by collecting information about the restrictions and maximum and minimum energy inquiries of system components.

 

Figure 1-overall view of a charge controller

 

Here we will introduce the new charge controller produced by EPEVER Company. The features and novelties provided by the mentioning charge controller will be discussed in detail. The new product called the DuoRacer MPPT charge controller will help solar systems to perform better. DuoRacer MPPT charge controller exhibits noticeable priorities over conventional MPPT charge controllers that here in this article, we will try to inform the customer about these features. EPEVER DuoRacer charge controllers, despite XTRA series, are designed to charge two distinct batteries simultaneously. These batteries, called BATT1 and BATT2 are utilized in the same solar system. BATT1 supports different types of batteries, including Sealed, Gel, Flooded, LiFePO4, and Li-NiCoMn, which is suitable for RV, Camper, Boat, and so on. The system voltage of the starter battery (BATT2) is recognized by the device automatically, and when the conditions of charging are satisfied, the trickle starts the process of charging.

Energy utilization in MPPT charge controllers is 20-30% more efficient than conventional PWM charge controllers. DuoRacer charge controller adopts the advanced MPPT control algorithm. This algorithm is employed to minimize loss time besides maximum power point loss rate and also leads to fast-tracking of maximum power point (MPP) of the photovoltaic array. The prominent feature of obtaining maximum energy from the solar array under any conditions distinguishes the EPEVER DuoRacer MPPT charge controller from other types of charge controllers. Fig. 2 illustrates the EPEVER DuoRacer charge controller, which is employed in solar systems to charge two batteries by solar energy.

Figure 2-EPEVER DuoRacer Charge controller

 

The low-power mode is the ability of EPEVER DuoRacer MPPT charge controller to reduce the loss and battery power waste when there is no manual operation for a long time, and charging conditions are not satisfied. MT11 remote meter and LCD/LED monitors are provided to demonstrate the system parameters in the DuoRacer charge controller. Let’s discuss the application of solar systems and charge controllers in recreational vehicles (RV). For example, the AES control signal of the car refrigerator is built in the EPEVER DuoRacer MPPT charge controller to supply the surplus solar power to the refrigerator to avoid energy waste. The novel EPEVER DuoRacer MPPT charge controller benefits several protection features such as battery overcharge protection, over-discharge protection, and reverse connection protection of the PV and battery, which effectively ensure the solar system safety, stability and lifetime. Also, waterproof and the dustproof IP33 protection level is applied to the EPEVER DuoRacer charge controller.

 

Features of EPEVER DuoRacer charge controllers

In this section, we will introduce some of the prominent features of the novel EPEVER DuoRacer charge controller.

  • Maximum Power Point Tracking technology with ultra-fast tracking speed and the tracking efficiency is no less than 99.5% guaranteed.
  • Advanced MPPT control algorithm to minimize the MPP loss rate and loss time
  • The wide range of the MPP operation voltage to improve the PV module utilization.
  • Auto control function of charging power & charging current limitation (BATT1).
  • High quality and low failure rate components of the ST, TI, and Infineon to ensure the product life.
  • Digital circuit control of adaptive three-stage charging mode to enhance BATT1 life.
  • BATT1 type can be set via LED/LCD.
  • Product runs into the low-power mode when there is no manual operation for a long time, and charging conditions are not satisfied (PV<5V). The low-power mode can significantly reduce the loss of the product at night.
  • 100% charging and discharging in the operation environmental temperature range.
  • LED and LCD display units selectable.
  • AES control signal for car refrigerator to avoid energy waste.
  • Standard Modbus protocol and RS485 (5V/200mA) communication port for the customer to expand the application area.

In this section, protection features of DuoRacer charge controller will be discussed, these features will help to enhance the product’s life duration and are among the important priorities over conventional charge controllers:

  • PV over current and power limit function
  • PV short circuit and reverse polarity protection
  • Night reverse charging protection
  • Battery reverse polarity protection
  • BAT1 over-voltage and overheating protection
  • BAT1 low-temperature protection(only for lithium battery)

As mentioned before, the DuoRacer charge controller is provided to charge two distinct batteries at the same time. These two batteries are employed for different applications; BATT1 also known as main battery storages the energy of battery to power household loads in the off-grid system, which supports Sealed, Gel, Flooded, LiFePO4, and Li-NiCoMn batteries, however, starter battery (BATT2) is the energy storage battery which usually built into the vehicle for powering the system such as RV and Boat, and only supports lead-acid battery. The controller recognizes the system voltage automatically for starter batteries, while system voltage cannot be recognized for the main battery. Note that BATT1 and BATT2 should be at the same level.

