victron energy MPPT 150 SmartSolar Charge Controller Instruction Manual

victron energy MPPT 150 SmartSolar Charge Controller

General Description

Charge current up to 35A and PV voltage up to 150V

The SmartSolar MPPT 150/35 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 12V, 24V or a 48V nominal battery voltage.

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 MPPTs tend to lock to a local MPP, which may not be the optimum MPP. The innovative SmartSolar 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).

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.

Internal temperature sensor

Compensates absorption and float charge voltages for temperature. (range 6°C to 40°C)

Optional external voltage and temperature sensor

(range -20°C to 50°C)
The Smart Battery Sense is a wireless battery voltage-andtemperature 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. Alternatively, Bluetooth communication can be set up between a BMV-712 battery monitor with battery temperature sensor and the solar charge controller.

For more detail please enter smart networking in the search box on our website.

Automatic battery voltage recognition

The MPPT 150/35 will automatically adjust itself to a 12V, 24V or a 48V 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 1.11.

Flexible charge algorithm

Fully programmable charge algorithm, and eight preprogrammed algorithms, selectable with a rotary switch.

Adaptive three step charging

The BlueSolar MPPT Charge Controller is configured for a three step charging process: Bulk ­ Absorption ­ Float.
Bulk
During this stage the controller delivers as much charge current as possible to rapidly recharge the batteries.
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 2A.
Float
During this stage, float voltage is applied to the battery to maintain it in a fully charged state.

Equalization
See section 3.8

Remote on-off

The MPPT 150/35 can be controlled remotely by a  VE.Direct non inverting remote on-off cable (ASS030550320). 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.

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

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS – This manual contains important instructions that shall be followed during installation and maintenance.

Danger of explosion from sparking
Danger of electric shock

• 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.
• 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 direct 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 3.6.
• 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.

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.

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 be guarded against inadvertent contact (e.g. install in an enclosure or install the optional WireBox M).

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 charger must not be connected with grounded PV arrays. (one ground connection only)

• 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.

PV configuration (also see the MPPT Excel sheet on our website)

• Provide a 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.
• 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: 150V.

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.

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).
Torque: 1,6 Nm

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

@%I nom

| 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)|

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)

|

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 (LiFePo4) 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. 3.8 to activate.
(do not equalize VRLA Gel and AGM batteries)
Note 3: any setting change performed with Bluetooth or via VE.Direct will override the rotary switch setting. Turning the rotary switch will override prior settings made with Bluetooth or VE.Direct.

On all models with software version V 1.12 or higher 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:

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

Thereafter, normal indication resumes, as described below.
Remark: the blink function is enabled only when PV power is present on the input of the controller.

LEDs

LED indication:

permanent on
blinking
off

Regular operation

LEDs

| Bulk| Absorption|

Float

---|---|---|---
Bulk (1)| | |
Absorption (2)| | |
Automatic equalisation (2)| | |
Float (2)| | |

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): The LED(s) might blink every 4 seconds indicating that the charger is receiving data from another device, this can be:

• A GX Device (eg Color Control with a Multi in ESS mode)
• A VE.Smart network link via Bluetooth (with other MPPT chargers and / or a BMV or Smart Battery Sense)

Fault situations

LEDs

| Bulk| Absorption|

Float

---|---|---|---
Charger temperature too high| | |
Charger over-current| | |
Charger over-voltage| | |
Internal error (*3)| | |

For the latest and most up to date information about the blink codes, please refer to the Victron Toolkit app. Click on or scan the QR code to get to the Victron Support and Downloads/Software page.

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 behaviour of MPPTs differs from AC connected battery chargers. Please read this section of the manual carefully to understand MPPT behaviour, 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:

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

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 value is 2A.

The default settings (voltages, absorption time multiplier and tail current) can be modified with the Victronconnect app via Bluetooth 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.

When, in case of the above-mentioned exceptions, several Solar Chargers are connected to a GX device, these chargers will automatically be synchronised.

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 (i.e. the absorption time has paused) 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 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)

Automatic equalization

Automatic equalization is default set to `OFF’. With the Victron Connect app (see sect 1.12) 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 (see table in sect. 3.5). 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.

Troubleshooting

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 or 48V system: wrong system voltage chosen by the charge controller| Set the controller manually to the required system voltage (see section 1.11)
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

Specifications

(adjustable)
Charge voltage ‘equalization’ 3)| Default setting: 16,2V / 32,4V / 64,8V (adjustable)
Charge voltage ‘float’| Default setting: 13,8V / 27,6V / 55,2V (adjustable)
Charge algorithm| Multi-stage adaptive (eight preprogrammed algorithms) or user defined algorithm
Temperature compensation| -16mV / -32mV / -68mV / °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 type 1, unconditioned
Pollution degree| PD3
Data communication port and remote on/off| VE.Direct (see the data communication white paper on our website)
ENCLOSURE
Colour| Blue (RAL 5012)
Power terminals| 16mm² / AWG6
Protection category| IP43 (electronic components), IP 22 (connection area)
Weight| 1,25kg
Dimensions (h x w x d)| 130 x 186 x 70 mm
STANDARDS
Safety| EN/IEC 62109-1, UL 1741, CSA C22.2
1a) If more PV power is connected, the controller will limit input power. 1b) The PV voltage must exceed Vbat + 5V for the controller to start.
Thereafter the minimum PV voltage is Vbat + 1V.
2) A higher short circuit current may damage the controller in case of reverse polarity connection of the PV array.
3) Default setting: OFF

Victron Energy B.V.
De Paal 35 | 1351 JG Almere
PO Box 50016 | 1305 AA Almere | The Netherlands

General phone  +31 (0)36 535 97 00
E-mail :sales@victronenergy.com

www.victronenergy.com

Documents / Resources

| victron energy MPPT 150 SmartSolar Charge Controller [pdf] Instruction Manual
MPPT 150, MPPT 35, SmartSolar Charge Controller
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