victron energy MPPT 100/50 SmartSolar Charge Controller Instruction Manual

victron energy MPPT 100/50 SmartSolar Charge Controller Instruction Manual

Catamaran setup Quattro 5kVA 230VAC 24VDC 600Ah Li Lynx Smart BMS & distributors Cerbo GX touch generator MPPT Extra Alternators & WS500.pdf What is this drawing about ?

This drawing has been setup for catamarans and can be used for sail or motor cats using 24V DC with 230V/50Hz AC but can easily be used for 120V/60Hz as well.

This Victron system works as follows:
This system has been build around the 5kVA Quattro with 3 x 200Ah 24 Volt Li battery capacity. Protection of the Li batteries from a charge and discharge point of view is in good hands with use of the Lynx Smart BMS. To make sure you will not run out of power that easy, there are multiple charge possibilities available for this setup:

1. AC Shore Power that will enable the 5kVA Quattro to charge with 120 Amps towards the Li batteries.
2. AC Generator Power that will enable the 5kVA Quattro to charge with 120 Amps towards the Li batteries.
3. DC Solar Power that will enable the 2 x Smart Solar MPPT 100|50 to charge towards the Li batteries. The total Charge capacity depends on the installed Solar array for each MPPT.
4. DC Engine charging power with an extra 24V/110A Alternator mounted on each engine that can either charge as standalone with 110 Amps or with both engines  runningwith 220 Amps.

Charge combinations of the above mentioned devices also are possible. DC Loads or users like lights, pumps, and so on, can be connected behind one of the two Smart Battery Protect 220 where the loads are split between main fuse 1 till 5 and 6 till 10.

AC Power will be available from the 5kVA Quattro Inverter/Charger the moment it has been switched on. This means that without any AC power on the input, the Quattro will give you 5kVA of inverter power on AC OUT-1. The moment AC Power is available on input AC IN-1 or AC IN-2, of the Quattro, AC Power will be used to charge the batteries and also is available for loads connected to AC OUT-1 and AC OUT-2. With use of the Cerbo one can adjust the available AC Shore power to the maximum AC current the Quattro will use and this is where the Power Assist function comes into play. Power Assist allows to supplement AC inverter power to for instance a limited Shore power connection when needed.

All information about the system and its connected Victron devices is clearly visible on the GX Touch 50 Screen that is connected to the Cerbo GX. All AC Input power and AC Loads are clearly visible. Here you can monitor what the SOC or state of charge is from your Li batteries and you also can exactly see what discharge current runs away and what charge current comes into the batteries. This will give you a rest asure feeling that you are in control of your “on board” AC and DC power availability. More info about the system and its individual Victron parts  used in thisinstallation are explained in more details down below.

This is how the system has been setup:
Around the Victron Lithium Batteries 25.6V Smart and Lynx Distributor-1 (Dip switch Pos-A)

A Lynx Distributor is an easy to use and connect DC distribution system. It can hold 4 Mega fuses and three of them are in use here. It is important to always start with connecting the negativecable first before connecting the positive for each distribution position. Read the  manual foradditional information.

1. The first fuse position at the bottom of Distributor-1 holds a 300A fuse together with its lower positioned negative for Li Battery-1.
2. The second fuse position of Distributor-1 holds a 300A fuse together with its lower positioned negative for Li Battery-2.
3. The third fuse position of Distributor-1 holds a 300A fuse together with its lower positioned negative for Li Battery-3.
4. The forth fuse position of Distributor-1 holds a spare fuse together with its lower positioned negative for a spare Li battery

Lynx Smart BMS:
The Lynx Smart BMS is connected between Lynx Distributor-1 and Lynx Distributor-2 The BMS is the controlling safety heart of the system as this device protects the LiFePO4 batteries against over Voltage, under Voltage and high temperature. The Victron Lithium Batteries