 

Structure of the EPEVER DuoRacer MPPT charge controller

This part of the article illustrates the different ports of the EPEVER DuoRacer charge controller to help the proper operation and wiring of solar systems.

 

 

1

Mounting hole size Φ 5mm

6

BATT1 terminals

2

LCD

7

BATT2 terminals

3

Grounding Terminal

8

RS485 Communication port

4

Remote temperature sensor port

9

AES (signal) output port

5

PV terminals

10

Terminal protection cover

 

We need to discuss two ports in detail. The temperature compensation is only designed for the lead-acid battery, for lithium battery, there is no temperature compensation. When the temperature sensor is not connected, or the sensor is damaged, the charge controller charges the BATT1 as default (25℃).

The output parameters of AES port are 12V/200mA, while for RS485 port is 5V/200mA, and the AES port output voltage is the battery voltage. Also, the AES signal port is designed for AES supporting the car refrigerator, it is required for the internal power switching device. To define the model of the DuoRacer charge controller, we will provide these instructions shown in the picture below. The AES signal turns on after the BATT1 voltage reaches the boost charging voltage or equalize charging voltage for 5 minutes. The controller will check if the BATT1 voltage is lower than the boost charging voltage or equalize charging voltage every 5 minutes (This value is the judgment delay time for turning off the AES signal which can be set via PC software, default as 5 minutes, ranging from 0 to 999 minutes.), the AES signal control will be turned off if it meets the conditions for 5 times.

 

Now we will introduce technical data for the charging process of EPEVER DuoRacer MPPT charge controller, which includes charging start and stop conditions for BATT2. The controller trickle charges the BATT2 at 1A constant current. When the voltage reaches the “Full voltage” during the BATT2 charging process, the controller will stop charging and exit from the constant voltage charging mode. Here we provide a table to inform about the charging parameters, which are illustrated below.

Item

Default

Modify range

Full voltage

13.8V/12V; 27.6V/24V

9~17V(24V×2)

Charge return voltage

13V/12V; 26V/24V

9~17V(24V×2)

But to start the charging process, proper conditions should be satisfied. Let’s define the proper condition for the charging process; BATT1 should be connected before starting the BATT2 charging. It should be noted that BATT2 only supports lead-acid battery type. The diagram demonstrated below informs us about the conditions for the start of the charging process.

 

 

We will have the same procedure and diagram to depict stop conditions of the charging process, which should be noted to have a safe system and avoid power loss.

 

 

Fig. 3 demonstrates the charging indication of BATT2 (Starter Battery); the parameters of charge indication were introduced in the previous table.

 

Figure 3-charging indication of EPEVER DuoRacer MPPT charge controller

 

Accessories

Now in this section, various useful accessories that are included in EPEVER DuoRacer MPPT charge controller will be introduced. Some of these accessories are optional and can be connected to the charge controller to employ astonishing features of the novel DuoRacer charge controller.

1. Local temperature sensor (Model:RT-MF58R47K3.81A) 

The temperature sensor is employed to control the charge process and temperature of the system to avoid overheating and also proper operation in cold climate conditions.

2. AES signal terminal (Model:3.81-2P) 

The properties of the AES port were discussed by previous sections.

 

These accessories introduced here, are included in the package of EPEVER DuoRacer MPPT charge controller. Other optional accessories can be connected to the controller, which will be introduced here.

1. Remote Meter (MT11) 

MT11 can display various operating data and fault information of the system. The information can be displayed on a backlit LCD screen, the buttons are easy-to-operate, and the numeric display is readable. The standard version is for the surface mounting, and an optional version is for the wall mounting. (the standard version includes the communication cable).

2. Remote temperature sensor(Model:RTS300R47K3.81A) 

Acquisition of battery temperature for undertaking temperature compensation of control parameters, the standard length of the cable is 3m (length can be customized).The RTS300R47K3.81A is connected to the port (❹) on the controller.

3. USB to RS485 converter cable (Model:CC-USB-RS485-150U-3.81) 

It used to monitor each controller on the network via PC software. The length of the cable is 1.5m. One of the terminals is connected to the ❽ port of the controller, the other terminal is connected to the PC.

4. WIFI Serial Adapter (Model: eBox-WIFI-01) 

The operating status and related parameters of the controller can be monitored by the mobile APP through WIFI signals. So, eBox-WIFI-01 is connected to the controller through standard Ethernet cable for proper monitoring by mobile devices.

