Victron energy VBC-HV User manual

Manual
EN
VE.Net Battery Controller (70-385V model)
VBC-HV

Copyrights 2010 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 EXPESSED 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.
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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.

1
1 INTRODUCTION
Victron Energy has established an international reputation as a leading
designer and manufacturer of energy systems. Our R&D department is
the driving force behind this reputation. It is continually seeking new ways
of incorporating the latest technology in our products. Each step forward
results in value-added technical and economical features.
1.1 The VE.Net Battery Controller (VBC-HV)
The VBC-HV is a device that monitors your battery status. It constantly
measures the battery voltage, battery temperature, and battery current,
and uses this information to calculate the actual state of charge of your
battery.
1.2 Introduction to VE.Net
VE.Net stands for Victron Energy Network. It allows all VE.Net
compatible devices to communicate with each other. This means that the
charger for example can get information from the battery monitor to
optimize the charge current. It is possible to control and monitor all your
VE.Net devices from a single VE.Net compatible control panel. This
saves space and allows you to control all your devices from one place. It
is however, not necessary to be limited to a single panel. Multiple panels
can be used on the network, allowing full control and monitoring
capabilities of all devices in multiple locations.
1.3 Why should you monitor your batteries?
The lifetime of your batteries depends on many factors. If the batteries
and the load process are monitored you can prevent your batteries from
being under- or over charged, or from being discharged too deeply. A
battery controller warns you if there is something wrong with the charge
current or with the general condition of the batteries.

2
1.4 How does the VE.Net Battery Controller work?
The capacity of a battery is rated in Amp hours (Ah). For example, a
battery that can deliver a current of 5 Amps for a period of 20 hours is
rated at 100 Ah (5 * 20 = 100). The VBC-HV continuously measures the
net current flow into or out of the battery. This way it can calculate the
amount of energy removed from or added to the battery. But since battery
age, discharge current and temperature all influence the battery‟s
capacity; you cannot rely simply on an Amp hours reading. When the
same 100 Ah battery is discharged completely in two hours, it may only
give you 56 Ah (because of the higher rate of discharge).
As you can see the battery‟s capacity is almost halved. This phenomenon
is called Peukert efficiency (see chapter 4.1.2). Also, when the
temperature of the battery is low, its capacity is decreased even more.
This is why simple Amp hour counters or Voltmeters give you far from an
accurate state-of-charge indication.
The VBC-HV can display both the Amp hours removed (not
compensated) and the actual state of charge (compensated by Peukert
efficiency and charge efficiency). Reading the state-of-charge is the best
way to read your battery. This parameter is shown as a percentage,
where 100% represents a fully charged battery and 0% represents a
completely flat battery. You can compare this with a fuel-gauge in a car.
The VBC-HV also makes an estimation of how long the battery can
support the present load (time to go readout). This is actually the time left
until the battery needs to be charged again. If the battery load is
fluctuating heavily it is best not to rely on this reading too much since it is
a momentary readout and must be used as a guideline only. We always
encourage the use of the state-of-charge readout for accurate battery
monitoring.

3
2 INSTALLATION OF YOUR BATTERY MONITOR
2.1 Safety Precautions!
1. Working in vicinity of a lead acid battery is dangerous. Batteries can
generate explosive gases during operation. Never smoke or allow a spark
or flame in the vicinity of a battery. Provide sufficient ventilation around
the battery.
2. Wear eye and clothing protection. Avoid touching eyes while working
near batteries. Wash your hands when done.
3. If battery acid contacts skin or clothing, wash immediately with soap
and water. If acid enters eye, immediately flood eye with running cold
water for at least 15 minutes and get medical attention immediately.
4. Be careful when using metal tools in vicinity of batteries. Dropping a
metal tool onto a battery might cause a short-circuit and, possibly an
explosion.
5. Remove personal metal items such as rings, bracelets, necklaces, and
watches when working with a battery. A battery can produce a short-
circuit current high enough to melt such items, leading to severe burns.
6. The VBC-HV contains no user serviceable parts, and operates at
dangerously high voltages. Never remove the housing, as this causes a
risk of electric shock.
To install your battery controller you will need:
1. Wired VBC-HV and shunt in housing. The standard supplied shunt is
500A / 50mV, but any shunt with a current indication up to 100mV
can be used.
2. Standard supplied VE.Net power cable.
RJ45 Cat5 cable to two wire insulated flexible connection cable
AWG21/0.4 mm² with inline fuse holder and 1 Amp slow blow fuse.
3. Standard supplied temperature sensor.
4. Cat5 cable with two RJ45 connectors (to connect a VE.Net Panel or
other VE.Net device) available in 5, 10, 15, 20, 25 and 30 meters.

