Victron energy BlueSolar MPPT 150/60-MC4 User manual

Manual
SmartSolar charge controllers
MPPT 150/45-Tr MPPT 150/45-MC4
MPPT 150/60-Tr MPPT 150/60-MC4
MPPT 150/70-Tr MPPT 150/70-MC4
MPPT 150/85-Tr MPPT 150/85-MC4
MPPT 150/100-Tr MPPT 150/100-MC4
MPPT 250/60-Tr MPPT 250/60-MC4
MPPT 250/70-Tr MPPT 250/70-MC4
MPPT 250/85-Tr MPPT 250/85-MC4
MPPT 250/100-Tr MPPT 250/100-MC4

1. General Description
Bluetooth Smart built-in: dongle not needed
The wireless solution to set-up, monitor and update the controller using
Apple and Android smartphones, tablets or other devices.
VE.Direct port
For a wired data connection to a Color Control, Venus GX, PC or other
devices.
Remote on-off input
On/off control by a VE.Bus BMS when charging Li-ion batteries.
Programmable relay
Can be programmed (a.o. with a smartphone) to trip on an alarm, or other
events.
Optional: pluggable LCD display
Simply remove the rubber seal that protects the plug on the front of the
controller and plug-in the display.
Ultra-fast Maximum Power Point Tracking (MPPT)
Especially in case of a clouded sky, when light intensity is changing
continuously, an ultra fast MPPT controller will improve energy harvest by up
to 30% compared to PWM charge controllers and by up to 10% compared to
slower MPPT controllers.
Advanced Maximum Power Point Detection in case of partial shading
conditions
If partial shading occurs, two or more maximum power points may be
present on the power-voltage curve.
Conventional MPPTs tend to lock to a local MPP, which may not be the
optimum MPP.
The innovative SmartSolar algorithm will always maximize energy harvest by
locking to the optimum MPP.
Outstanding conversion efficiency
No cooling fan. Maximum efficiency exceeds 98%. Full output current up to
40°C (104°F).
Extensive electronic protection
Over-temperature protection and power derating when temperature is high.
PV reverse polarity protection.
Internal temperature sensor
Compensates absorption and float charge voltages for temperature.
(range 6°C to 40°C)

Optional external voltage and temperature sensor
(range -20°C to 50°C)
The Smart Battery Sense is a wireless battery voltage-and-temperature
sensor for Victron MPPT Solar Chargers. The Solar Charger uses these
measurements to optimize its charge parameters. The accuracy of the data it
transmits will improve battery charging efficiency, and prolong battery life
Alternatively, Bluetooth communication can be set up between a BMV-712
battery monitor with battery temperature sensor and the solar charge
controller.
For more detail please enter smart networking in the search box on
our website.
Automatic battery voltage recognition
The controllers will automatically adjust to a 12V, 24V or a 48V system one
time only. If a different system voltage is required at a later stage, it must be
changed manually, for example with the Bluetooth app or the optionel LCD
display. Similarly, manual setting is required in case of 36V system.
Flexible charge algorithm
Fully programmable charge algorithm, and eight preprogrammed algorithms,
selectable with a rotary switch.
Adaptive three step charging
The SmartSolar MPPT Charge Controller is configured for a three step
charging process: Bulk – Absorption – Float.
A regular equalization charge can also be programmed: see section 3.8 of
this manual.
Bulk
During this stage the controller delivers as much charge current as possible
to rapidly recharge the batteries.
Absorption
When the battery voltage reaches the absorption voltage setting, the
controller switches to constant voltage mode.
When only shallow discharges occur the absorption time is kept short in
order to prevent overcharging of the battery. After a deep discharge the
absorption time is automatically increased to make sure that the battery is
completely recharged. Additionally, the absorption period is also ended when
the charge current decreases to less than 2A.
Float
During this stage, float voltage is applied to the battery to maintain it in a fully
charged state.
Equalization
See section 3.10

Configuring and monitoring
Configure the solar charge controller with the VictronConnect app. Available
for iOS & Android devices; as well as macOS and Windows computers. An
accessory might be required; enter victronconnect in the search box on our
website and see the VictronConnect download page for details.
For simple monitoring, use the MPPT Control; a panel mounted simple yet
effective display that shows all operational parameters. Full system
monitoring including logging to our online portal, VRM, is done using the GX
Product range
MPPT Control
Color Control
Venus GX

