Victron energy BlueSolar MPPT 150/45-Tr User manual

Manual
EN
Handleiding
NL
Manuel
FR
Anleitung
DE
Manual
ES
Användarhandbok
SE
Appendix
BlueSolar 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

1
EN NL FR DE ES SE Appendix
1. General Description
1.1 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.
1.2 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 BlueSolar algorithm will always maximize energy
harvest by locking to the optimum MPP.
1.3 Outstanding conversion efficiency
No cooling fan. Maximum efficiency exceeds 98%. Full output
current up to 40°C (104°F).
1.4 Extensive electronic protection
Over-temperature protection and power derating when
temperature is high.
PV short circuit and PV reverse polarity protection.
PV reverse current protection.
1.5 Internal temperature sensor
Compensates absorption and float charge voltages for
temperature.
1.6 Automatic battery voltage recognition
The controllers will automatically adjust to a 12V, 24V or a 48V
system. A computer or a Color Control panel is required to set the
controller to 36V.
1.7 Flexible charge algorithm
Eight preprogrammed algorithms, selectable with a rotary switch.

2
1.8 Adaptive three step charging
The BlueSolar 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.
1.8.1. Bulk stage
During this stage the controller delivers as much charge current
as possible to rapidly recharge the batteries.
1.8.2. Absorption stage
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.
1.8.3. Float stage
During this stage, float voltage is applied to the battery to
maintain it in a fully charged state.
1.8.4. Equalization
See section 3.7.1
1.9 Connectivity
See section 3.8 of this manual.
1.10 Remote on-off
VE.Direct non inverting remote on-off cable (ASS030550300)
needed. An input HIGH (Vi > 8V) will switch the controller on, and
an input LOW (V < 2V, or free floating) will switch the controller
off.
Application example: on/off control by a VE.Bus BMS when
charging Li-ion batteries.
1.11 Real-time data display on Apple and Android
smartphones, tablets and other devices
VE.Direct Bluetooth Smart dongle
and VictronConnect app
needed: see section 3.8.

3
EN NL FR DE ES SE Appendix
2. Safety instructions
● 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.
● 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.
● 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).
Danger of explosion from sparking
Danger of electric shock

4
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.
3. Installation
3.1 General
● Mount vertically on a non-flammable surface, with the power
terminals facing downwards.
● Mount close to the battery, but never directly above the battery
(in order to prevent damage due to gassing of the battery).
● Grounding: the heatsink of the controller should be connected
to the grounding point.
● Use one grounding point only (preferably close to the battery,
for safety reasons) to which the battery negative or battery
positive should be connected. Do not also connect the the solar
array negative to ground. This would result in unwanted ground
currents
Tr models: use flexible multistranded copper cable for the battery
and PV connections: see safety instructions.
MC4 models: several splitter pairs will be needed to parallel the
strings of solar panels.

5
EN NL FR DE ES SE Appendix
3.2 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.
The controllers can be used with any PV configuration that
satisfies the three above mentioned conditions.
For example:
24V battery and mono- or polycristalline panels
● 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 and mono- or polycristalline panels
● Minimum number of cells in series: 144
(4x 12V panel or 2x 24V panel in series).
● Maximum: 216 cells.
Remark: at low temperature the open circuit voltage of a 216
cell solar array may exceed 150V, depending on local conditions
and cell specifications. In that case the number of cells in series
must be reduced.
3.3 Cable connection sequence (see figure 1)
First: connect the battery.
Second: connect the solar array (when connected with reverse
polarity, the controller will heat up but will not charge the
battery).
3.4 More about automatic battery voltage recognition
The system voltage is stored in non volatile memory.
In case of a 24V or 48V battery, a reset (to 12V) occurs only
when the output voltage decreases to less than 2V and the
voltage on the PV input exceeds 7V. This may occur when the
battery has been disconnected before PV voltage starts to rise in
the early morning. When the (24V or 48V) battery is reconnected
later during the day, the system voltage is restored to 24V resp.

