Victron energy BlueSolar MPPT 150/70 User manual

Manual
EN
Handleiding
NL
Manuel
FR
Anleitung
DE
Manual
ES
Användarhandbok
SE
Appendix
BlueSolar charge controller MPPT 150/70

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EN NL FR DE ES SE Appendix
1. PRODUCT INTRODUCTION
Charge current up to 70 A and PV voltage up to 150 V
The BlueSolar 150/70-MPPT charge controller is able to charge a lower nominal-
voltage battery from a higher nominal voltage PV array.
The controller will automatically adjust to a 12, 24, or 48 V nominal battery voltage.
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 MPPT’s tend to lock to a local MPP, which may not be the optimum MPP.
The innovative BlueSolar 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).
Flexible charge algorithm
Several preprogrammed algorithms. One programmable algorithm.
Manual or automatic equalisation.
Battery temperature sensor. Battery voltage sense option.
Programmable auxiliary relay
For alarm or generator start purposes
Extensive electronic protection
Over-temperature protection and power derating when temperature is high.
PV short circuit and PV reverse polarity protection.
Reverse current protection.

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2. SAFETY INSTRUCTIONS
●It is advised to 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.
●Ensure that the equipment is used under the correct operating conditions. Never operate
it in a wet or dusty 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 insulated tools only.
●At a voltage >75 V, particularly with regard to the open circuit voltage of the PV array, the
solar system must be installed according to protection class II. A chassis grounding point is
located on the outside of the product. If it can be assumed that the grounding protection is
damaged, the product should be taken out of operation and prevented from accidentally
being put into operation again; contact qualified maintenance personnel.
●Ensure that the connection cables are provided with fuses or circuit breakers. Never
replace a protective device by a component of a different type. Refer to the manual for the
correct part.
●Connections must always be made in the sequence described in section 4
Danger of explosion from sparking
Danger of electric shock

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EN NL FR DE ES SE Appendix
3. INSTALLATION
3.1 Location
The product must be installed in a dry and well-ventilated area, as close as possible to -
but not above - the batteries. There should be a clear space of at least 10 cm around
the product for cooling.
The charge controller is intended for wall mounting. For mounting purposes, a hook and
two holes are provided at the back of the casing (see appendix G)
3.2 Battery cables and battery fuse
Do not invert the plus and minus battery connection: this will
permanently damage the charger.
In order to utilize the full capacity of the product, battery cables with sufficient cross section
and a fuse of sufficient current rating should be used.
Some basic formulas for copper cable:
Resistance Rc (mΩ@47°C) of a cable with length L (m) and cross section A (mm²): Rc = 20*L/A (1)
Or, with Rc in Ω(Ohm): Rc =0,02*L/A (2)
Power loss Pc (W) in a cable carrying current I (A): Pc = I²*Rc = 0,02*l²*L/A (3)
Power loss Pc relative to solar array output Pv in %: α= (Pc/Pv)*100 (4)
Cable cross section required to limit relative power loss to α(%): A = 2*2L*I/(α*V) (5)
(with total cable length 2L) or:
A = 2*2L*Pv/(α*V²) (6)
This product may only be installed by a qualified electrical
engineer.