2. Safety instructions
SAVE THESE INSTRUCTIONS - This manual contains
important instructions that shall be followed during
installation and maintenance.
● Please read this manual carefully before the product is
installed and put into use.
● This product is designed and tested in accordance with
international standards. The equipment should be used for the
designated application only.
● Install the product in a heatproof environment. Ensure
therefore that there are no chemicals, plastic parts, curtains or
other textiles, etc. in the immediate vicinity of the equipment.
● The product is not allowed to be mounted in a user accessible
area.
● Ensure that the equipment is used under the correct operating
conditions. Never operate it in a wet environment.
● Never use the product at sites where gas or dust explosions
could occur.
● Ensure that there is always sufficient free space around the
product for ventilation.
● Refer to the specifications provided by the manufacturer of the
battery to ensure that the battery is suitable for use with this
product. The battery manufacturer's safety instructions should
always be observed.
● Protect the solar modules from incident light during installation,
e.g. cover them.
● Never touch uninsulated cable ends.
● Use only insulated tools.
● Connections must always be made in the sequence described
in section 3.5.
● The installer of the product must provide a means for cable
strain relief to prevent the transmission of stress to the
connections.
● In addition to this manual, the system operation or service
manual must include a battery maintenance manual applicable to
the type of batteries used.
Danger of explosion from sparking
Danger of electric shock

● Use flexible multistranded copper cable for the battery and PV
connections.
The maximum diameter of the individual strands is
0,4mm/0,125mm² (0.016 inch/AWG26).
A 25mm² cable, for example, should have at least 196 strands (class 5 or
higher stranding according to VDE 0295, IEC 60228 and BS6360).
An AWG2 gauge cable should have at least 259/26 stranding (259 strands of
AWG26).
Maximum operating temperature: ≥ 90°C.
Example of suitable cable: class 5 “Tri-rated” cable (it has three approvals:
American (UL), Canadian (CSA) and British (BS))
In case of thicker strands the contact area will be too small and the
resulting high contact resistance will cause severe overheating,
eventually resulting in fire.
● Maximum current through a MC4 terminal: 30A
● The grounding terminal is located in the wiring compartment
and is identified by the symbol below:

3. Installation
WARNING: DC (PV) INPUT NOT ISOLATED FROM BATTERY CIRCUIT.
CAUTION: FOR PROPER TEMPERATURE COMPENSATION
THE AMBIENT CONDITION FOR CHARGER AND BATTERY MUST BE
WITHIN 5°C.
3.1 General
● Mount vertically on a non-flammable surface, with the power terminals
facing downwards. Observe a minimum clearance of 10 cm under and above
the product for optimal cooling.
● Mount close to the battery, but never directly above the battery (in order to
prevent damage due to gassing of the battery).
● Improper internal temperature compensation (e.g. ambient condition
battery and charger not within 5°C) can lead to reduced battery lifetime.
We recommend using a direct battery voltage sense source (BMV,
Smart Battery Sense or GX device shared voltage sense) if larger
temperature differences or extreme ambient temperature conditions
are expected.
● Battery installation must be done in accordance with the storage battery
rules of the Canadian Electrical Code, Part I.
● The battery connections (and for Tr version also PV connections) must be
guarded against inadvertent contact (e.g. install in an enclosure or install the
optional WireBox).
Tr models: use flexible multistranded copper cable for the battery and PV
connections: see safety instructions.
MC4 models: several splitter pairs may be needed to parallel the strings of
solar panels. (Maximum current through a MC4 terminal: 30A)
3.2 Grounding
● Battery grounding: the charger can be installed in a positive or negative
grounded system.
Note: apply a single ground connection (preferably close to the battery) to
prevent malfunctioning of the system.
● Chassis grounding: A separate earth path for the chassis ground is
permitted because it is isolated from the positive and negative terminal.
● The USA National Electrical Code (NEC) requires the use of an external
ground fault protection device (GFPD). These MPPT chargers do not have
internal ground fault protection. The system electrical negative should be
bonded through a GFPD to earth ground at one (and only one) location.
● The charger must not be connected with grounded PV arrays. (one ground
connection only)
● The plus and minus of the PV array should not be grounded. Ground the
frame of the PV panels to reduce the impact of lightning.
WARNING: WHEN A GROUND FAULT IS INDICATED, BATTERY
TERMINALS AND CONNECTED CIRCUITS MAY BE UNGROUNDED
AND HAZARDOUS.