4
2.2 Mounting
The VBC-HV box can be mounted using the 4 mounting holes. To ensure
the best read out we recommend that you use the standard supplied
cables and place the controller as close as possible to the batteries.
During prolonged periods of high current, the shunt will become hot. It is
therefore recommended that the box is mounted so that the blades of the
shunt are oriented vertically to allow optimal air-flow.
2.3 Wiring
Turn off the power from the batteries and remove the fuse before you
start installation. Connect the wiring as shown in figure 1. The thick lines
represent the main current path cables; these should be of a heavy duty
type. Most of the connections are already made to the VBC-HV. You will
only need to connect the battery minus and system ground wires to the
shunt and the Battery+ wire to the battery. Optionally you can connect the
wires coming from the alarm relay.
Connect the Battery Controller to a VE.Net Panel or other VE.Net device
using a standard straight Cat5 cable. The total length of Cat5 cables used
in a VE.Net network should not exceed 100m.
After installation, and checking all the connections place the fuse to
power the battery controller.
Note: The VBC-HV cannot provide power to other VE.Net devices. In
order to power other VE.Net devices (such as the VPN), use either the
VE.Net power cable or connect another device to the network that is
capable of supplying power. Such devices include the VE.Net Battery
Controller 12/24/48V (VBC000300000), the VE.Net to VE Bus Converter
(VVC000200000), the VE.Net Tank Monitor, current model
(VCS000100000) and the VE.Net Tank Monitor, voltage model
(VVC000100000).
Note: The shunt and temperature sensor should be the only wires
connected to the negative terminal of the battery. The negative
connections of all other devices (including chargers) must be made to the
load side of the shunt (system ground). If devices are connected directly
to the negative terminal of the battery the VBC-HV will be unable to
measure their current consumption, and will give incorrect readings.

5
Note: Do not connect any other wires to the shunt measurement output,
as this will affect the accuracy of the readings.
V+
I -
VE.Net
I +
T-
T+
GND
VBC
Battery system
+ -
Relay connection
Fuse 100mAT
Temperature sensor
Battery Vin
max 385V
VE.Net Vin max 70V
Figure 1
Battery negative
(System ground)
Battery positive
(Load)
Read the Safety precautions
in chapter 2.1 before
installing your VBC-HV.
Make sure that you first
connect the system before
placing the fuse.

6
Battery Monitor
157V -0.5A 99%
3 USING YOUR BATTERY MONITOR
All control of the VBC-HV is provided through the VPN. To switch on the
VPN, hold down one of the buttons until the VPN beeps. When the VPN
has finished starting up, the device list will be displayed. If there are other
VE.Net devices connected, it may be necessary to press “▼” until the
Battery Controller is displayed. For more information on using the VPN,
refer to the VPN manual.
3.1 Quick status line
In the root menu of the VPN you will see this screen, which consists of
the name of the battery controller and the “quick status” line.
Notes:
1. You can always return to this position by pressing “Cancel”
repeatedly.
2. The state of charge is only displayed when the Battery Controller is
synchronised (see chapter 4.1.3 for more information).
3.2 Main menu
To view more detailed information, press the “Enter” button to enter the
Battery Controller menu.
Name
Description
Units
Battery voltage
Displays the voltage of the battery.
Volts.
Battery current
Displays the DC current that flows into or out of the battery.
Amps.
Consumed Ah
Displays the energy consumed since the battery was last fully
charged.
Amp hours.
State of charge
The state of charge indicates the percentage of the battery capacity
that is still available for consumption. A full battery will show 100%,
and an empty battery will show 0%. This is the best way to see
when the batteries need to be recharged.
Percent.
Time to go
Displays the estimated time, based on the current load, before the
batteries need to be recharged.
Hours and
minutes.
Bat. temperature
Displays the battery temperature.
Degrees
Celsius.
Software version
The software version of this device.
Battery voltage
State of charge
Battery current

