Victron energy BlueSolar MPPT 75/10 User manual

Manual
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Manuel
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Manual
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Appendix
BlueSolar charge controllers
MPPT 75/10
MPPT 75/15
MPPT 100/15
MPPT 100/20
MPPT 100/20-48V

1 General Description
1.1 Ultra fast MPPT tracking
Especially in case of a clouded sky, when light intensity is changing continuously, a fast
MPPT algorithm will improve energy harvest by up to 30% compared to PWM charge
controllers and by up to 10% compared to slower MPPT controllers.
1.2 VE.Direct
For a wired data connection to a Color Control panel, PC or other devices
1.3 Load output
Deep discharge of the battery can be prevented by connecting all loads to the load output.
The load output will disconnect the load when the battery has been discharged to a pre-set
voltage.
Alternatively, an intelligent battery management algorithm can be chosen: see Battery Life.
The load output is short circuit proof.
Some loads (especially inverters) can best be connected directly to the battery, and the
inverter remote control connected to the load output. A special interface cable may be
needed, please see section 3.6.
1.4 Battery Life: intelligent battery management
When a solar charge controller is not able to recharge the battery to its full capacity within
one day, the result is often that the battery will continually be cycled between a ‘partially
charged’ state and the ‘end of discharge’ state. This mode of operation (no regular full
recharge) will destroy a lead-acid battery within weeks or months.
The Battery Life algorithm will monitor the state of charge of the battery and, if needed, day
by day slightly increase the load disconnect level (i.e. disconnect the load earlier) until the
harvested solar energy is sufficient to recharge the battery to nearly the full 100%. From that
point onwards the load disconnect level will be modulated so that a nearly 100% recharge is
achieved about once every week.
1.5 Three step charging
The controller is configured for a three step charging process: Bulk – Absorption - Float.
See section 3.8 and section 5 for default settings.
See section 1.8 for user defined settings
1.5.1. Bulk
During this stage the controller delivers as much charge current as possible to rapidly
recharge the batteries.
1.5.2. 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 1A.
1.5.3. Float
During this stage, float voltage is applied to the battery to maintain a fully charged state.

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1.5.4. Equalization
See section 3.9
1.6 Internal temperature sensor
Compensates absorption and float charge voltages for temperature (range 6°C to 40°C)
1.7 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 (VE.Direct Bluetooth Smart dongle needed).
Alternatively, Bluetooth communication can be set up between a BMV-712 battery
monitor with battery temperature sensor and the solar charge controller
(VE.Direct Bluetooth Smart dongle needed). For more detail please enter smart
networking in the search box on our website.
1.8 Automatic battery voltage recognition
The controller will automatically adjust itself to a 12V or a 24V 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, see section 3.8.
1.9 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 GX
Venus GX

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2. IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS - This manual contains important instructions that
shall be followed during installation and maintenance.
● 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.
● 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
maintance manual applicable to the type of batteries used.
Danger of explosion from sparking
Danger of electric shock

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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 substrate, 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 and PV connections must guarded against inadvertent contact (e.g. install
in an enclosure or install the optional WireBox S).
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 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)
● Provide means to disconnect all current-carrying conductors of a photovoltaic power
source from all other conductors in a building or other structure.
● A switch, circuit breaker, or other device, either ac or dc, shall not be installed in a
grounded conductor if operation of that switch, circuit breaker, or other device leaves the
grounded conductor in an ungrounded state while the system remains energized.

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● The controller 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: 75V respectively 100V
For example:
12V battery and mono- or polycristalline panels connected to a 75V controller
● Minimum number of cells in series: 36 (12V panel).
● Recommended number of cells for highest controller efficiency: 72
(2x 12V panel in series or 1x 24V panel).
● Maximum: 108 cells (3x 12V panel in series).
24V battery and mono- or polycristalline panels connected to a 100V controller
● Minimum number of cells in series: 72
(2x 12V panel in series or 1x 24V panel).
● Maximum: 144 cells (4x 12V panel in series).
Remark: at low temperature the open circuit voltage of a 108 cell array may exceed 75V
and and the open circuit voltage of a 144 cell solar array may exceed 100V, 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 3)
First: connect the cables to the load, but ensure that all loads are switched off.
Second: connect the battery (this will allow the controller to recognize system voltage).
Third: connect the solar array (when connected with reverse polarity, the controller will
heat up but will not charge the the battery).
Torque: 0,75 Nm
The system is now ready for use.
3.5 Configuration of the controller
The VE.Direct communication port (see sect. 1.9) can be used to configure the controller.
(dongle needed when using the Bluetooth app)
3.6 The load output (see figure 1 and 2 at the end of the manual)
The VE.Direct communication port (see sect. 1.8) can be used to configure the load output.
(dongle needed when using the Bluetooth app)
Alternatively, a jumper can be used to to configure the load output as follows:
● No jumper: BatteryLife algorithm (see 1.4)
● Jumper between pin 1 and pin 2: conventional
Low voltage load disconnect: 11,1V or 22,2V
Automatic load reconnect: 13,1V or 26,2V
● Jumper between pin 2 and pin 3: conventional
Low voltage load disconnect: 11,8V or 23,6V
Automatic load reconnect: 14V or 28V

