Solar Energy Systems - Solar Charge Controller
A charge controller, sometimes referred to as a photovoltaic controller or battery charger, is only necessary in systems with battery back-up. The primary function of a charge controller is to prevent overcharging of the batteries. Most also include a lowvoltage disconnect that prevents over-discharging batteries. In addition, charge controllers prevent charge from draining back to solar modules at night. Some modern charge controllers incorporate maximum power point tracking, which optimizes the PV array’s output, increasing the energy it produces.
Types of Charge Controllers – There are essentially two types of controllers: shunt and series. A shunt controller bypasses current around fully charged batteries and through a power transistor or resistance heater where excess power is converted into heat. Shunt controllers are simple and inexpensive, but are only designed for very small systems. Series controllers stop the flow of current by opening the circuit between the battery and the PV array. Series controllers may be single-stage or pulse type. Single-stage controllers are small and inexpensive and have a greater load-handling capacity than shunt-type controllers. Pulse controllers and a type of shunt controller referred to as a multi-stage controller (e.g., three-stage controller) have routines that optimize battery charging rates to extend battery life.
Most charge controllers are now three-stage controllers. These chargers have dramatically improved battery life.
Selection – Charge controllers are selected based on:
• PV array voltage – The controller’s DC voltage input must match the nominal voltage of the solar array.
• PV array current – The controller must be sized to handle the maximum current produced by the PV array.
Interaction with Inverter – Since the majority of charge controllers have been installed in off-grid systems, their default settings may not be appropriate for a grid-connected system. The charge controller must be set up such that it does not interfere with the proper operation of the inverter. In particular, the controller must be set up such that charging the batteries from the PV array takes precedence over charging from the grid.
Interaction with Batteries – The charge controller must be selected to deliver the charging current appropriate for the type of batteries used in the system. For example, on a 12V system, flooded lead-acid batteries have a voltage of 14.6V to 15.0V when fully charged, while sealed lead-acid batteries are fully charged at 14.1 V. Refer to the battery manufacturer for the charging requirements of particular batteries.
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