6
48V after 10 seconds if the battery voltage exceeds 17,5V resp.
35V.
Automatic voltage recognition can be switched off and a fixed
12/24/36 or 48V system voltage can be set with the
VictronConnect app (see sect 3.8): recommended if the battery is
frequently disconnected from the controller.
The controller can be reset by short circuiting the output and
applying a voltage exceeding 7V on the input (for example with a
small power supply, or a solar panel) during a few seconds. After
a reset, the controller will automatically adjust itself to a 12V
system, a 24V system (when connecting a 24V battery with at
least 17,5V) or a 48V system (when connecting a 48V battery
with at least 35V).
The VictronConnect app (see sect. 3.8) is required to set the
MPPT to 36V.

7
EN NL FR DE ES SE Appendix
3.5 Configuration of the controller
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)
Rolls Marine (flooded)
Rolls Solar (flooded)
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)
Rolls Marine (flooded)
Rolls Solar (flooded)
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. 3.7.1 to activate

8
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 below.
3.6 LEDs
LED indication:
permanent on
blinking
off
Regular operation
LEDs
Bulk
Absorption
Float
Bulk (*1)



Absorption



Automatic equalisation (*2)



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.
Note (*2): Automatic equalisation is introduced in firmware v1.16
Fault situations
LEDs
Bulk
Absorption
Float
Charger temperature too high



Charger over-current



Charger or panel over-voltage



Internal error (*3)



Note (*3): 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

9
EN NL FR DE ES SE Appendix
3.7 Battery charging information
The charge controller starts a new charge cycle every morning,
when the sun starts shining.
The maximum duration of the absorption period is determined
by the battery voltage measured just before the solar charger
starts up in the morning:
Battery voltage Vb (@start-up) Maximum absorption time
Vb < 23,8V 6h
23,8V < Vb < 24,4V 4h
24,4V < Vb < 25,2V 2h
Vb > 25,2V 1h
(divide voltages by 2 for a 12V system and multiply by two in
case of a 48V system)
If the absorption period is interrupted due to a cloud or due to a
power hungry load, the absorption process will resume when
absorption voltage is reached again later on the day, until the
absorption period has been completed.
The absorption period also ends when the output current of the
solar charger drops to less than 2Amps, not because of low
solar array output but because the battery is fully charged (tail
current cut off).
This algorithm prevents over charge of the battery due to daily
absorption charging when the system operates without load or
with a small load.

10
3.7.1 Automatic equalization
Automatic equalization is default set to ‘OFF’. With the Victron
Connect app (see sect 3.8) 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 (see table
in section 3.5). The current is limited to 8% of the bulk current for
all VRLA (Gel or AGM) batteries and some flooded batteries, and
to 25% of the bulk current for all tubular plate batteries and the
user defined battery type. The bulk current is the rated charger
current unless a lower maximum current setting has been
chosen.
In case of all VRLA batteries and some flooded batteries
(algorithm number 0, 1, 2 or 3) automatic equalization ends when
the voltage limit maxV has been reached, or after t = (absorption
time)/8, whichever comes first.
For all tubular plate batteries and the user defined battery type
automatic equalization ends after t = (absorption time)/2.
When automatic equalisation is not completely finished within one
day, it will not resume the next day, the next equalisation session
will take place as determined by the day interval.
3.8 Connectivity
3.8.1 The VictronConnect app
Several parameters can be customized with the VictronConnect
app.
The VictronConnect app can be downloaded from
http://www.victronenergy.nl/support-and-downloads/software/
● Bluetooth dongle needed when using Bluetooth Smart.
● VE.Direct to USB cable needed when using a computer.
See the data communication white paper on our website.
3.8.2 Monitoring
The ColorControl panel or the MPPT control, VE.Direct cable
needed
MPPT Control
Color Control

