Victron energy Bluesolar-5 User manual

ACDC Header
Features
Load output with low battery voltage disconnect function.
Lighting control function, one timer only.
Two digit display for parameter setting.
Three stage charging (Bulk, Absorption, Float)
Over load and short circuit protected.
Reverse polarity protected.
Day / Night timing functions.
Feature
Rated Charge Current
Battery Voltage
Auto Load Disconnect
Max Solar Voltage
Self Consumption 10mA
Load OutputManual control + Low voltage disconnect
Protection Battery reverse polarity (fuse)
Output Short circuit
Over Temp
Overload Protection
Shut down after 60sec with load at 130%
Shut down after 5sec with load 160%
Short circuit immediate shutdown
Grounding Common Positive
Operating Temperature
‐20 to 50⁰C
Humidity Max 95%RH
Battery
Charge Voltage "Absorption"
14.2 / 28.4V
Charge Voltage "Float" 13.8 / 27.6V
Low Voltage Load Disconnect
11.2 / 22.4V
Low Voltage Load Reconnect
12.6 / 25.2V (manual)
13.1 / 26.2V (automatic)
Enclosure
Protection Class IP20
Terminal Size
5mm²
Weight 0.15kg
Dimensions (HxWxD)mm70 x 133 x 33.5
Bluesolar-5, Bluesolar-10
12/24V with auto system voltage detection
Yes
10A
5A
Bluesolar-10
Bluesolar-5
28V / 55V(1)

Manual
EN
Appendix
BlueSolar Charge controller
12/24V-10A with timer

Copyrights 2008 Victron Energy B.V.
All Rights Reserved
This publication or parts thereof may not be reproduced in any form, by any method, for
any purpose.
For conditions of use and permission to use this manual for publication in other than the
English language, contact Victron Energy B.V.
VICTRON ENERGY B.V. MAKES NO WARRANTY, EITHER EXPRESSED OR
IMPLIED, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, REGARDING
THESE VICTRON ENERGY PRODUCTS AND MAKES SUCH VICTRON ENERGY
PRODUCTS AVAILABLE SOLELY ON AN “AS IS” BASIS.
IN NO EVENT SHALL VICTRON ENERGY B.V. BE LIABLE TO ANYONE FOR
SPECIAL, COLLATERAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES IN
CONNECTION WITH OR ARISING OUT OF PURCHASE OR USE OF THESE
VICTRON ENERGY PRODUCTS. THE SOLE AND EXCLUSIVE LIABILITY TO
VICTRON ENERGY B.V., REGARDLESS OF THE FORM OF ACTION, SHALL NOT
EXCEED THE PURCHASE PRICE OF THE VICTRON ENERGY PRODUCTS
DESCRIBED HERE IN.
Victron Energy B.V. reserves the right to revise and improve its products as it sees fit.
This publication describes the state of this product at the time of its publication and may
not reflect the product at all times in the future

2

3
EN
Appendix
Installation and Operation Manual
Specification Summary
Nominal system voltage: 12 / 24VDC*
Maximum PV input voltage: 50V
Nominal charge / discharge current 10A
* The controller will recognize the system rated voltage when start up. If the battery
voltage is lower than 18V, it will recognize the system as 12V. If the battery voltage is
greater than 18V, it will recognize the system as 24V.

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Contents
1 Important Safety Information...................................................... 5
2 General Information.................................................................... 6
2.1 Product Overview .................................................................... 6
2.2 Product Features ..................................................................... 7
3 Installation Instructions............................................................... 9
3.1 General Installation Notes....................................................... 9
3.2 Mounting.................................................................................. 9
3.3 Wiring..................................................................................... 11
4 Operation .................................................................................. 15
4.1 PWM Technology .................................................................. 15
4.2 Battery Charging Information ................................................ 15
4.3 LED Indicators ....................................................................... 16
4.4 Operation and settings .......................................................... 18
4.5 Setting the timers................................................................... 19
5 Protections, Troubleshooting and Maintenance...................... 22
5.1 Protection............................................................................... 22
5.2 Troubleshooting..................................................................... 23
5.3 Maintenance .......................................................................... 24
6 Technical Specifications........................................................... 25
Appendix A: Dimensions ............................................................. 29

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EN
Appendix
1. Important Safety Information
This manual contains important safety, installation and operating instructions.
The following symbols are used throughout this manual to indicate potentially
dangerous conditions or mark important safety instructions, please take care when
meeting these symbols.
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 the safe
and proper operation of the controller.
General Safety Information
Read all of the instructions and cautions in the manual before beginning
installation.
There are no user serviceable parts inside the controller. Do not disassemble or
attempt to repair it.
Install external fuses/breakers as required.
Disconnect the solar module and fuse/breakers near to battery before installing or
adjusting the controller.
Do not allow water to enter the controller.
Confirm that power connections are tightened to avoid excessive heating from
loose connection.

