Victron energy BlueSolar MPPT 150/70 User manual

Manual
EN
Appendix
BlueSolar charge controller MPPT 150/70

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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.
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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
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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

1
EN 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 P array.
The controller will automatically adjust to a 12, 24, or 48 nominal battery voltage.
Ultra fast Maximum Power Point racking (MPP )
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.
P short circuit and P reverse polarity protection.
Reverse current protection.
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.
Danger of explosion from sparking
Danger of electric shock

2
●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
3. INSTALLATION
This product may only be installed by a qualified electrical engineer.
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 R c (mΩ@47°C) of a cable with length L (m) and cross section A (mm²): R c = 20*L/A (1)
Or, with R c in Ω(Ohm): R c =0,02*L/A (2)
Power loss P c (W) in a cable carrying current I (A): P c = I²*R c = 0,02*l²*L/A (3)
Power loss P c relative to solar array output P v in %: α= (P c /P v )*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*P v /(α*V²) (6)

3
EN Appendix
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 cables
α (%)
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
36V system (solar array up to 3
000W)
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
48V system (solar array up to 4
000W)
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
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 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.
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)

4
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
36V system
(solar array
up to
3000W)
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
54 Max 50A 1 25 3 35 2 Not recommended
72 42 0,75 16 5 25 3 Not recommended
90 33 0,5 16 5 25 3 35 2
108 28 0,5 10 7 25 3 35 2
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
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.

5
EN Appendix
The CAN bus on this charger is not galvanically isolated. The CAN bus is referenced to the
minus battery connection.
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 charger is in over-voltage mode (adjustable over 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.

6
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