25.6V Smart have an integrated Balancing, Temperature and Voltage control (acronym: BTV) and connect to the BMS connections with two M8 circular connector cable sets. The BTV’s of several batteries can be daisy chained like in this drawing with 3 connected batteries. When cables are not long enough, extensions cables are available in several lengths to fit your purpose available from your Victron dealer. A shunt has been build inside this BMS in the negative connection bus. This shunt is needed to measure what the charge/discharge current is for all connected batteries. The protective part of the BMS for the Li batteries is called ATC (Allow To Charge) and ATD (Allow To Discharge) and this happens trough two potential free contacts called ATC and ATD. You can see all these connection clearly in the enlarged part of the Lynx Smart BMS in the bottom left of the drawing. Power for these contacts to control external equipment can be taken from the Aux positive and Negative power connections trough a fuse. ATC for both WS500 regulators has to be connected as follows: Positive power from the Aux + contact towards a 0.5A fuse. From the fuse to the left ATC contact and from the right ATC contact to Relay contact COM. From Relay contact NO, the ATC signal go’s to WS500 Port ATC+ and to WS500 Stbd ATC+ Wakespeed Charge enable/Feature in connections. ATD for Smart battery Protect-1/220 and 2/220 has to be connected as follows: Positive power from the Aux + contact towards a 0.5A fuse. From the fuse to the left ATD  contact and from theright ATD contact to SBP 1/220 and SBP 2/220 H connections

Power for the Cerbo has to be connected as follows: from the Aux + contact towards a 1A fuse. From the fuse to the positive power connection of the Cerbo and from the Aux – contact to the negative power connection of the Cerbo.

The Distributor RJ11 cables on the left and right hand side of the BMS have to be connected to Distributor-1 and Distributor-2 as they provide power to the LED PCB for each Distributor and can be daisy chained from Distributor 2 to 3. These cables transfer data between the Distributor and the BMS about each main fuse status. Dip switches in each distributor need to be set properly to make this work. See settings behind each Distributor header.

Data at Can bus level to/from the BMS has to be connected to the Cerbo VE.Can port and to the Wakespeed Can bus connection. The VE.Can cable between the BMS and the Cerbo is a normal RJ45 cable, but the cable between the Cerbo and the WS500 is a Victron to Wakespeed Cross over cable. Do not forget to terminate the Can bus system at each end. Only use Wakespeed terminators for the WS500 as they are different compared to the ones for Victron.

The ATD contacts of the BMS will stop connected devices from discharging when the Battery Voltage has decreased below a preset value. (Detailed description as explained above)

The following Victron devices will be stopped when this happens

• Smart Battery Protect SBP 1/220 and SBP 2/220 both controlling a full Load disconnect of what is connected to both SBP OUT Connection.

The ATC contacts of the BMS will stop connected devices from charging to prevent Cell overVoltage or a Cell temperature that runs too high. (Detailed description as explained above)

The following Wakespeed devices will be stopped when this happens:

• WS500 Port ATC+ when connected to Charge enable/Feature in connection.
• WS500 Stbd ATC+ when connected to Charge enable/Feature in connection

Other connected Victron devices in this system also need to be controlled from a  charge anddischarge point of view and this can be achieved trough the connected GX device:

• Quattro Inverter/Charger will be controlled digitally trough the GX device DVCC feature.
• Solar chargers will be controlled digitally trough the GX Device DVCC feature.

Lynx Distributor-2 (Dip switch Pos-B)

1. The first fuse position at the bottom of Distributor-2 holds a 400A fuse together with its lower positioned negative connections for the biggest device in this installation, a 5kVA Quattro inverter/charger. Keep the distance between Lynx Distributor Fuse-1, Main switch-1 and the negative Quattro connections as short as possible. Read the Quattro manual carefully to proceed further. Mind you that 2 negative connections are used here, 1 below  Fuse-1 and onebelow Fuse-2.
2. The second fuse position of Distributor-2 holds a 150A fuse for the positive outputs of both Smart Solar charge controllers MPPT 100|50. The lower negative is used for the Quattro second negative connection as both negative outputs for the Solar charge controllers are connected to the negative Busbar.
3. The third fuse position of Distributor-2 holds a 250A fuse for Smart Battery Protect-1 220. Its lower positioned negative connection is used to connect to the Negative Busbar. Keep the distance between Lynx Distributor fuse-3, Main switch-2 and SBP-1 as short as possible.
4. The fourth fuse postion of Distributor-2 holds a 250A fuse for Smart Battery Protect-2 220. Its lower positioned negative connection is used to connect to the Negative Busbar. Keep the distance between Lynx Distributor fuse-4, Main switch-2 and SBP-2 as short as possible.