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2. General Information
2.1 Product Overview
12/24V automatic recognition
Efficient Series PWM charging, increases battery lifetime and improves solar
system performance.
Uses MOSFET as electronic switch, without any mechanical switch
Automatic day/night recognition.
Digital LED menu.
Intelligent timer function with 1-15 hours option.
Unique dual timer function, enhances the flexibility of street light system.
Gel, Sealed and Flooded battery type option.
Temperature compensated charging and discharging.
Electronic protection: overheating, over charging, over discharging, overload, and
short circuit.
Reverse current protection.
The controller is for off-grid solar systems, especially solar light systems, and protects the
battery from being over charged by the solar module and over discharged by the loads. The
charging process has been optimized for long battery life and improved system
performance. The comprehensive self-diagnostics and electronic protection functions can
prevent damage from installation mistakes or system faults.
Though the controller is easy to operate and use, please take your time to read this manual
and become familiar with it. This will help you make full use of all the functions and improve
your solar PV system.

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EN
Appendix
2.2 Product Features
Figure 2-1 Features
1 –Temperature Sensor
Measures ambient temperature. Used for temperature compensated charging and
discharging.
2 –Charging status LED indicator
A LED indicator that shows charging status and also indicates when a solar input fault
condition exists
3 –Battery status LED indicator
A LED indicator that shows battery status
4 –Battery type setting indicator
The indicator will be on when the battery type is selected.
5 –Timer 2 setting indicator
The indicator will be on when setting timer 2.
6 –Timer 1 setting indicator
The indicator will be on when setting timer 1.
7 –LED digital display
Displays the load mode and status
8 –Setting button (in manual mode used for load ON/OFF)
To set load mode and to select battery type.

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9 –Solar Module Terminals
Connect solar modules.
10 –Battery Terminals
Connect batteries.
11 –Load Terminals
Connect loads.

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EN
Appendix
3. Installation Instructions
3.1 General Installation Notes
Read through the entire installation section 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.
Uses insulated tools and avoid placing metal objects near the batteries.
Explosive battery gasses may be present during charging. Be certain there is
sufficient ventilation.
Avoid direct sunlight and do not install in locations where water can enter the
controller.
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.
Use with Gel, Sealed or Flooded batteries only.
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.
Select the system cables according to 3A/mm2current density.
3.2 Mounting
NOTE: When mounting the controller, ensure free air through the controller heat
sink fins. There should be at least 6 inches (150 mm) of clearance above and
below the controller to allow for cooling. If mounted in an enclosure, ventilation
is highly recommended.

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WARNING: Risk of explosion! Never install the controller in a sealed enclose
with batteries! Do not install in a confined area where battery gasses can
accumulate.
Step 1: Choose Mounting Location
Locate the controller on a vertical surface protected from direct sun, high temperature,
and water.
Step 2: Check for clearance
Place the controller in the location where it will be mounted. Verify that there is
sufficient room to run wires and that there is sufficient room above and below the
controller for air flow.
Figure 3-1 Mounting and cooling
Step 3: Mark Holes
Use a pencil or pen to mark the four (4) mounting hole locations on the mounting
surface.
Step 4: Drill Holes
Remove the controller and drill 4.5mm holes in the marked locations.
Step 5: Secure 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.
150mm(5.9inches)
Warm air
Cool air
150mm(5.9inches)

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EN
Appendix
3.3 Wiring
NOTE: Please follow the recommended connection order for maximum safety
during installation.
NOTE: The controller is a common positive ground controller.
CAUTION: Don’t connect loads with surge power exceeding the ratings of the
controller.
CAUTION: For mobile applications, be sure to secure all wiring. 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.
Step1: Battery Wiring
WARNING: Risk of explosion or fire! Never short circuit battery positive (+) and
negative (-).
Figure 3-2 Battery connecting
Before connecting the battery, make sure that battery voltage is greater than 6V so as to
start up the controller. If the system is 24V, make sure battery voltage is not less than 18V.
System voltage can only be automatically recognized when the controller starts up for the
first time.
When installing a fuse, make sure that the distance between the fuse holder and the
positive terminal of battery is at most 150mm. Do not insert a fuse at this time.
Battery
150mm(5.9inches)
MAX
Fuse

