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Battery Charging

Welcome to the Basic Charge Controllers Electrical Specification presentation. Here are the learning
objectives for this presentation.

* List the common specifications used with basic charge controllers

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When choosing a controller and for doing a complete system design, the charge controller specifications
need to be used. The manufacturer’s website usually has all the needed information and data on the
different models. Online stores also often provide the specification sheets, or they have links to allow
downloading and viewing of them. The installation and user manuals that are included ‘in the box’ when
you purchase a controller usually have the specifications as well.

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The most important information available from a specification sheet includes:

Max PV Voltage (also called the Voc): In this example the charge controller can only accept a maximum of 47 volts DC.
This is the maximum PV voltage that is allowed on the coldest day - and will determine which module to pair with this
controller, and how to configure multiple modules without exceeding this voltage limit.

Max PV Current: In this example, the charge controller can only accept 8 amps DC from the PV array. When pairing a
PV module, the array must not exceed this number in any condition.

Maximum Load Current: In this example, the charge controller can deliver up to 9 amps to DC loads. In order to
determine if this controller is large enough for an application, all of the potential load current would need to be calculated
and compared.

System Voltage (or nominal battery voltage) - In this example, the charge controller have a system voltage of 12 volts
DC. Basic or simple charge controllers will use the nominal voltage to match all components. If a 12V basic controller is
purchased, then it would be installed with a 12 V nominal PV array, connected to a 12 V battery bank, and use 12 V
loads.

These values should also be shown on the product itself, but the labels can be hard to understand or read sometimes.

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Here is another example of a very common charge controller - The Morningstar SunSaver 10L - it is
available in several different models with different current and voltage ratings. The one in this example is
a SS-10L-24V - so it has the following specifications:

Maximum PV Voltage (Voc) = 60 volts DC

Maximum PV Current = 10 amps DC

Maximum Load Current = 10 amps DC

System Voltage (nominal battery voltage) = 24 volts DC

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A critical point to understand when connecting components to this type of basic charge controller is that
the nominal voltages of the battery, controller, PV array, and loads MUST all match.

As shown here, the PV module, the charge controller, the battery, and the loads are all rated at a nominal
12 V. A 12 V nominal PV module actually produces between 17 – 18 V under load. It needs to start higher
than 12 V because the PV module needs to fully charge the battery (to 14 – 15 V) even on hot days.
Remember that the voltage of a PV module will decrease at hotter temperatures and will only produce 17
– 18 V when at 25 degrees C.

If a 24V PV module were used, or two 12V PV modules were wired in series, a 24V charge controller
would be required, and a 24V battery bank and load would be used.

In a later presentation we will discuss more advanced charge controllers which allow the PV array to have
a different voltage than the battery and loads.

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The next specification to look at when connecting a controller to a PV array and loads is the current
ratings. The solar current cannot exceed the limits of the controller input, and the load current cannot
exceed the controller’s output current ratings.

To match the solar input current, the PV module Isc is used. This is found from the module specification
sheet. The module’s Isc ‘corrected’ by multiplying it by a factor of 1.25. By using the Isc (which is higher
than the current under load) and adding in a safety factor of 1.25, this ensures that the solar array will
never exceed the ratings of the charge controller input. The basic controller’s solar amperage rating
should be greater than or equal to the module’s Isc x 1.25.

It is important to know how many amps the DC load connected to the charge controller will require. To
calculate load amps, divide the total load watts by the system voltage (Watts / Volts = Amps). For
example, a 100W, 12v DC load would have a current of 8.3A (100W / 12V = 8.3A). The basic controller’s
load amperage rating should be greater than or equal to the actual connected loads.

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Charge controller are available with a wide range of additional features. Some models require
purchasing these additional features as part of the unit while others have the option of adding them in the
field.

Some common additional features includes:

* Meters (LED, digital, graphical, remote) for the PV array, battery, and load giving the volts, amps, and
even amp-hours for the system.

* Temperature Sensors (internal or remote) - some have to be ordered separately and plug-in to the
controller

* Wiring methods, conduit adaptability - some use an optional add-on box to allow connection of conduit
and to protect the wiring and terminals from tampering or damage

* Enhanced reliability, extended warranty terms. Some manufacturers allow the purchase of an extended
warranty term.
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