Main switch-1 is a single circuit model used for the Quattro with dual output connections to provide two positive connections towards the Quattro. Main switch-2 is a dual circuit model used for Main fuse 3 and 4 towards SBP-1  and SBP-2.The PE/Earth connection will be dealt with later together with the Quattro.

Lynx Distributor-3 (Dip switch Pos-C)

1. The first fuse position of Distributor-3 at the bottom of the Distributor holds a 150A fuse together with its lower positioned negative connection for the extra STBD Alternator. Also look at the 3 Amp in line fuse for the WS500 battery sense STBD connected to the same 150A fuse and the negative connection for the WS500 battery sense STBD connected to the negative busbar of Distributor-3.
2. The second fuse position of Distributor-3 holds a 150A fuse together with its lower positioned negative connection for the extra PORT Alternator. Also look at the 3 Amp in line fuse for the WS500 battery sense PORT connected to the same 150A fuse and the negative connection for the WS500 battery sense PORT connected to the negative busbar of Distributor-3. Main fuse 3 and 4 are Spares and can be used for future users or  chargepossibilities.

Smart Battery Protect 1/220:
This smart battery protect 220 is used for DC loads 1 till 5. One can make a choice what to use it for. The SBP is needed to protect the Li batteries from discharging beyond a low Voltage setpoint. It comes highly recommended to install a fuse of 300mA in the negative connection of the SBP

Smart Battery Protect 2/220:
This smart battery protect 220 is used for DC loads 6 till 10. One can make a choice what to use it for. The SBP is needed to protect the Li batteries from discharging beyond a low Voltage setpoint. It comes highly recommended to install a fuse of 300mA in the  negativeconnection of the SBP.

Cerbo GX with GX Touch 50 Display:
The Cerbo GX with its GX Touch 50 Display is visible next to Distributor-3. This device together with the GX Touch 50 Display is the monitoring heart of your installation showing you what is going on with all connected devices. Monitoring of your installation can be done either with the Cerbo in front of you or from anywhere in the world using an internet connection as shown in the drawing with VRM World that connects to the Victron VRM portal either using the Victron connect app or website. The Cerbo also provides Remote Firmware updates and allows  settings to bechanged Remotely. This all has been clearly explained in the Cerbo manual.

The positive power for the Cerbo comes from the Lynx Smart BMS AUX connections as explained with the BMS. The GX Touch 50 Display HDMI connector with attached USB power cable obviously has to go into the HDMI port of the Cerbo and the USB cable directly next to it. The VE.Bus cable coming from the Quattro go’s into a VE.Bus port of the Cerbo and the Ethernet cable and its connector, to connect to the VRM Portal, into the Network port of the Cerbo. The VE.Direct cables from Smart Solar MPPT 100|50 Port and Stbd, both connect into a VE.Direct port of the Cerbo. Data at VE.Can bus level to/from the Lynx Smart BMS has to be connected to the Cerbo VE.Can port. Do not forget to terminate the Can bus at the Cerbo with a Victron terminator.

These are all the connection you have to make for the Cerbo. There is plenty more you can connect and do with a Cerbo and that all is very well explained in its manual.

Smart Solar charge Controller MPPT 100|50 Port:

Next to Wakespeed WS500 Port, you will find Smart Solar charge Controller MPPT 100|50 Port. Also visible here is a PV breaker/Isolator. The Solar array as shown in the drawing is just to visualize some solar panels and how things need to be connected.

It might be a good idea that you use the free MPPT sizing calculator available from the Victron website. This is a great and accurate tool to size what you need on Solar panel power and charge controllers for your Van or Motorhome. DC power from the solar array first passes trough the PV breaker/Isolator and then connects to the MPPT PV input connections. The positive DC Output connection of the MPPT connects to a 60A Blue Sea breaker before connecting to the second fuse position of Distributor-2. The negative DC output connection of the MPPT connects to the Negative busbar. The VE.Direct cable and connector from the MPPT has to be connected to a Cerbo VE.Direct Port. The Cerbo in connection with the BMS controls the MPPT from overcharging the Li batteries via DVCC or Distributed Voltage and Current Control.

