Amali 2 (Exercise 3)

Charge Controller

The solar charge controller is an electronic device that often uses an internal
microprocessor to regulate the voltages and currents in a solar-powered system. It
is primarily used to properly charge the system battery bank from an alternative
energy source while preventing overcharging or over-discharging. Other features
are sometimes included in the charge controller, such as remote voltage sense and
remote temperature sense for improved charging voltage and current control. Some
additional features may include load control, energy management, overload and
reverse-polarity protection, status indication (using lamps, meters, and alarms),
night-time solar array disconnect, and self-diagnostics (fault detection). The solar
charge controller is normally connected between the solar array and the battery
bank.

Figure 24. Solar charge controller.

Types

There are several main types of solar charge controllers: series, shunt, PWM,
and MPPT.
Exercise 3 – Charge Controller

Series charge controllers: partially (and temporarily) open the PV source circuit to
limit battery charging current. Series charge controllers can open-circuit the solar
array at night also, to prevent the battery bank from discharging through the solar
array.
Shunt charge controllers: use the current-limiting abilities of PV solar modules to
limit charging current. The controller partially (and temporarily) short-circuits the
solar panel (in parallel) to limit battery charging current. The battery bank is never
shorted by the shunt charge controller circuitry.
Pulse-width modulated (PWM) charge controllers: are a type of series charge
controller that switches the PV source circuit opened and closed at a rapid rate.
Regulation is provided by pulsing the full charging current on and off, and adjusting
the pulse width to change the average charging current that flows into the battery
bank. PWM controllers are well suited for sealed lead-acid batteries.
Maximum power point tracking (MPPT) charge controllers: incorporate a
microprocessor to carefully control the maximum power operating point of the solar
array. These controllers can manipulate both the input and output voltages and
currents based upon irradiance and temperature changes. MPPT controllers
ensure the most effective utilization of array power and battery performance
under adverse environmental conditions.
The solar charge controller provided in your trainer uses PWM operation toregulate
the charging voltages and currents for a 12 V dc PV solar energy systemrated at
30 A maximum. Some charge controllers allow different types of alternative energy
to be controlled simultaneously, such as inputs from a PV solar array, wind turbine
generator, and a gasolinepowered electric generator.
Exercise 3 – Charge Controller

Figure 25. Solar charge controller block diagram.

There are several different charge modes for battery bank charging: bulk,
absorption, float, and equalization. These charge modes are discussed in detail in
the Battery Bank exercise.

Setpoints

Setpoints are voltage threshold levels at which the controller regulates charging
or switches sources and/or loads. For example, the low-voltage disconnect (LVD)
and high-voltage disconnect (HVD) setpoints can be adjusted and set to protect
the power system from overvoltage and under-voltage conditions. Similarly, the
array and load reconnect voltage levels (ARV, LRV, LVR and HVR) are sometimes
adjustable; but are often preprogrammed. Setpoints for the trainer’s solar charge
controller are listed in the following table for various battery types. The charging
options for these battery types can be set using switches 4, 5, and6 of the DIP
switch block on the solar charge controller, as shown in the following table.

Your trainer uses a sealed lead-acid battery. The settings for this
specific sealed battery type are shown in the following table.
Exercise 3 – Charge Controller

Table 6. Solar charge controller setpoints for various battery types.

Description Abbreviation Flooded

off off off off on on

DIP switch
settings (4, N/A off off on on off off
5, 6)
off on off on off on

Low-voltage
disconnect LVD (load) 11.5 11.3 11.5 11.7 11.9 12.1
(load)

Low-voltage
reconnect LVR (load) 12.6 12.8 13.0 13.2 13.4 13.6
(load)

Regulation
RV 14.0 14.15 14.3 14.4 14.6 14.7
voltage

Float
FV 13.5 13.5 13.5 13.5 13.5 13.5
voltage

Equalization
EV N/A 14.4 14.6 15.1 15.3 15.4
voltage

High-
voltage
HVD (load) 15.3 15.3 15.3 15.3 15.3 15.3
disconnect
(load)

High-
voltage
HVD (load) 14.5 14.5 14.5 14.5 14.5 14.5
reconnect
(load)

Terminals

The connection terminals to and from the solar charge controller are listed below.
Some charge controllers allow the use of remote voltage sense leads to minimize
the effects of voltage drops throughout the system wiring. Some charge controllers
also use a remote temperature sense probe to compensate for changes in battery
temperature. This feature can also protect against high temperature conditions by
disconnecting the array and load if necessary.

Solar (+): connects to the positive terminal of the PV solar module or

array.
Exercise 3 – Charge Controller

Solar (–): connects to the negative terminal of the PV solar module or

array.

Battery (+): connects to the positive terminal of the battery bank via the
power bus bar.

Sense (+): optionally connects to the positive terminal of the battery (not
used because the battery bank is within 5 m (16.4 ft).

Sense (–): optionally connects to the negative terminal of the battery (not
used because the battery bank is within 5 m (16.4 ft).

Battery (–): connects to the negative terminal of the battery bank via the
power bus bar.

Load (+): optionally connects to the positive terminals of any DC loads

(not used, see note below).

Load (–): optionally connects to the negative terminals of any DC loads

(not used, see note below).

Temperature probe (non-polarized): the two terminals are connected to

the two remote temperature sensor leads. The sensor is attached to the
side of the battery.

The load control is not normally used on this trainer because a

bidirectional ammeter is needed to monitor the controlled loads. Under
certain test conditions, the student might not want the load to
automatically disconnect.

Figure 26. Solar charge controller terminals.