7
3.3 Historic data
The VBC-HV will keep track of historical data to enable you to get more
information about the state and the past use of the batteries.
3.3.1 Where to find the “Historical data” menu
Step 1) Press “Enter” to enter the VBC-HV
menu.
Step 2) Press “▼” to scroll through the
menu until you see „Historic data”.
Step 3) Press “Enter” to enter the “Historic
data” menu
3.3.2 Historical data explained
Historic data
Name
Description
Unit
Deepest
discharge
The deepest discharge in Ah.
Amp hours.
Depth last disch.
The depth of the last discharge in Ah. This value will be reset to 0
when the State of Charge reaches 100% again.
Amp hours.
Average
discharge
The average discharge over all the cycles counted
Amp hours.
Number of cycles
Every time the battery is discharged below 65% of its rated
capacity and charged back to at least 90%, one cycle is counted.
Full discharges
The number of times the battery has been discharged to a 0%
state of charge.
Cumulative Ah
Records the total energy consumed over all charge cycles.
Amp hours.
Last full charge
The time that has elapsed since the battery was last fully charged.
Days.
Maximum voltage
Maximum measured voltage. Can be used to check for faulty
chargers and alternators.
Volts.
Minimum voltage
Lowest measured voltage. Can be used to check if the batteries
have been excessively discharged.
Volts.
Battery Monitor
157V-0.5A 99%
Battery voltage
157.40V
Historic data
[Press enter]

8
4 SETUP
4.1 Background information
4.1.1 Charge Efficiency Factor (CEF)
During battery charging, not all of the energy transferred into the battery
is available when the battery is being discharged. The charge efficiency
factor (CEF) of a brand new battery is approximately 90 %. This means
that 10 Ah must be transferred to the battery to get 9 Ah actually stored in
the battery. The CEF of a battery will decrease as the battery ages.
4.1.2 Peukert’s exponent
As mentioned in chapter 1.4, the Peukert efficiency describes how, when
you discharge a battery faster than the 20 h rating, its Ah capacity
decreases. The amount of battery capacity reduction is called the
„Peukert exponent‟ and can be adjusted from 1.00 to 1.50. The higher the
Peukert exponent the faster the battery size shrinks with increasing
discharge rate. An ideal (theoretical) battery has a Peukert exponent of
1.00 and has a fixed capacity; regardless of the size of the discharge
current. Of course such batteries do not exist, and a setting of 1.00 in the
VBC-HV is only implemented to bypass Peukert compensation. The
default setting for the Peukert exponent is 1.25, and is an acceptable
average value for most types of lead acid battery. However for precise
battery monitoring, entering the right Peukert exponent is essential. If the
Peukert exponent is not provided with your battery, you can calculate it
by using other specifications which should be provided with your battery.
The Peukert equation is stated below:
t
n
ICp
where the Peukert exponent, n =
21
12
loglog
loglog
II
tt
The battery specifications needed for calculation of the Peukert exponent,
are the rated battery capacity (usually the 20 h discharge rate1) and for
example a 5 h discharge rate2. See below for an example of how to
define the Peukert exponent using these two specifications.
1Please note that the rated battery capacity can also be defined as the 10 h or even 5 h discharge rate.
2The 5 h discharge rate in this example is just arbitrary. Make sure that besides the C20 rating (low discharge current) you
choose a second rating with a substantially higher discharge current.

9
5 h rating
20 h rating,
1.26
5log15log
5log20log
exponent,Peukert n
When no ratings are given at all, you can measure your battery using a
„constant load bank‟. In this way a second rating can be obtained,
together with the 20 h rating which represents the rated battery capacity
in most cases. This second rating can be determined by discharging a
fully charged battery with a constant current; until the battery reaches
1.75 V per cell (which is 10.5 V for a 12 V battery or 21 V for a 24 V
battery). A calculation example is shown below:
A 200 Ah battery is discharged with a constant current of 20 A and after
8.5 hours 1.75 V/cell is reached.
So,
20 h rating,
1.23
10log20log
5.8log20log
exponent,Peukert n
A Peukert calculator is available at www.victronenergy.com.
4.1.3 Synchronising the VBC-HV
For a reliable readout of the state of charge of your battery, the battery
monitor has to be synchronised regularly with the battery and charger.
A
h
Ah
I
ht
AhChr
15
5
75
5
75
1
1
5
A
h
Ah
I
h
AhChr
5
20
100
20t
capacity)(rated100
2
2
20
AI
ht
20
5.8
1
1
A
h
Ah
I
ht
AhCh
10
20
200
20
200
2
2
20