Smart Solar charge Controller MPPT 100|50 Stbd:
Next to Wakespeed WS500 Stbd, you will find Smart Solar charge Controller MPPT 100|50 Stbd. This MPPT connects up the same way as the MPPT 100|50 Port. It also feeds its positive DC Output connection of the MPPT to a 60A Blue Sea breaker before connecting to the second fuse position of Distributor-2. The negative DC output connection of the MPPT connects to the Negative busbar. Mind you that both 60A Blue Sea breakers are connected together with a small positive Busbar before connecting to the second fuse position of Distributor-2.

Engine Systems:
The starter circuits for both engines Port & Stbd with Starter Battery, Starter Motor, standard Alternator with main fuse and Ignition visible in this drawing should be seen as samples to show you how to connect your Victron products.

Quattro Inverter/Charger 5kVA/24V 230V/50Hz AC:
Below the Stbd starter circuit you will find the Quattro Inverter/Charger. The Quattro should be mounted in such a way that it can cool itself down properly and the space where it is in should be dry and well ventilated. Free space around the device should be at least 10cm or 4”. Don’t box the device in as this will certainly have a bad effect on its functioning and service life.

Most connection to and from the Quattro already have been discussed, but it might be a good idea to have them all together here again: The DC power to and from the Quattro connects to the first fuse position at the bottom of the Lynx Distributor-1 holding a 400A fuse together with its lower positioned negative connection and the lower positioned negative connection of Fuse-2. The Positive connection from the first Fuse position connects to Main Switch-1. After Main

Switch-1, one can connect two Positive connections towards the Quattro

Incoming AC power comes trough a Victron Shore Power connection. From there it passes trough an incoming AC breaker panel towards the Quattro AC IN-2 connections.  Incoming Generator power comes trough an incoming AC breaker panel towards the Quattro AC IN-1 connections. AC OUT-1 of the Quattro is connected to an AC breaker panel. These ar  NO Break AC outputs and as the name suggests are constantly powered  trough theQuattro Inverter. AC OUT-2 of the Quattro is also connected to an AC breaker panel. These are switched AC outputs and as the name here suggest are switched off when there is no incoming AC power available. AC OUT-2 is live only when AC power is available on the input of the Quattro with a 2 minute connect delay

The Quattro has two VE.Bus connections:
One is used for the Cerbo and the other one is Spare.

The Quattro has a Case Ground connection-L that should be connected to the Lynx Distributor negative Busbar as shown in this drawing. The Case Ground cable should be one size smaller compared to its total connected negative. All shown connections in this drawing, are made according to US ABYC regulations that are quite similar to CE.

This is a NON Isolated DC System setup. When in doubt about how to continue with these connections, consult your Victron dealer. Read the Quattro manual carefully to proceed further

Maintenance Chargers for starter batteries 230V/50Hz AC:
There are 3 Victron Blue Smart 12V 5A chargers in this drawing each with a 10A in-line fuse. AC power for all chargers comes from switched Load Quattro output AC Out- 2trough a breaker.

Software settings for all shown Victron devices in this drawing,
including Wakespeed WS500 regulator

• When setting up a new system, it will be good practice to update all Victron devices to the latest available Software/Firmware.
• The three Victron LiFePO4 25,6V 200Ah Smart batteries can be set, monitored and updated with use of the VictronConnect App.
• The two Victron Smart Battery Protects 220 can be set, monitored and updated with use of the VictronConnect App. Must be programmed for Li-Ion mode-C and 12V.
• The two Victron Smart Solar charge controllers MPPT 100|50 can be set, monitored and updated with use of the VictronConnect App. Must be programmed for Li Ion mode and 12V.
• The Victron Cerbo GX Device can be updated to the latest Firmware in two different ways: 1 – Update it via the internet, either manually or let it check for new updates every day. 2 – Update it from a microSD-card or USB-stick. Check the Cerbo manual for this.
• The Victron Lynx Smart BMS can be can be set, monitored and updated with use of the  ictronConnect App.
• The Victron Quattro can be set, monitored and updated with use of the MK3-USB interface and VEConfigure software (Windows only) or use the VictronConnect App (Multi Platform). Limitations of Victron Connect are that one can not add assistants, use Virtual Switch and/or change the Grid Code.
• The three Victron Blue Smart chargers of 12V 5A can be set, monitored and updated with use of the VictronConnect App.
• Both WS500’s need to be configured for use with the Victron Lynx Smart BMS and Victron Li batteries. Download the configuration utility guide, the latest Lynx.Lithium.configFile.txt as well as the latest WS500 firmware from version v.2.4.2 and up at: http://wakespeed.com/ technical.html.