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Some loads with high inrush current can best be connected directly to the battery. If
equipped with a remote on-off input, these loads can be controlled by connecting the load
output of the controller to this remote on-off input. A special interface cable may be
needed.
Alternatively, a BatteryProtect may be used to control the load. Please see our website
for specifications.
Low power inverters, such as the Phoenix VE.Direct inverters up to 375VA, can be
powered directly by the load output, but the maximum output power will be limited by the
current limit of the load output.
Phoenix VE.Direct inverters can also be controlled by connecting the left side
connection of the remote control to the load output.
The bridge on the remote control between left and right must be removed.
The Victron inverters model Phoenix 12/800, 24/800, 12/1200 and 24/1200 can be
controlled by connecting the right side connection of the inverter remote control directly to
the load output (see figure 4 at the end of this manual).
For the Victron inverters model Phoenix 12/180, 24/180, 12/350, 24/350, the Phoenix
Inverter Compact models and the MultiPlus Compact models an interface cable is
needed: the Inverting remote on-off cable, article number ASS030550100, see figure 5 at
the end of this manual.
3.7 LEDs
Green LED: indicates which load output control algorithm has been chosen.
On: one of the two conventional load output control algorithms (see Fig 2)
Blinking: BatteryLife load output control algorithm (see Fig 2)
Yellow LED: signals charge sequence
Off: no power from PV array (or PV array connected with reverse polarity)
Blinking fast: bulk charge (battery in partially charged state)
Blinking slow: absorption charge (battery charged to 80% or more)
On: float charge (battery fully charged)
3.8 Battery charging information
The charge controller starts a new charge cycle every morning, when the sun starts shining.
Lead-acid batteries: default method to determine length and end of absorption
The charging algorithm behavior of MPPTs differs from AC connected battery chargers.
Please read this section of the manual carefully to understand MPPT behavior, and always
follow the recommendations of your battery manufacturer.
By default, the absorption time is determined on idle battery voltage at the start of each day
based on the following table:

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Battery voltage Vb (@start-up) Multiplier Maximum absorption time
Vb < 11,9V x 1 6h
11,9V < Vb < 12,2V x 2/3 4h
12,2V < Vb < 12,6V x 1/3 2h
Vb > 12,6V x 1/6 1h
(12V values, adjust for 24V))
Default absorption voltage: 14,4V
Default float voltage: 13,8V
The absorption time counter starts once switched from bulk to absorption.
The MPPT Solar Chargers will also end absorption and switch to float when the battery
current drops below a low current threshold limit, the ‘tail current’.
The default tail current value is 1A.
For models with a load output the current on the battery terminals is used; and for the
larger models; the current on the output terminals is used.
The default settings (voltages, absorption time multiplier and tail current) can be modified
with the Victronconnect app via Bluetooth (VE.Direct Bluetooth Smart dongle needed) or
via VE.Direct.
There are two exceptions to normal operation:
1. When used in an ESS system; the solar charger algorithm is disabled; and instead it
follows the curve as mandated by the inverter/charger.
2. For CAN-bus Lithium batteries, like BYD, the battery tells the system, including the
solar charger, what charge voltage to use. This Charge Voltage Limit (CVL) is for some
batteries even dynamic; changes over time; based on for example maximum cell
voltage in the pack and other parameters.
Variations to expected behaviour
1. Pausing of the absorption time counter
The absorption time counter starts when the configured absorption voltage is reached
and pauses when the output voltage is below the configured absorption voltage.
An example of when this voltage drop could occur is when PV power (due to clouds,
trees, bridges) is insufficient to charge the battery and to power the loads.
When the absorption timer is paused, the absorption LED will flash very slowly.
2. Restarting the charge process
The charging algorithm will reset if charging has stopped for an hour. This may occur
when the PV voltage drops below the battery voltage due to bad weather, shade or
similar.
3. Battery being charged or discharged before solar charging begins
The automatic absorption time is based on the start-up battery voltage (see table). This
absorption time estimation can be incorrect if there is an additional charge source (eg
alternator) or load on the batteries.
This is an inherent issue in the default algorithm. However, in most cases it is still better
than a fixed absorption time regardless of other charge sources or battery state.
It is possible to override the default absorption time algorithm by setting a fixed

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absorption time when programming the solar charge controller. Be aware this can
result in overcharging your batteries. Please see your battery manufacturer for
recommended settings.
4. Absorption time determined by tail current
In some applications it may be preferable to terminate absorption time based on tail
current only. This can be achieved by increasing the default absorption time
multiplier.
(warning: the tail current of lead-acid batteries does not decrease to zero when the
batteries are fully charged, and this “remaining” tail current can increase substantially
when the batteries age)
Default setting, LiFePO4 batteries
LiFePO4 batteries do not need to be fully charged to prevent premature failure.
The default absorption voltage setting is 14,2V (28,4V).
And the default absorption time setting is 2 hours.
Default float setting: 13,2V (26,4V).
These settings are adjustable.
Reset of the charge algorithm:
The default setting for restarting the charge cycle is Vbatt < (Vfloat – 0,4V) for lead-acid,
and Vbatt < (Vfloat – 0,1V) for LiFePO4 batteries, during 1 minute.
(values for 12V batteries, multiply by two for 24V)
3.9 Automatic equalization
Automatic equalization is default set to ‘OFF’. With the Victron Connect app (see sect 1.9)
this setting can be configured with a number between 1 (every day) and 250 (once every
250 days).
When automatic equalization is active, the absorption charge will be followed by a voltage
limited constant current period. The current is limited to 8% or 25% of the bulk current. The
bulk current is the rated charger current unless a lower maximum current setting has been
chosen.
When using a setting with 8% current limit, automatic equalization ends when the voltage
limit has been reached, or after 1 hour, whichever comes first.
Other settings: automatic equalization ends after 4 hours.
When automatic equalization is not completely finished within one day, it will not resume the
next day, the next equalization session will take place as determined by the day interval.
3.10 VE.Direct communication port
See section 1.9 and 3.5.