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Table 1 below gives some examples of battery cable cross sections calculated with formula
(5).
(in this case I and V in formula (5) are the output current and output voltage of the charge
controller)
12V system (solar array up to 1000W)
Maximum
solar array
output
Maximum
Charge
current
@13,4V
Battery
Fuse
Rating
Power loss
in battery
cablesα(%)
Length 2x1,5 m Length 2x2,5 m Length 2x5 m
mm
2
AWG mm
2
AWG mm
2
AWG
500W 37A 63A 1 25 3 35 2 Not recommended
750W 55A 80A 1,5 25 3 35 2 Not recommended
1000W 70A 1) 100A 2 25 3 35 2 Not recommended
24V system (solar array up to 2000W)
Maximum
solar array
output
Maximum
Charge
current
@26,8V
Battery
Fuse
Rating
Power loss
in battery
cables α(%)
Length 2x1,5 m Length 2x2,5 m Length 2x5 m
mm
2
AWG mm
2
AWG mm
2
AWG
500W 18A 35A 1 6 10 10 7 16 5
1000W 37A 63A 1,5 6 10 10 7 25 3
2000W 70A 1) 100A 2 10 7 16 5 35 2
48V system (solar array up to 4000W)
Maximum
solar array
output
Maximum
Charge
current
@53,6V
Battery
Fuse
rating
Power loss
in battery
cables α(%)
Length 2x2,5 m Length 2x5 m Length 2x10 m
mm
2
AWG mm
2
AWG mm
2
AWG
1000W 21 35 0,5 6 10 10 7 16 5
2000W 42 63 0,5 10 7 16 5 35 2
4000W 70A 1) 100 1 10 7 16 5 35 2
1) Taking into account 6% loss (battery cables + controller + PV cables + fuses)
Table 1: Battery cable cross section and power loss
36V system (solar array up to 3000W)
Maximum
solar array
output
Maximum
Charge
current
@40,2V
Battery
Fuse
Rating
Power loss
in battery
cables α(%)
Length 2x2,5 m Length 2x5 m Length 2x10 m
mm
2
AWG mm
2
AWG mm
2
AWG
750W 21 35 0,5 6 10 10 7 16 5
1500W 42 63 0,5 16 5 25 3 35 2
3000W 70A 1) 100 1 16 5 25 3 35 2

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EN NL FR DE ES SE Appendix
3.3 PV connection
The PV input current of the charge controller is limited to 50A. In case of a potential
solar array output exceeding 50A, the solar array voltage will increase up to the level at
which the output is reduced to 50A.
The required PV cable cross section depends on array power and voltage. The table
below assumes that maximum PV power has been installed. Cable cross section can
be reduced in case of smaller solar arrays.
The best efficiency is reached at a PV input voltage that is twice the battery voltage.
DC circuit breakers or fuses must be installed in the positive and negative PV cables, to
enable isolation of the charger during installation or maintenance.
The table below gives some examples of cable cross sections calculated with formula
(5).
(in this case I and V are the output current and output voltage of the solar array)
12V system (solar array up to 1000W)
Solar array
MPP-voltage
[V]
Solar array
MPP-current
[A]
Power loss
in PV cables
α(%)
Length 2x5 meter Length 2x10 meter
Length 2x20
meter
mm
2
AWG mm
2
AWG mm
2
AWG
18 Max 50A Not recommended Not recommended Not
recommended
36 27 1 16 5 35 2 Not
recommended
54 18 1 10 7 16 5 25 3
72 13 0,75 6 10 10 7 25 3
90 11 0,5 6 10 10 7 16 5
108 9 0,5 4 11 6 10 16 5
24V system (solar array up to 2000W)
Solar array
MPP-voltage
[V]
Solar array
MPP-current
[A]
Power loss
in PV cables
α(%)
Length 2x5 meter Length 2x10 meter
Length 2x20
meter
mm
2
AWG mm
2
AWG mm
2
AWG
36 Max 50A 1 35 2 Not recommended Not
recommended
54 37 1 16 5 25 3 Not
recommended
72 28 0,75 10 7 25 3 35 2
90 22 0,5 10 7 25 3 35 2
108 19 0,5 6 10 16 5 25 3
The voltage on the PV input should never exceed 150V under any condition.
The charger will be permanently damaged if the input voltage is too high.