Wiring Calculations:
There are no wire sizes visible in this drawing and there is a good reason why this is not available in any drawing on the Victron website. We at Victron do not know what the physical size of your project is and it therefore will be impossible to give you specific wire sizes that will fit your setup. But there is a very handy tool available from Victron called Victron Toolkit for Android and iPhone users. In this app you will find Cable Calc that will help you size any cable for AC and DC. This will help you find all the right cable sizes for your project.

Wiring Unlimited:
This is a book freely available for downloading from the Victron Website. This book is all about electrical wiring for systems containing batteries, inverters, charger, inverter/ chargers and so on. With this book Victron aims to explain wiring basics of electrical systems. This book helps to explain the importance of ‘getting it right’ and the issues that might happen when a system has inferior wiring. It also assists electrical installers or users to troubleshoot issues that have arisen from bad wiring. This book will certainly help to get it right and to make sure proper conclusions can be drawn for the electrical systems its readers are involved with.

Using the Victron-Remote-Monitoring / VRM app or website:
Monitoring of your installation can be done either with the Cerbo in front of you or from anywhere in the world using an internet connection as shown in the drawing with VRM World that connects to the Victron VRM portal either using the Victron connect app or website. Just login to your VRM account or setup a new one and tap on your account to view your installation. You can for instance set alarm status information for the state of charge or SOC and this will automatically warn you when a certain level has been reached. This is extremely useful when not being on board for a specific amount of days or winterizing mode and.…. It is free of charge !

For more info read the latest available VRM manual.
The VRM app is available for Android and iPhone users

Not being on board for a longer periode of time:

Make sure to switch the Quattro to charger only. This prevents the inverter from draining the batteries when no AC input power is available. Switch off all unnecessary users. When proper calculations for both Solar systems were made, both solar arrays on Port and Stbd will maintain the batteries.

Winterizing:
Before putting the boat in hibernation for winterizing, make sure to fully charge the batteries first. Then switch off the Quattro and its main switch-2. You can also decide to switch off main switch-1 and the engine main switches 4-5-6 as well if needed be. Solar charging will continue to maintain the Li batteries. Check on a regular interval if the batteries are not loosing too much capacity and make sure to prevent freezing at all times. A regular interval is 4-6 weeks. To keep communication of your system going with use of the VRM app or website, you do need an Internet connection to make this work and Victron also has a solution for this with the GX LTE 4G cellular modem. Check it out on the Victron website.

Peter Bakker

In this drawing you will find the following Victron equipment with some additional material:

chargers
Cables with M8 circular connector (for Li-ion batteries) Male to Female 3 pole 2 m (bag of 2)| ASS030560200| 1| Bag of 2
Cerbo GX| BPP900450100| 1|
Fuse holder 2AG or 5x20mm by Little Fuse including fuses| 150 series| 10| Order on line or from your Victron dealer
GX Touch 50 Display| BPP900455050| 1|
LiFePO4 Battery 25,6V/200Ah – Smart-a| BAT524120610| 3|
Lynx Smart BMS 500| LYN034160200| 1|
Lynx Distributor| LYN060102000| 3| Order fuses from your Victron dealer
Modular Mega fuse holder| CIP100200100| 10|
Modular Mega fuse holder Busbar CIP100200100| CIP100400060| 2|
Quattro 24/5000/120-100/100| QUA245021010| 1|

known
RJ45 Can bus cables| …………..| 3| Cable lengths not known
WS500 Advanced Alternator Regulator| WS500| 2|
WS500 Regulator Wiring Harness for N-type Alternator. Includes Alt. Temp. Sensor.| WS500/NH| 2| Check if the Alternator is P or N regulated
Data Terminator Kit for WS500 Alternator Regulator. Includes two terminators.| WS500-DT-K| 1|
WS500 to Victron Energy Can bus Crossover Cable| WS-VE-CABLE| 1|

References

• Wakespeed Charge Smarter - Wakespeed

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