GSL electronics BMPPT800 User manual

Page 1 of 8
Model:
BMPPT800
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
800W Solar Battery Charger
Booster Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
BMPPT800-R2
This revolutionary maximum power point tracker solar charger was designed using the technology
that won GSL Electronics the prestigious “2008 EDN Innovation Award” and the “2009 Greentech
Consensus Award”. A simple, efcient and low cost alternative to charge sealed or vented
batteries from low voltage or parallel panels. With built in low voltage disconnect. Compatible with
our MCM module and PC Based GUI.
The BMPPT800 is designed to automatically charge 24V and 48V sealed and vented lead
acid batteries from silicon based PV panels such as monocrystalline, polycrystalline and thin
lm.
PATENT APPLIED FOR - 2010901565

Page 2 of 8
Model:
BMPPT800 800W Solar Battery Charger
Booster Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
BMPPT800-R2
Important notes:
•The panel open circuit voltage MUST be below 27V on battery systems or below 54V on 48V
battery systems.
• Use only sealed or vented 24V or 48V lead acid batteries and conrm the BMPPT settings,
charge voltages and currents are correct for your battery system – if in any doubt seek
qualied advice!
• This equipment must be installed by qualied personnel only and incorrect wiring can cause
re, injury or death – GSL will accept no responsibility for BMPPT misconnection or misuse.
•Use wires suitable for at least 30A, but if wire runs are over 3m then larger wires are
recommended to limit voltage drop and losses.
• Install the unit in a dry place out of direct sunlight and away from ammable liquids or gases.
•Battery fuse ( BF ) is always required and must be located as close to the battery as possible,
its sizing depends on the wire size and load ratings. Typically a 30A 60VDC fuse would do.
•The lowest Maximum Power Point reqired for proper operation is 14V.
BMPPT800 Specications
Efciency typical 96%
Input voltage 14V to 54V
Output voltage
Float 27V / 54V
Absorption - Vented LA Batteries 29V / 58V
Sealed - LA Batteries 28.4V / 56.8V
Output Current 14A @ Vout / Vin ≈ 2 , 7A @ Vout / Vin ≈ 4
Quiescent current 0.04A (0.08A with MCM)
Thermal protection Multilevel Type
Dimensions (mm) 220 X 145 X 67mm
Indications LED display – OUTPUT STATUS
BMPPT800 General Information:
• Green LED On – Battery Ok.
•Green LED Flashing – Battery Low.
• This MPPT is designed to auto detect 24V or 48V battery systems and select a suitable charge
regime.
• The BMPPT800 is shipped in a sealed battery setting which is the safest setting but if your
batteries are vented then, BEFORE wiring the BMPPT in, follow the
CHANGING BATTERY TYPE SETTING PROCEDURE.
•The absorption phase is entered following a low battery condition or dawn and is
maintained until the battery demand falls below 1.5A.
• Custom oat and absorption voltages and thresholds are possible but minimum orders apply.
•This BMPPT has a built in multilevel over temperature protection to improve product reliability
while maximising output power availability.

Page 3 of 8
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
800W Solar Battery Charger
Booster Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Model:
BMPPT800
BASIC WIRING OPTIONS:
Permanent Load Connection
(Figure 1):
Simplest wiring option where the
load is permanently connected
and the batteries are not
protected from overdischarge.
Wiring With Low Voltage
Disconnect (Figure 2) :
This option protects the
battery from overdischarge by
disconnecting the load. The
LVD option disconnects the
load when the battery voltage
drops below 0.85 of nominal
voltage to protect the battery
from damage. The load
reconnects when the battery
voltage exceeds 0.95 of
nominal voltage. This feature
will not trigger during short
transients. LVD load is 30A
continuous or 50A transient.
Figure 2.
BMPPT800-R2
Figure 1.

Page 4 of 8
1700W Solar Battery Charger
Booster Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
Model:
BMPPT800
Wiring With Critical And Non Critical Loads (Figure 3):
Critical loads are generally light loads which are powered under any condition. Non critical loads are
loads which can be disconnected to ensure maximum on time for critical loads as well as to extend
the life expectancy and reliability of the system. The non critical load can be set up as LVD or Dawn
to Dusk loads.
Figure 3.
Wiring with MCM option:
Connecting the optional MCM to the BMPPT will allow various system parameter display, output
voltage and alarm settings and enable the programmable dawn to dusk or remote load control
options. For more details please refer to MCM Manual.
BMPPT800-R2