10
This is accomplished by fully charging the battery. When the charger is
operating in the „float‟ stage, the charger considers the battery full. At this
moment the VBC-HV must also determine that the battery is full. Now the
Amp hour count can be reset to zero and the state-of-charge reading can
be set to 100.0 %. By precisely adjusting the charged-parameters in the
VBC-HV, the battery monitor can automatically synchronise with the
charger when the „float‟ stage is reached. The range of the charged
parameters is wide enough to adjust the VBC-HV to most battery
charging methods.
When the voltage supply to the VBC-HV has been interrupted, the
battery monitor must be resynchronised before it can operate
correctly.
Please note that regularly (at least once per month) fully charging your
battery not only keeps it in sync with the VBC-HV, but also prevents
substantial capacity loss of your battery which limits its lifetime.
4.1.4 Synchronisation parameters
Based on increasing charge voltage and decreasing charge current, a
decision can be made whether the battery is fully charged or not. When
the battery voltage is above a certain level during a predefined period
while the charge current is below a certain level for the same period, the
battery can be considered fully charged. These values are called
synchronisation parameters. In general for a 144 V lead acid battery, the
synchronisation voltage is 158.4 V and the synchronisation current is
4.0 % of the total battery capacity (e.g. 8 A with a 200 Ah battery). A
synchronisation time of 4 minutes is sufficient for most battery systems.
Please note that these parameters are very important for correct
operation of your VBC-HV, and must be set appropriately in the
corresponding menu items.

11
4.2 General settings
4.2.1 Where to find the “Setup monitor” menu
Step1) Press “Enter” to enter the VBC-HV
menu.
Step 2) Press “▼” to scroll through the
menu until you see “Setup
controller”.
Step 3) Press “Enter” to enter the “Setup
monitor “menu.
Note: If you can‟t find the “Setup monitor” menu, make sure that your
VE.Net Panel is in “user and install”mode.
4.2.2 Setup parameters explained:
Setup monitor
Name
Description
Default
Value
Range
Step
size
Battery capacity
The battery capacity in amp hours (Ah) at a 20h
discharge rate.
200 Ah
20-
65535
5
Sync. voltage
The battery controller considers the battery as
fully charged if the voltage is above this level.
158.4 V
96-384
0.1
Sync. current
If the charge current is below this percentage of
the battery capacity, the battery can be
considered as fully charged.
4 %
1-10
1
Sync. time
The minimum time that the above two
parameters must be met to consider the battery
as fully charged.
4 min
1-4
1
Bat. temperature
If the connection to the temperature sensor is
lost, this value is used in the calculations.
20 °C
0-50
1
Resync. to 100%?
Resets the state of charge manually to 100%.
Device name
The name of the battery controller that is used
in the VE.Net Panel.
Battery
Monitor
The settings on the advanced menu allow fine control of the battery
monitoring calculations performed by the VBC-HV. The default values
are suitable for most battery systems, so do not adjust these settings
without fully understanding the consequences.
Setup controller
[Press enter]
Battery voltage
157.40V
Battery Monitor
157V0.0A 100%