5. RS485 to Bluetooth adapter(Model:eBox-BLE-01) 

EBox-BLE-01 is also employed for remote monitoring of the status of the system by mobile devices while EBox-BLE-01utilizes Bluetooth protocol to connect the EPEVER DuoRacer charge controller to the mobile device.

6. AES adapter (Model: AES-ADP) 

The adapter is provided to convert the 5V output of the controller into 12V output, which supplies the refrigerator to avoid waste of the solar energy.

Now we display the topology of the charge controller with the introduced accessories. This topology can be employed to proper usage of optional accessories which will enhance the performance of the whole Photovoltaic system.

 

Figure 4- topology of EPEVER DuoRacer MPPT charge controller with assigned accessories.

 

Installation

Let’s discuss the proper installation requirements. As we know, to achieve specific electrical parameters in a solar system, PV arrays are employed. To set up a PV array, solar panels are connected to each other in series/parallel orientations. As the core component of the solar system, the controller could be suitable for various types of PV modules and maximize converting solar energy into electrical energy. According to the open-circuit voltage (Voc) and the maximum power point voltage (Vmpp) of the MPPT controller, the series number of different types of PV modules can be calculated. The table below illustrates the specifications for different models of EPEVER DuoRacer MPPT charge controller to operate successfully with the series of solar panels that are connected to each other.

 

DR1106/2106/3106/1206/2206/3206N-DDB/DDS

System Voltage

36 cell

Voc<23V

48 cell

Voc<31V

54 cell

Voc<34V

60 cell

Voc<38V

Max.

Best

Max.

Best

Max.

Best

Max.

Best

12V

2

2

1

1

1

1

1

1

24V

2

2

-

-

-

-

-

-

 

System Voltage

72 cell

Voc<46V

96 cell

Voc<62V

Thin-Film Module

Voc>80V

Max.

Best

Max.

Best

Max.

Best

12V

1

1

-

-

-

-

24V

1

1

-

-

-

-

NOTE: The above parameter values are calculated under standard test conditions STC (Standard Test Condition): Irradiance 1000W/m2, Module Temperature 25 ℃, Air Mass 1.5.)

 

DR2210/3210N-DDB/DDS

System Voltage

36 cell

Voc<23V

48 cell

Voc<31V

54 cell

Voc<34V

60 cell

Voc<38V

Max.

Best

Max.

Best

Max.

Best

Max.

Best

12V

4

2

2

1

2

1

2

1

24V

4

3

2

2

2

2

2

2

 

System Voltage

72 cell

Voc<46V

96 cell

Voc<62V

Thin-Film Module

Voc>80V

Max.

Best

Max.

Best

Max.

Best

12V

2

1

1

1

1

1

24V

2

1

1

1

1

1

 

The other important parameter which should be noted in controller installation is about the wiring and cables used in the various connections of the PV system. It was mentioned that the charge controller gets the energy of the sun by the proper solar panel and then charges the batteries which are connected to the controller to supply the appliances. The main feature of DuoRacer controller is the ability to charge two distinct batteries simultaneously. So for proper wiring, the parameters of the PV solar panel and the batteries should be noted. Proper wire size according to the solar equipment and the model of the controller is demonstrated in two subsequent tables which helps the customer to choose the right controller to adapt to the desired application.

 

Model

Max. PV input current

Max. PV wire size

DR1106N-DDB/DDS DR1206N-DDB/DDS

10A

4mm2/12AWG

DR2106N-DDB/DDS DR2206N-DDB/DDS

DR2210N-DDB/DDS

20A

6mm2/10AWG

DR3106N-DDB/DDS DR3206N-DDB/DDS

DR3210N-DDB/DDS

30A

10mm2/8AWG

 

Model

Rated Charge Current

Battery wire size

DR1106N-DDB/DDS DR1206N-DDB/DDS

10A

4mm2/12AWG

DR2106N-DDB/DDS DR2206N-DDB/DDS

DR2210N-DDB/DDS

20A

6mm2/10AWG

DR3106N-DDB/DDS DR3206N-DDB/DDS

DR3210N-DDB/DDS

30A

10mm2/8AWG

Detailed information about the installation and wiring of the solar system can be found in the user manual of the product, which is available on the EPEVER website.

 

Display

This section of the article is dedicated to DuoRacer Display Basic (DDB). Here, we will introduce the screen options of the DuoRacer MPPT charge controller; the buttons and the indicators of the controller will be discussed through technical tables.