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Step 2: Load Wiring
The controller loads can be connected to such electrical equipments as lights, pumps,
motors and others.
Figure 3-3 Load Wiring
Connect the positive (+) and negative (-) to the controller load terminals as shown in Figure
3-3.
An in-line fuse holder should be wired in series in the load positive (+) or negative (-) wire as
show in Figure 3-3. Do not insert a fuse at this time.
If wiring the load connection to a load distribution panel, each load circuit should be fused
separately. The total load draw should not exceed the load rated current of the controller.
Fuse
Load

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EN
Appendix
Step 3: Solar wiring
WARNING: Risk of electric shock! Exercise caution when handling solar wiring.
The solar module(s) high voltage output can cause severe shock or injury. Cover
the solar module(s) from the sun before installing solar wiring.
The controller can accept 12V or 24V nominal off-grid solar module(s).
Figure 3-4 Solar wiring
Step 4: Confirm Wiring
Double-check the wiring. Confirm correct polarity at each connection. Verify that all six
terminals are tightened.
Figure 3-5 System wiring review
Solar Module
Fuse
Load
Fuse
150mm(5.9inches)
MAX
Battery
Solar Module

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Step 5: Install Fuse
Install a suitable fuse in each fuse holder in the following order:
1. Battery circuit
2. Load circuit
Step 6: Confirm power on
When battery power is applied and the controller starts up, the battery LED indicator will be
green.
If the controller doesn't start up, or the battery status LED error is on, please refer to section
5 for troubleshooting.

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EN
Appendix
4. Operation
4.1 PWM Technology (Series Pulse Width Modulation)
The controller features advanced series pulse width modulation.
4.2 Battery Charging Information
Figure 4-1 PWM Charging mode
Bulk Charge
In this stage, the battery voltage has not yet reached boost voltage and 100% of
available solar power is used to charge the battery.
Boost/absorption Charge
When the battery has been recharged to the Boost/absorption voltage setpoint,
constant-voltage regulation is used to prevent heating and excessive battery
gassing. The Boost/absorption time is 120 minutes
Float Charge
After the battery is fully charged in the Boost/absorption voltage stage, the
controller reduces the battery voltage to the Float voltage set point. 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.
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 drop below the Boost setpoint, the controller will exit Float stage and
return to Bulk charge.

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Equalize Charge
WARNING: Risk of explosion!
Equalizing a flooded battery can produce explosive gases, good ventilation of the
battery box is therefore necessary.
NOTE: Equipment damage!
Equalization may increase battery voltage to a level that is damaging to sensitive DC
loads. Ensure that the allowable input voltage of the loads is greater than the
equalize charging set point voltage.
NOTE: Equipment damage!
Over-charging and excessive gassing may damage the battery plates and activate
material.
Excessive equalizing charge 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 will stir the
electrolyte and balance battery voltage.
Only if the battery has been over discharged, the solar controller will automatically
turn to equalize charging, and the equalize stage will remain on during 120 minutes.
4.3 LED Indicators
Charging Status LED indicator Battery Status LED indicator
Figure 4-2 LED indicators
Charging status indicator
GREEN ON whenever sunlight is available for battery charging,
GREEN FAST FLASHING in case of system over voltage.
Please refer to section 5 for troubleshooting.

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EN
Appendix
Charging Status LED indicator Table 4-1
Color
Indicator
Charging Status
Green
On Solid
Charging
Green
Fast Flashing
Over voltage
Battery status indicator
GREEN ON when battery voltage in normal range
GREEN SLOWLY FLASHING when battery full
ORANGE ON in case of battery under voltage
RED ON when the battery is over discharged
Please refer to section 5 for troubleshooting.
Battery status LED indicator Table 4-2
Color
Indicator
Battery Status
Green
On solid
Normal
Green
Slowly Flashing
Full
Orange
On solid
Under voltage
Red
On solid
Over discharged
Load status indicator
When the load current is 1.25 times rated current for 60 seconds, or the load current is 1.5
times rated current for 5 seconds (overload); or load current is more than 3.5 times rated
current (Short Circuit), the LED display shows “L”, slowly flashing. Please refer to section 5
for troubleshooting.
Load status LED indicator Table 4-3
Color
LED digital tube
Load status
Red
“L” with slowly
flashing
Overload or short
circuit