Page 5 of 8
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
800W Solar Battery Charger
Booster Maximum Power Point Track-
er
Operating Instructions
Please read these instructions before use
Model:
BMPPT800
BMPPT800-R2
For optimal performance from panel and BMPPT please use the following table to
determine the best setup for your situation.
VOC
VMP
24V Charging 48V Charging
21 16 
42 32 
63 48
84 64
42 32 
84 64
Grid Connect Panel (size
per cells in grid)
1x18 Cell Grid 10 8
1x48 Cell Grid 28 23 
2x48 Cell Grid 56 46
3x48 Cell Grid 84 69
1x52 Cell Grid 31 25 
2x52 Cell Grid 62 50
3x52 Cell Grid 93 75
1x54 Cell Grid 32 26 
2x54 Cell Grid 64 52
3x54 Cell Grid 96 78
1x60 Cell Grid 36 29 
2x60 Cell Grid 72 58
1x72 Cell Grid 44 36 
2x72 Cell Grid 88 72
1x96cgsp 65 55

Page 6 of 8
800W Solar Battery Charger
Booster Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
Model:
BMPPT800
Changing Battery Type Setting Procedure
1.Ensure all the BMPPT wires are disconnected.
2.Remove 7 front panel screws and the front panel and slide out cover – see Figure 4.
3.Locate connector J4 – see Figure 4.
4.Shift link on J4 to vented position – see Figure 5.
5.Slide back cover and t in front panel carefully, insuring led ts properly into housing,
and screw back the 7 mounting screws.
•The above procedure can be repeated to turn back to sealed mode – see Figure 6.
Figure 4.
BMPPT800-R2

Page 7 of 8
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
800W Solar Battery Charger
Booster Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Model:
BMPPT800
Figure 5 (Above): Vented Battery Setting Figure 6 (Above): Sealed Battery Setting
BMPPT FAQs
Q: What is an BMPPT?
BMPPT stands for Booster Maximum Power Point Tracker and is a specialised converter designed to
maintain the PV voltage at the level in which it delivers maximum power to the load or battery while at
the same time boosting the output voltage above the input. The nominal panel output power can only
be ensured with the use of an MPPT
Q: When is a BMPPT Required?
The BMPPT is required when the panel voltage is below the battery voltage such as when a 12V panel
needs to charge a 24V battery.
The BMPPT enables the parallel connection of panels which can make the system more tolerant to
partial shading when compared to series panel connection.
BMPPT800-R2
Q: What sort of batteries should I use?
1. A deep cycle battery is a must due to the cyclical nature of the solar system with a
recommended battery capacity of at least 180AH.
2. A larger battery will not only give longer run time during low light but also will be able to avoid
available PV power being unstored such as when battery reaches the oat stage.

Page 8 of 8
800W Solar Battery Charger
Booster Maximum Power Point Tracker
Operating Instructions
Please read these instructions before use
Unit 2, 110 Station Road, Seven Hills ,NSW, 2147, Australia
Warranty Conditions: The product is warranted to be free from defects in materials and workmanship under normal use and
service for a period of 24 months from the date of sale. This warranty covers defective parts and workmanship provided that
the product is shipped prepaid to the seller within 24 months of purchase of goods. This warranty is limited to the repair or
replacement (at the manufacturers’ discretion) of parts and shipping prepaid to the original despatch destination. We regret that
no liability can be accepted for consequential or special damages of any kind howsoever arising in connection with products
supplied by the seller. This warranty is in lieu of all other warranties expressed or implied. No representative is authorised to
assume for the seller any other liability in connection with the seller’s products.
Model:
BMPPT800
Q: How do PV temperatures affects charge current?
Temperature increase brings down the PVs maximum power point voltage reducing the BMPPTs
current gain available. In principle at 25C it is possible to achieve 30% gain but at 40C, a more
realistic average temperature, about 20% is still available.
Q: What sorts of loads can I power with the BMPPT800?
1. The maximum bulk charge current with the BMPPT30 on a 24V battery and a 12V 750W panel
is approximately 26A, so you can expect about 100AH per day which means a 240W load for
about 10 hours daily.
2. Following the same reasoning with a 48V Battery and 24V 1500W panel the MPPT30 will
supply a daily load of 480W for about 10 hours.
BMPPT800-R2
Q: Is interference possible? and If so what do I do?
GSL’s BMPPTs produce far less interference than conventional solar regulator during
the absorption and oat stages, that is during most of its operating time, and its
designed to comply with local and international EMI standards however some
interference is still possible. If interference occurs rst try and reorient the aerial or move
the sensitive equipment away from the BMPPT wires. Ensure the BMPPT chassis is grounded.
Grounding a battery terminal may also help and nally you can try adding ferrite clamps.