11
EN NL FR DE ES SE Appendix
4. Troubleshooting
Problem
Possible cause
Solution
Charger does not
function
Reversed PV connection Connect PV correctly
Reverse battery
connection
Non replacable fuse
blown.
Return to VE for repair
The battery is not fully
charged
A bad battery connection
Check battery
connection
Cable losses too high
Use cables with larger
cross section
Large ambient
temperature difference
between charger and
battery (Tambient_chrg >
Tambient_batt)
Make sure that
ambient conditions
are equal for charger
and battery
Only for a 24V system:
wrong system voltage
chosen (12V instead of
24V) by the charge
controller
Disconnect PV and
battery, after making
sure that the battery
voltage is at least
>19V, reconnect
properly
(reconnect battery
first)
The battery is being
overcharged
A battery cell is defect
Replace battery
Large ambient
temperature difference
between charger and
battery (Tambient_chrg <
Tambient_batt)
Make sure that
ambient conditions
are equal for charger
and battery

12
5. Specifications
BlueSolar charge controller MPPT 150/45 MPPT 150/60 MPPT 150/70
Battery voltage
12/24/48V Auto Select (36V: manual)
Maximum battery current
45A
60A
70A
Nominal PV power, 12V 1a,b)
650W
860W
1000W
Nominal PV power, 24V 1a,b)
1300W
1720W
2000W
Nominal PV power, 36V 1a,b)
1950W
2580W
3000W
Nominal PV power, 48V 1a,b)
2600W
3440W
4000W
Max. PV short circuit current 2)
50A
50A
50A
Maximum PV open circuit voltage
150V
Peak efficiency
98%
Self consumption
Less than 35mA @ 12V / 20mA @ 48V
Charge voltage 'absorption'
Default setting: 14,4V / 28,8V / 43,2V / 57,6V
Charge voltage 'equalization'
Default setting: 16,2V / 32,4V / 48,6V / 64,8V
Charge voltage 'float'
Default setting: 13,8V / 27,6V / 41,4V / 55,2V
Charge algorithm
Multi-stage adaptive
(eight preprogrammed algorithms)
Temperature compensation
-16mV/°C / -32mV/°C / -48mV/°C / -64mV/°C
Protection
Battery reverse polarity (fuse, not user accessible)
Output short circuit / Over temperature
Operating temperature
-30 to +60°C (full rated output up to 40°C)
Humidity
95%, non-condensing
Maximum altitude
5000m (full rated output up to 2000m)
Environmental condition
Indoor, unconditioned
Pollution degree
PD3
Data communication port and
remote on/off
VE.Direct
See the data communication white paper on our website
Parallel operation
Yes, but not synchronized
ENCLOSURE
Colour
Blue (RAL 5012)
PV terminals 3) 35mm² / AWG2 (Tr models),
or dual MC4 connectors (MC4 models)
Battery terminals
35mm² / AWG2
Protection category IP43 (electronic components)
IP 22 (connection area)
Weight
3kg
Dimensions (h x w x d) Tr models: 185 x 250 x 95mm
MC4 models: 215 x 250 x 95mm
STANDARDS
Safety
EN/IEC 62109
1a) If more PV power is connected, the controller will limit input power.
1b) PV voltage must exceed Vbat + 5V for the controller to start.
Thereafter minimum PV voltage is Vbat + 1V.
2) A PV array with a higher short circuit current may damage the controller.
3) MC4 models: several splitter pairs will be needed to parallel the strings of solar panels