 

 

Status Indicator

indicator

Color

Status

Instruction

Green

OFF

No charging

Green

Slowly flashing

(1Hz)

Charging, in Boost or Equalize charging stage

Green

On solid

Full, in Float charging stage

Red

OFF

BATT1 Temperature normal

Red

Fast flashing

(4Hz)

BATT1 over-temperature or

BATT1 low temperature

Green

On solid

Connect to BATT1 and in charging

Green

Slowly flashing

(0.2Hz)

Connect to BATT1 and no charging

Green

OFF

Not connect BATT1

Red

On solid

BATT1 over-discharged/Low voltage

Red

OFF

BATT1 low voltage reconnect

Green

On solid

AES signal is ON

Green

OFF

AES signal is OFF

Green

On solid

Connect to BATT2 and in charging

Green

Slowly flashing(1Hz)

Connect to BATT2 and no charging

Green

OFF

Not connect BATT2

Green

On solid

In the mode of setting battery type

Green

OFF

Settings are saved and quit the setting mode

All indicator Fast flashing(4Hz)

System voltage error①

All indicator Slowly flashing(1Hz)

Controller overheating

①The controller doesn’t recognize the system voltage when the battery type is lithium battery

 Indicator "OFF".  Indicator "On solid".

 Indicator "Slowly flashing (1Hz) ".

 Indicator "Slowly flashing (0.2Hz)".

 

Battery Type Indicator

Indicator

Color

Status

Instruction

Sealed

Green

On solid

12V system

Flashing

24V system

Gel

Red

On solid

12V system

Flashing

24V system

Flooded

Green

On solid

12V system

Flashing

24V system

LiFePO4

Red

On solid

12V system

Flashing

24V system

Li-NiCoMn

Green

On solid

12V system

Flashing

24V system

 

After the introduction of DuoRacer Display basics, we will discuss the standards as the DuoRacer Display Standards (DDS). Again the same procedure of tables will be employed to announce the prominent features of EPEVER DuoRacer MPPT charge controller, which are included the LCD/LED screen of the product. These indicators and warnings can provide beneficial information for remote monitoring of the whole solar system and avoid any dangerous accidents. 

 

 

Charging indicator

Indicator

Color

Status

Instruction

Green

On solid

PV connection normal but the low voltage(low irradiance) from PV, no charging.

Green

OFF

No PV voltage(night time) or PV connection problem

Green

Slowly flashing(1Hz)

In charging

Green

Fast flashing(4Hz)

PV overvoltage

 

Operation Interface

Icon

Instruction

Icon

Instruction

BATT1 battery capacit①0~12%

BATT2battery capacity①

0~12%

BATT1battery capacity①

13%~35%

BATT2battery capacity①

13%~35%

BATT1battery capacity①

36%~61%

BATT2battery capacity①

36%~61%

BATT1battery capacity①

62%~86%

BATT2battery capacity①

62%~86%

BATT1battery capacity①

87%~100%

BATT2battery capacity①

87%~100%

Day

PV array

Night

BATT1 charging icon

Display the parameters of PV

BATT2charging icon

Display the parameters of BATT1

BATT1temperature parameters

Display the parameters of BATT2

AES signal icon

Setting icon

 

Battery type icon

Auto global browsing icon

Minimum voltage icon

Fault Icon

Maximum voltage icon

①Battery capacity is calculated by the linear relationship between the LVD voltage and float charging voltage

 

Fault Indication

Fault

Fault indicator

Charge indicator

LCD

Instruction

BATT1 overvoltage

Red

Fast flashing

——

Battery capacity shows full, battery frame blink, fault icon blink.

BATT1 over-discharged

——

——

Battery capacity shows empty, battery frame blink, fault icon blink.

BATT1 over temperature

Red

Fast flashing

——

Battery frame blink, fault icon blink, the temperature icon blink.

BATT1  system voltage error①

Red

Fast flashing

Green

Fast flashing

Battery capacity shows empty, battery frame blink.

Fault icon blinks and battery frame blink

①No alarm for system voltage error when BATT1 is lithium battery.

 

Buttons

Press the button

 Parameters of PV array

 Parameters of BATT1

 Parameters of BATT2

 Auto global browsing mode()

Press the button

 Browse the parameters of PV array

 Browse the parameters of BATT1

 Browse the parameters of BATT2

Press the button and hold on 5s

 Select the temperature unit

 Select the battery type

 

This part of the article introduces the important features and instructions which the screen of EPEVER DuoRacer MPPT charge controller provides for the customer. More information about the screen and the programming of the charge controller are available in the user manual of the product. It should be noted that important information about the protection, maintenance, and troubleshooting of the controller are assigned in the user manual, which should be noted before the usage of DuoRacer controller. In the last part of the article, we will illustrate the electrical, environmental, and mechanical parameters of various EPEVER DuoRacer MPPT charge controllers to summarize the astonishing properties of the novel product. We hope this article and specification, which are summarized here, could have introduced the novelties and priorities of DuoRacer controller over conventional controllers.