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48V system (solar array up to 4000W)
Solar array
MPP-voltage
[V]
Solar array
MPP-current
[A]
Power loss
in PV cables
α(%)
Length 2x5 meter Length 2x10 meter
Length 2x20
meter
mm
2
AWG mm
2
AWG mm
2
AWG
72 Max 50A 1 16 5 35 2 Not
recommended
90 44 1 10 7 25 3 35 2
108 37 0,75 10 7 16 5 35 2
Table 2: PV cable cross section and power loss

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EN NL FR DE ES SE Appendix
3.4 Optional connections
3.4.1 Voltage Sense
For compensating possible cable losses during charging, two sense wires can be
connected to measure voltage directly on the battery. Use wire with a cross-section of
0,75mm² and insert a 0,1 Amp fuse close to the battery.
During battery charging, the charger will compensate the voltage drop over the DC
cables up to a maximum of 1 Volt (i.e. 1V over the positive connection and 1V over the
negative connection). If the voltage drop threatens to become larger than 1V, the
charging current is limited in such a way that the voltage drop remains limited to 1V.
The warning triangle on the LCD will blink if the voltage drop reaches 1 Volt
3.4.2 Temperature Sensor (see figure 1)
The temperature sensor supplied with the product may be used for temperature-
compensated charging. The sensor is isolated and must be mounted on the battery
minus pole.
3.4.3 CAN bus interface
The charger is equipped with two CAN bus RJ45 sockets.
The CAN bus interface will be referenced to ground if the minus pole of the battery is
grounded.
In case of a positive grounded system, a CAN isolation module will be needed to
reference the CAN bus interface to ground.
To prevent ground-loops, the charge controller has an internal 33 Ohm resistor between
CAN-GND and the battery minus output of the charge controller.
3.4.4 Programmable relay
The charge controller is equipped with a potential-free Single Pole Double Throw relay that
by default is programmed according to option 3 below.
The relay can be programmed to energize on one of the following events:
option 1: when the maximum voltage on the PV input is exceeded
option 2: when the temperature protection becomes active
option 3: when the battery voltage becomes too low (adjustable low voltage limit)
option 4: when the charger is in equalisation mode
option 5: when the charger is in error mode
option 6: when the charger temperature drops below -20°C (-40°F)
option 7: when the battery voltage becomes too high (adjustable high voltage limit)
3.4.5 Parallel charging
Several charge controllers can be connected to the same battery.
The PV inputs should not be connected in parallel. Each charge controller
should be connected to its own PV array.
The CAN bus on this charger is not galvanically isolated. The CAN bus is
referenced to the minus battery connection.

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4. POWERING UP
4.1 Connecting the battery
Close the connection to the battery, but DO NOT connect the solar array.
All the icons of the display will now light up:
This is followed by the software version:
In this case the Software-version is 1.1.6
After the software-version has been displayed, the
charger will start the system voltage recognition
phase.
The LCD-screen displays two values:
Left: system (= nominal battery) voltage (12/24/36 or
48V), blinking during the battery recognition phase.
Right: actual measured battery voltage.
In some instances the charge controller might not reflect the correct system voltage (e. g. if
the battery is deeply discharged and the actual battery voltage is far below the nominal
voltage). In that case the system voltage can be adjusted manually, see section 4.2.
If the nominal battery voltage shown is correct, press the SETUP button to accept.
Alternatively, the battery voltage shown becomes final automatically after connecting the PV
array, when PV current starts flowing.
4.2 Adjusting system voltage (adjust only if the system voltage as displayed is
wrong)
a. Press SETUP during 3 seconds: the “Menu” icon will light up.
b. Press the "-" or "+" button several times until
the screen shows “AUto”, or a system voltage.
c. Press SELECT: “AUto” or the system voltage will blink.
d. Use the "-" or "+" button to decrease or increase
system voltage.
e. Press SETUP to confirm the change, the value will stop
blinking, and the change is made final.
f. Press SETUP during 3 seconds: the display is back in normal. mode and the “Menu” icon
will disappear.
Note: a 36V system will not be detected automatically and must be set with help of the
above mentioned procedure.
Blinking:
Nominal battery voltage
(12/24/36 or 48V)
Actual battery voltage