3.3 PV configuration (also see the MPPT Excel sheet on our website)
● The controllers will operate only if the PV voltage exceeds
battery voltage (Vbat).
● PV voltage must exceed Vbat + 5V for the controller to start.
Thereafter minimum PV voltage is Vbat + 1V.
● Maximum open circuit PV voltage: 150V or 250V, depending on model.
For example:
24V battery, mono- or polycristalline panels, max PV voltage 150V:
● Minimum number of cells in series: 72 (2x 12V panel in series
or one 24V panel).
● Recommended number of cells for highest controller efficiency:
144 cells (4x 12V panel or 2x 24V panel in series).
● Maximum: 216 cells (6x 12V or 3x 24V panel in series).
48V battery, mono- or polycristalline panels, max PV voltage 250V:
● Minimum number of cells in series: 144
(4x 12V panel or 2x 24V panel in series).
● Maximum: 360 cells (10x 12V or 5x 24 panel in series).
Remark: at low temperature the open circuit voltage of a 216 cell solar array
may exceed 150V, and the open cicuit voltage of a 360 cell array may
exceed 250V, depending on local conditions and cell specifications. In that
case the number of cells in series must be reduced.
3.4 Cable connection sequence (see figure 1)
First: connect the battery.
Second: if required, connect the remote on-off and programmable relay
Third: connect the solar array (when connected with reverse polarity, the
controller will heat up but will not charge the battery).
Torque: 2,4 Nm
3.5 Remote on-off
The left terminal is connected to the internal 3,3V supply, with a resistor in
series for short circuit protection.
The right terminal (marked as + or marked as H) will switch the controller on
if >3V is applied, and will switch the controller off if <2V is applied or if the
terminal is left free floating.
The recommended use of the remote on-off is:
a. A switch wired between the left and right terminal
b. A switch wired between battery plus and the right terminal.
c) A switch between the right terminal and the charge disconnect terminal of a VE.Bus BMS

3.6 Configuration of the controller with the rotary switch
Fully programmable charge algorithm (see the software page on our
website) and eight preprogrammed charge algorithms, selectable with a
rotary switch:
Pos
Suggested battery type
Absorption
V
Float
V
Equalize
V
@%Inom
dV/dT
mV/°C
0
Gel Victron long life (OPzV)
Gel exide A600 (OPzV)
Gel MK
28,2 27,6
31,8
@8%
-32
1 Gel Victron deep discharge
Gel Exide A200
AGM Victron deep discharge
Stationary tubular plate (OPzS)
28,6 27,6
32,2
@8% -32
2
Default setting
Gel Victron deep discharge
Gel Exide A200
AGM Victron deep discharge
Stationary tubular plate (OPzS)
28,8 27,6
32,4
@8% -32
3
AGM spiral cell
Stationary tubular plate (OPzS)
Rolls AGM
29,4
27,6
33,0
@8%
-32
4
PzS tubular plate traction batteries or
OPzS batteries
29,8
27,6
33,4
@25%
-32
5
PzS tubular plate traction batteries or
OPzS batteries
30,2
27,6
33,8
@25%
-32
6
PzS tubular plate traction batteries or
OPzS batteries
30,6
27,6
34,2
@25%
-32
7
Lithium Iron Phosphate (LiFePo
4
)
batteries
28,4 27,0 n.a. 0
Note 1: divide all values by two in case of a 12V system and multiply by two
in case of a 48V system.
Note 2: equalize normally off, see sect. 3.9 to activate
(do not equalize VRLA Gel and AGM batteries)
Note 3: any setting change performed with the pluggable LCD display or via
Bluetooth will override the rotary switch setting. Turning the rotary switch will
override prior settings made with the pluggable LCD display or via Bluetooth.

A binary LED code helps determining the position of the rotary switch.
After changing the position of the rotary switch, the LEDs will blink during 4
seconds as follows:
Thereafter, normal indication resumes, as described in the LEDs section.
3.7 LEDs
LED indication:
permanent on
blinking
off
Regular operation
LEDs
Bulk
Absorption
Float
Not charging (*1)



Bulk



Absorption



Manual equalisation (blink
alternating)
  
Automatic equalisation



Float



Note (*1): The bulk LED will blink briefly every 3 seconds when the system is powered but
there is insufficient power to start charging.
Fault situations
LEDs
Bulk
Absorption
Float
Charger temperature too high



Charger over-current



Charger or panel over-voltage



VE.Smart networking or BMS
issue
  
Internal error (*2)



Note (*2): E.g. calibration and/or settings data lost, current sensor issue.
Switch
position
LED
Bulk
LED
Abs
LED
Float
Blink
frequency
0
1
1
1
Fast
1
0
0
1
Slow
2
0
1
0
Slow
3
0
1
1
Slow
4
1
0
0
Slow
5
1
0
1
Slow
6
1
1
0
Slow
7
1
1
1
Slow