12
Advanced
Name
Description
Default
Value
Range
Step
size
Charge eff. fact
When a battery is charged, energy is lost. The
charge efficiency factor compensates for the lost
energy, where 1 is no loss of energy and 0.5 is a
50 % loss of energy.
0.9
0.5-1
0.05
Peukert exponent
The Peukert exponent for your battery (refer to
chapter 4.1.2 for more information). Set to 1.00
to disable the Peukert compensation. Contact
your battery manufacturer for the Peukert
exponent.
1.25
1-1.5
0.01
Temperature coef
This is the percentage the battery capacity
changes with temperature.
0.5
0.5-0.95
0.05
Current threshol
This value will be considered as zero amps, to
ensure that errors are eliminated.
0.1 A
0-5
0.1
Shunt current
The maximum current rating of the shunt.
500 A
5-50000
5
Shunt voltage
The output voltage of the shunt at the maximum
rated current.
50 mV
1-100
1
Current offset
Used to compensate for small errors in current
measurement caused by unwanted offsets
picked up by the measurement cables.
0 A
-60000 -
60000
0.01
Battery current
Duplicates the current reading from the top level
menu. This allows the effects of changes to the
current offset to be observed without having to
navigate the menu hierarchy.
4.3 Alarms
The VBC-HV is equipped with a relay that can be programmed to signal
alarms; or when connected to a generator, to automatically start and stop
a generator. Alarms can also be sent to the VPN, which can be
configured to sound an alarm, or control another relay. Each alarm type
can be configured to activate the relay, send a panel alarm, or both. They
can also be completely disabled.
4.3.1 Where to find the “Setup alarms” menu
Step 1.) Press “Enter” to enter the VBC-HV
menu.
Step 2.) Press “▼” to scroll through the
menu until you see “Setup
Alarms”.
Battery voltage
157.40V
Battery Monitor
157V 0.0A 100%

13
Step 3.) Press “Enter” to enter the “Setup
alarms” menu.
Note: If you can not find the “Setup alarms” menu, make sure that your
VPN is in “user and install”mode.
4.3.2 Alarm options explained
Setup alarms
Name
Description
Default
Value
Rang
e
Step
size
Low
voltage
The battery voltage has to be below this threshold to
trigger the low voltage alarm.
126 V
96-384
0.1
Low
voltage clr
The threshold that has to be reached again to cancel
an active low voltage alarm.
126 V
96-384
0.1
Low volt.
action
The type of action to take when the alarm condition is
met.
None
None,
Relay,
Panel,
Both
High
voltage
The battery voltage has to be above this threshold to
trigger the high voltage alarm.
192 V
96-384
0.1
High
voltage clr
The threshold that has to be reached again to cancel
an active high voltage alarm.
192 V
96-384
0.1
High volt.
action
The type of action to take when the alarm condition is
met.
None
None,
Relay,
Panel,
Both
Low SOC
The low state of charge threshold that will activate the
alarm.
50 %
0-100
1
Low SOC
clr
The state of charge threshold that has to be reached to
cancel an active state of charge alarm.
80 %
0-100
1
Low SOC
action
The type of action to take when the alarm condition is
met.
None
None,
Relay,
Panel,
Both
Low current
The level below which a low current alarm will be
triggered.
-100 A
-30000
–0
5
Low current
clr.
The level above which a low current alarm will be
cleared.
-90 A
-30000
–0
5
Low current
action
The type of action to take when a low current alarm is
active.
None
None,
Relay,
Panel,
Both
High
current
The level above which a high current alarm will be
triggered.
100
0 –
30000
5
High
current clr
The level below which a high current alarm will be
cleared.
90
0 –
30000
5
High cur.
action
The type of action to take when a high current alarm is
active.
None
None,
Relay,
Panel,
Both
Enable
delay
The amount of time an alarm condition must be present
in order to trigger the alarm.
0 s
0 –255
1
Disable
delay
The amount of time an alarm clear condition must be
present in order to disable the alarm.
0 s
0 –255
1
Min. enable
time
The minimum amount of time the relay may remain
closed once an alarm condition has occurred.
0 min
0 –255
1
Setup alarms
[Press Enter]

14
4.4 Menu structure
Root menu
Historic data
Setup alarms
Setup controller
Advanced
5 TECHNICAL DATA
Supply voltage range
70 ... 385VDC
Supply current (relay inactive):
@144V
<5mA
@288V
<5mA
Operating temperature range
0 ... 50 C
Potential free alarm contact:
Mode
Normally open
Rating
30V/3A max.
Dimensions:
VBC-HV
Housing
75 x 110 x 23mm
230x140x110mm
Net weight:
VBC-HV
Housing (total)
95 gram
1350 gram
Material:
VBC-HV body
Housing
Cover
Cover screws
ABS
PC (10% glass fibre)
PC
PA

Victron Energy Blue Power
Distributor:
Serial number:
Version : 06
Date : 5 March 2010
Victron Energy B.V.
De Paal 35 | 1351 JG Almere
PO Box 50016 | 1305 AA Almere | The Netherlands
General phone : [phone]
Customer support desk : [phone]
Fax : [phone]
E-mail : [email protected]
www.victronenergy.com