13
EN NL FR DE ES SE Appendix
Specifications, continued
BlueSolar charge controller MPPT 150/85 MPPT 150/100
Battery voltage
12/24/48V Auto Select (36V: manual)
Maximum battery current
85A
100A
Nominal PV power, 12V 1a,b)
1200W
1450W
Nominal PV power, 24V 1a,b)
2400W
2900W
Nominal PV power, 36V 1a,b)
3600W
4350W
Nominal PV power, 48V 1a,b)
4900W
5800W
Max. PV short circuit current 2)
70A
70A
Maximum PV open circuit voltage
150V
Peak efficiency
98%
Self consumption
Less than 35mA @ 12V / 20mA @ 48V
Charge voltage 'absorption'
Default setting: 14,4V / 28,8V / 43,2V / 57,6V
Charge voltage 'equalization'
Default setting: 16,2V / 32,4V / 48,6V / 64,8V
Charge voltage 'float'
Default setting: 13,8V / 27,6V / 41,4V / 55,2V
Charge algorithm
Multi-stage adaptive
(eight preprogrammed algorithms)
Temperature compensation
-16mV/°C / -32mV/°C / -48mV/°C / -64mV/°C
Protection
Battery reverse polarity (fuse, not user accessible)
Output short circuit / Over temperature
Operating temperature
-30 to +60°C (full rated output up to 40°C)
Humidity
95%, non-condensing
Maximum altitude
5000m (full rated output up to 2000m)
Environmental condition
Indoor, unconditioned
Pollution degree
PD3
Data communication port and
remote on/off
VE.Direct
See the data communication white paper on our website
Parallel operation
Yes (not synchronized)
ENCLOSURE
Colour
Blue (RAL 5012)
PV terminals 3) 35mm² / AWG2 (Tr models),
or three pairs of MC4 connectors (MC4 models)
Battery terminals
35mm² / AWG2
Protection category IP43 (electronic components)
IP 22 (connection area)
Weight 4,5kg
Dimensions (h x w x d)
Tr models: 216 x 295 x 103mm
MC4 models: 246 x 295 x 103mm
STANDARDS
Safety
EN/IEC 62109
1a) If more PV power is connected, the controller will limit input power.
1b) PV voltage must exceed Vbat + 5V for the controller to start.
Thereafter minimum PV voltage is Vbat + 1V.
2) A PV array with a higher short circuit current may damage the controller.
3) MC4 models: several splitter pairs will be needed to parallel the strings of solar panels

14

1
EN NL FR DE ES SE Appendix
1. Algemene beschrijving
1.1 Ultrasnelle Maximum Power Point Tracking (MPPT)
Vooral als het bewolkt is en de lichtintensiteit voortdurend
verandert, verbetert een ultrasnelle MPPT-controller de
energieopbrengst tot 30% in vergelijking met PWM-
laadcontrollers en tot 10% in vergelijking met tragere MPPT-
controllers.
1.2 Advanced Maximum Power Point Detection in het geval
van wisselende schaduw
In het geval van wisselende schaduw kan de vermogen-
spanningscurve twee of meer maximale vermogenspunten
bevatten.
Conventionele MPPT's benutten meestal plaatselijke MPP,
hetgeen mogelijk niet het optimale MPP is.
Het innovatieve BlueSolar-algoritme maximaliseert de
energieopbrengst altijd door het optimale MPP te benutten.
1.3 Uitstekend omzettingsrendement
Geen koelventilator. Het maximale rendement bedraagt meer
dan 98%. Volledige uitgangsstroom tot 40°C (104°F).
1.4 Uitgebreide elektronische beveiliging
Beveiliging tegen overtemperatuur en vermogensvermindering
bij hoge temperaturen.
Beveiliging tegen PV-kortsluiting en omgekeerde PV-polariteit.
Beveiliging tegen PV-sperstroom.
1.5 Interne temperatuursensor
Compenseert absorptie- en druppelladingsspanningen voor
temperatuur.
1.6 Automatische herkenning van de accuspanning
De controllers passen zich automatisch aan aan een systeem van
12V, 24V of 48V. Om de controller op 36V in te stellen, is een pc
of Color Control-paneel vereist.
1.7 Flexibel laadalgoritme
Acht voorgeprogrammeerde algoritmes die met een
draaischakelaar gekozen kunnen worden.