 

Electrical Parameters

Item

DR1106N

-DDB/DDS

DR2106N

-DDB/DDS

DR3106N -DDB/DDS

DR1206N -DDB/DDS

DR2206N -DDB/DDS

DR3206N -DDB/DDS

DR2210N -DDB/DDS

DR3210N -DDB/DDS

BATT1 rated voltage

12VDC

12/24VDC

BATT2 rated voltage

12VDC

12/24VDC自动识别

Rated Charge Current

10A

20A

30A

10A

20A

30A

20A

30A

Battery Input Voltage Range

8.5~16V

8.5~32V①

Max. PV Open Circuit Voltage

60V②

46V③

100V②

92V③

MPP Voltage Range

(Battery Voltage+2V)~36V

(Battery Voltage+2V)~72V

Rated Charge Power

130W/12V

260W/12V

390W/12V

130W/12V 260W/24V

260W/12V 520W/24V

390W/12V 780W/24V

260W/12V 520W/24V

390W/12V 780W/24V

Max. conversion efficiency

97.4%

97.5%

98%

97.4%

97.5%

98%

97.5%

98%

Full load efficiency

97%

96%

96%

97%

96%

96%

96%

96%

Self-consumption

12mA/12V;4mA/12V (Low-power mode)

12mA/12V;8mA/24V

4mA/12V;3mA/24V(Low-power mode)

26mA/12V;15mA/24V

19mA/12V;10mA/24V

(Low-power mode)

Temperature compensate

coefficient④

-3mV/℃/2V(default)

Grounding

Common negative

BATT2Full voltage

13.8V/12V

13.8V/12V;27.6V/24V(default)

BATT2 Charge return voltage

13V/12V

13V/12V;26V/24V(default)

AES signal port⑤

12VDC/Max.200mA(3.81-4P)

5VDC/Max.200mA(2*(3.81-4P))

RS485 com. port⑤

5VDC/Max.200mA(3.81-4P)

Com. baud rate⑥

115200(default)

LCD backlight time⑦

60S(default)

① Warning: When the lithium battery of 12V is used, and the BMS is protected, the lithium battery voltage may increase up to 35V, which may damage the load, so please consider the load’s voltage.

② At minimum operating environment temperature.

③ At 25℃ environment temperature.

④ The Temperature compensate coefficient is zero and not changeable when the main battery type is a lithium battery.

⑤ AES port in which output is 12V/200mA and RS485 Port, which output is 5V/200mA are independent of DR1106/2106/3106N models, the AES port output voltage is the battery voltage. The above two ports of DR1206/2206/3206/2210/3210N models share the power of 5VDC/Max. 200mA.

⑥ The communication baud rate can only be set via PC software.

⑦ The LCD backing time can only be set via PC software, setting range is 0~999S, and the 0s means the LCD is on all the time.

 

Environmental Parameters

Item

DR1106/2106/1206/2206/2210N-DDB/DDS

DR3106/3206/3210N-DDB/DDS

Working environment temperature(100% input and output)

-20℃~+50℃(DDS)

-30℃~+50℃(DDB)

-20℃~+45℃(DDS)

-30℃~+45℃(DDB)

Storage temperature range

-30℃~+80℃

Relative humidity

≤95%, N.C

Enclosure

IP33

3-protection against solid objects: protected against solids objects over 2.5mm.

3-protected against sprays to 60°from the vertical.

Pollution degree

PD2

 

Mechanical Parameters

Item

DR1106/1206N-DDB/DDS

DR2106/2206/2210N-DDB/DDS

DR3106/3206/3210N-DDB/DDS

Dimension

227.2×143×58.1mm

243.7×158×63mm

247.2×165×68.5mm

Mounting dimension

160×134mm

180×149mm

180×156mm

Mounting hole size

φ5mm

Terminal

12AWG/4mm2(BATT1)

12AWG/4mm2(BATT2)

6AWG/16mm2(BATT1)

12AWG/4mm2(BATT2)

6AWG/16mm2(BATT1)

12AWG/4mm2(BATT2)

Recommended cable size

12AWG/4mm2(BATT1)

12AWG/4mm2(BATT2)

10AWG/6mm2(BATT1)

12AWG/4mm2(BATT2)

8AWG/6mm2(BATT1)

12AWG/4mm2(BATT2)

Weight

0.8kg

1.1kg

1.4kg

 

 

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