Victron energy BlueSolar MPPT 150/85 Manual de usuario

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Appendix

BlueSolar charge controller MPPT 150/85

EN NL FR DE ES SE Appendix

1. PRODUCT INTRODUCTION

Charge current up to 85 A and PV voltage up to 150 V

The BlueSolar 150/85-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.

Synchronised parallel operation of up to 25 units

Interconnect the charge controllers with RJ45 UTP cables and they will automatically

synchronise.

Charge process controlled by a Multi or Quattro

Connect the charge controller to a Multi or Quattro and build a Hub-1 off-grid or grid-

interactive self-consumption system.

Remote on/off connector

Less wiring and no additional Cyrix relay needed in a system with Li-ion batteries.

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.

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

●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 0,4 mm/0,125 mm² (0.016 inch/AWG26).

A 25 mm² cable, for example, should have at least 196 strands (class 5 or higher stranding

according to VDE 0295, IEC 60228 and BS6360). Also known as H07V-K cable.

An AWG2 gauge cable should have at least 259/26 stranding (259 strands of AWG26).

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.

Danger of explosion from sparking

Danger of electric shock

EN NL FR DE ES SE Appendix

3. INSTALLATION

Important:

In order to enable automatic system voltage recognition always connect the

batteries before connecting the solar panels.

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.

Mount wall bracket (for top holding), make sure it is level.

Put charger on mounting bracket and secure it with two screws in the mounting holes at

the lower backside of the charger.

3.2 Battery cables and battery fuse

Do not invert the plus and minus battery connection: this will

permanently damage the charger.

Cable strain relief must be provided, close to battery and PV

connectors.

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.

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 1200W)

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

AWG mm

AWG

500W 37A 63A 1 16 5 25 3 Not recommended

750W 55A 80A 1,5 16 5 25 3 Not recommended

1200W 85A 1) 120A 2 25 3 35 2 Not recommended

24V system (solar array up to 2400W)

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

AWG mm

AWG

500W 18A 35A 1 6 10 10 7 16 5

1000W 37A 63A 1,5 6 10 10 7 25 3

2400W 85A 1) 120A 2 10 7 16 5 25 3

48V system (solar array up to 4850W)

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

AWG mm

AWG

1000W 21 35 0,5 6 10 10 7 16 5

2000W 42 63 0,5 10 7 16 5 35 2

4850W 85A 1) 120 1 10 7 25 3 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 3600W)

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

AWG mm

AWG

750W 21 35 0,5 6 10 10 7 16 5

1500W 42 63 0,5 10 5 25 3 35 2

3600W 85A 1) 120 1 16 5 25 3 35 2

EN NL FR DE ES SE Appendix

3.3 PV connection

The PV input current of the charge controller is limited to 75A. In case of a potential

solar array output exceeding 75A, the solar array voltage will increase up to the level at

which the output is reduced to 75A.

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 12

00W)

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

AWG mm

AWG

18 66 2 35 2 Not recommended Not

recommended

36 33 1 16 5 35 2 Not

recommended

54 22 1 10 7 16 5 25 3

72 16 0,75 6 10 16 5 25 3

90 13 0,5 6 10 10 7 25 3

108 11 0,5 4 11 6 10 16 5

24V system (solar array up to 24

00W)

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

AWG mm

AWG

36 66 1 35 2 Not recommended Not

recommended

54 44 1 16 5 35 2 Not

recommended

72 33 0,75 16 5 25 3 35 2

90 27 0,5 16 5 25 3 35 2

108 22 0,5 10 7 16 5 35 2

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.

Cable strain relief must be provided, close to PV and battery connectors.

8V system (solar array up to 485

0W)

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

AWG mm

AWG

72 67 1 16 5 35 2 Not

recommended

90 54 1 10 7 25 3 35 2

108 45 0,75 10 7 25 3 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.

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.

The end of a CAN cable should have a bus terminator. This is achieved by inserting a bus

terminator in one of the two RJ45 connectors and the CAN cable in the other. In case of a

node (two CAN cables, one in each RJ45 connector), no termination is needed.

The CAN bus on this charger is not galvanically isolated. The CAN bus is

referenced to the minus battery connection.

EN NL FR DE ES SE Appendix

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)

option 8: when the charger is in float mode.

option 9: when the solar panel is irradiated (day/night indication).

3.4.5 Synchronised parallel operation

Several charge contollers can be synchronised with the CAN interface. This is achieved

by simply interconnecting the chargers with RJ45 UTP cables (bus terminators needed,

see section 3.4.3).

The paralleled charge contollers must have identical settings (e.g. charge algorithm).

The CAN communication ensures that the controllers will switch simultaneously from

one charge state to another (from bulk charge to absorption for example). Each unit

will (and should) regulate its own output current, depending a.o. on the output of

each PV array and cable resistance.

In case of using remote sensors (voltage and/or temperature), the remote sensor must

be connected to only one of the paralleled charge controllers. All other contollers will

share the information via the CAN interface.

In case of synchronized parallel operation the network icon will blink every 3

seconds on all paralleled units.

The PV inputs should not be connected in parallel. Each charge controller

must be connected to its own PV array.

3.4.6 Charge process controlled by a Multi or Quattro inverter/charger: HUB-1

operation

To build a Hub-1 off-grid or grid-interactive self-consumption system the charge controller(s)

must be connected to a Multi or a Quattro using the VE.BUS to VE.CAN interface. The

Micropressor of the Multi or Quattro will then control the charge process (HUB-1 assistant

software needed). The display on the controller will show ‘HUB-1’.

Please see Support & Downloads / software on our website for details about the required

software.

4. POWERING UP

(The REMOTE connector should be wired , see 4.5)

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 2.03

After the software-version has been displayed, the

charger will start the system voltage recognition

phase.

The LCD-screen displays two values:

Left: actual measured battery voltage.

Right: system (= nominal battery) voltage (12/24/36

or 48V), blinking during the battery recognition

phase.

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 “03 BATTERY VOLTAGE”.

c. Press SELECT: “AUTo” or the system voltage will

blink.

d. Use the "-" or "+" button to decrease or increase

system voltage.

e. Press SELECT 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.

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