2
1.8 Adaptief drietraps laden
De BlueSolar MPPT-laadcontroller is geconfigureerd voor een
drietraps oplaadproces: Bulklading, absorptielading en
druppellading.
Een regelmatige egalisatielading kan ook worden
geprogrammeerd: zie paragraaf 3.8 van deze handleiding.
1.8.1. Bulklading
Tijdens deze fase levert de controller zoveel mogelijk laadstroom
om de accu's snel op te laden.
1.8.2. Absorptielading
Als de accuspanning de ingestelde absorptiespanning bereikt,
schakelt de controller over op de constante spanningsmodus.
Als enkel lichte ontladingen optreden, wordt de absorptietijd kort
gehouden om overlading van de accu te voorkomen. Na een
diepe ontlading wordt de absorptietijd automatisch verhoogd om
ervoor te zorgen dat de accu opnieuw volledig wordt geladen.
Daarnaast wordt de absorptietijd ook beëindigd als de laadstroom
onder 2A daalt.
1.8.3. Druppellading
Tijdens deze fase wordt de druppelladingsspanning toegepast op
de accu om deze volledig opgeladen te houden.
1.8.4. Egalisatie
Zie hoofdstuk 3.7.1
1.9 Connectiviteit
Zie paragraaf 3.8 in deze handleiding.
1.10 Aan/uit op afstand
De MPPT 150/45 kan op afstand worden bestuurd door een
VE.Direct niet-omvormende kabel voor het op afstand in- of
uitschakelen (ASS030550300). De ingang HIGH (Vi > 8V)
schakelt de controller in en de ingang LOW (V < 2V, of ‘free
floating’) schakelt de controller uit.
Toepassingsvoorbeeld: in-/uitschakelen op afstand door een
VE.Bus BMS voor het opladen van lithium-ionaccu's.

3
EN NL FR DE ES SE Appendix
1.11 Real-time-gegevensweergave op Apple- en Android-
smartphones, -tablets en andere apparaten
Hiervoor is een VE.Direct Bluetooth Smart dongle en
VictronConnect app vereist: zie par. 3.8.

4
2. Veiligheidsvoorschriften
● Lees deze handleiding zorgvuldig voordat het product wordt
geïnstalleerd en in gebruik wordt genomen.
● Dit product is ontworpen en getest conform de internationale
normen. De apparatuur mag enkel worden gebruikt voor de
bedoelde toepassing.
● Installeer het product in een hittebestendige omgeving. Zorg er
daarom voor dat zich geen chemische stoffen,
kunststofonderdelen, gordijnen of andere soorten textiel enz. in
de onmiddellijke omgeving van de apparatuur bevinden.
● Zorg ervoor dat de apparatuur wordt gebruikt onder de juiste
bedrijfsomstandigheden. Gebruik het product nooit in een
vochtige omgeving.
● Gebruik het product nooit op plaatsen waar zich gas- of
stofexplosies kunnen voordoen.
● Zorg ervoor dat er altijd voldoende vrije ruimte rondom het
product is voor ventilatie.
● Raadpleeg de specificaties van de accufabrikant om te
waarborgen dat de accu geschikt is voor gebruik met dit
product. Neem altijd de veiligheidsvoorschriften van de
accufabrikant in acht.
● Bescherm de zonne-energiemodules tegen rechtstreekse
lichtinval tijdens de installatie, bv. door deze af te dekken.
● Raak niet geïsoleerde kabeluiteinden nooit aan.
● Gebruik alleen geïsoleerd gereedschap.
● De aansluitingen moeten altijd plaatsvinden in de volgorde
zoals beschreven in paragraaf 3.5.
● Degene die het product installeert moet zorgen voor een
trekontlasting voor de accukabels, zodat een eventuele
spanning niet op de kabels wordt overgedragen.
● Naast deze handleiding moet de bedieningshandleiding of de
onderhoudshandleiding een onderhoudshandleiding voor de
accu bevatten die van toepassing is op de gebruikte accutypen.
● Gebruik flexibele koperen kabel bestaande uit meerdere aders
voor de accu- en de zonnepaneelaansluitingen.
De maximale diameter van de afzonderlijke adres is
0,4 mm/0,125 mm² (0,016 inch/AWG26).
Kans op ontploffing door vonken
Kans op elektrische schok