THE MICRO-GRID ACADEMY

Module no. 2.2 Renewable minigrids components

(PV)

Lesson no. 2.2.10

Title: Charge controllers and MPPTs

The Micro-Grid Academy- All rights, including translation, reserved. No part of this document may be disclosed to any third party, for purposes other than the original, without written consent of RES4Africa Foundation.
 Contents

• Review functions of a charge controller

• Examples of larger charge controllers
• Charge controller accessories
• Matching PV arrays to standard charge controllers
• MPPTs
• Examples of charge controllers with MPPTs
• Matching solar arrays to MPPTs controllers
• Charge controller standards
Glossary
A Ampere
Isc Short circuit current
MPPT Maximum power point tracker
PV Photovoltaic
PWM Pulse width modulated
VDC Direct current voltage
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 Introduction: Review functions of a
charge controller

• The function of charge controllers is to;

• protect the batteries from over-discharge
• protect the batteries from overcharge.
• They block reverse current
• ensure efficient charging of batteries

Steca PR3030 charge controller showing SoC

Source: T3 PV Off-grid systems (PV-only, hybrid, mini-grids)

Source: GIZ Solar mini-grid site selection handbook

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 Introduction: Review functions of a charge
controller cont’d

Charge controller specifications

• Ratings in amps (amps in, amps out)
• Low voltage disconnect
• High voltage disconnect
• Efficiency rating
• Stand-by power consumption
• Short circuit protection
• Overload protection
• Battery state of charge indicators/display
• Solar charge indicators
• Load indicators
• Reverse polarity protection
Solar Charge Controller
• Temperature compensation Source: Solar Charge Controller Types, Functionality and Applications

Source: Solar Charge Controller Types, Functionality and Applications

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 Introduction: Review functions of a charge
controller cont’d

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 Examples of larger charge controllers

Types of charge controllers

• Shunt-type controllers,
• Series-type controllers,
• Pulse-width modulation (PWM) controllers (these charge batteries more efficiently),
• Charge controllers with integrated MPPTs

Schematic diagram of series type charge controller:

Source: T3 off grid master

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 Examples of larger charge controllers cont’d

Schematic diagram of a shunt type charge controller:

Source: T3 off grid master

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 Examples of larger charge controllers cont’d

• Pulse-width modulation (PWM)

Source: T3 off grid master

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 Examples of larger charge controllers

Prostar Series from Morningstar

• 20A charge/ 16A load & 30A charge/ 30A load versions
• LCD display
• Full range of features

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 Examples of larger charge controllers cont’d

Steca Power Tarom

• 8,400 watts
• IP 65
• 12 / 24 / 48 VDC
• Built in Ah meter
• 10 kg

Source: T3 off grid master

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 MPPTs for off-grid systems
• Maximum power point trackers (MPPTs) use DC to DC conversion electronics to ‘track’ the maximum
power point (MPPT) of a PV module or array I-V curve. They can increase the energy yield from a PV
module or array by 10 - 35%.

Advantages of MPPT:
• Maximum power point tracking in an off-grid system ensures that the module always operates at
maximum possible power. Unlike the normal charge controller charges batteries at a less than optimum
voltage since the battery voltage determines the module voltage.
• MPPTs ensure that all the energy produced by all cells is harvested. Unlike in the normal charge
controllers where some energy is lost.
• MPPTs are used mostly in larger systems (i.e. above 200 Wp).

• These days MPPTs are very often integrated into the charge controller.

Source: GIZ Solar mini-grid site selection handbook

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 MPPTs for off-grid systems cont’d

PV cell maximum power point (MPP)

The graph shows a Crystalline silicon: MPP at 80% of Voc and 95% of Isc
Source: T3 off grid master

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 MPPTs for off-grid systems cont’d

• Effect of temperature on MPPT

Source: T3 off grid master

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 MPPTs for off-grid systems cont’d

• Effect of irradiance on MPPT

Source: T3 off grid master

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 MPPTs for off-grid systems

Disadvantage of MPPT charge controllers

• They only work efficiently within a specified voltage range.
• If the PV array voltage is too low, they will not work (this could be a problem when modules are
operating at high temperatures).
• If the PV voltage is too high, they can be damaged (low module temperatures).
• It is important to consider these issues when designing off-grid systems with MPPTs.

Source: GIZ Solar mini-grid site selection handbook

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 Examples of charge controllers with MPPTs data sheet

Source: T3 off grid master

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 Examples of charge controllers with MPPTs data sheet cont’d

Source: T3 off grid master

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 Examples of charge controllers with MPPTs data sheet

BlueSolar charge controllers

datasheet
Source: Victron energy; Bluesolar charge controller 18
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 Charge controllers with MPPTs data sheet

BlueSolar charge controllers

datasheet

Source: Victron energy; Bluesolar charge controller

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 Matching solar arrays to MPPTs controllers

• In order to correctly choose the right size of charge controller for a system the amperage of a charge
controller can be manually determined by knowing;

• The wattage of the solar array

• The battery-bank voltage/system voltage (12, 24, or 48).

• Ohm’s Law also comes into play i.e.

Amps x Volts = Watts

Example:

80 amp controller x 48 volt battery bank = 3,840 watts of solar panels.

•After getting the wattage, choose controllers with a bit more wattage.
•Also, input voltage that controller can take should not be exceeded
•Consider temperature and open-circuit voltages
•Manufacturer’s sizing tools con also be used.
Source: Solar power world, 2014, How to choose the perfect charge controller, Bob Gudgel & Kim Silva 20
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 Charge controller standards

• There are two main international standards of charge controllers

• IEC 62509
• IEC 62093

IEC 62509
• This standard addresses the following features of battery charge control
• Load control,
• Protection functions,
• Interface functions
• Photovoltaic generator charging of a battery,
• It provides tests to determine the functioning and performance characteristics of charge controllers

Source: SINO Voltaics, 2015, Solar charge controller certifications: IEC 62509 and IEC 62093, Chaina, Dircus
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 Charge controller standards

IEC 62093
• This standard specifies the requirements for the design qualification of balance-of-system (BOS)
components

Kenya/local charge controller standard

• KS IEC 62509:2010 Battery charge controllers for photovoltaic systems - Performance and functioning

Source: Draft-Energy Solar-Photovoltaic-Regulations_2019

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 Recommended reading/sources of information

• Installation, Operation & Maintenance of Solar PV Microgrid

Systems http://isolaralliance.org/docs/Microgrid-Trainers-Handbook.pdfM
• GIZ Solar mini-grid site selection handbook
• Victron energy; BlueSolar charge controller
https://www.victronenergy.com/upload/documents/Datasheet-Blue-Solar-Charge-Controller-MPPT-75-
10,-75-15,-100-15-&-MPPT-100-20-EN-.pdf
• Solar power world, 2014, How to choose the perfect charge controller, Bob Gudgel & Kim Silva.
https://www.solarpowerworldonline.com/2014/09/how-to-choose-the-perfect-charge-controller/
• SINO Vltaics, 2015, Solar charge controller certifications: IEC 62509 and IEC 62093, Chaina, Dircus
https://sinovoltaics.com/learning-center/certifications/iec-62509-and-iec-62093/

• PPTs for off-grid systems

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 Thank You for Your Kind Attention.

Contacts RES4Africa Foundation

Renewable Energy Solutions
Micro-Grid Academy for Africa Foundation
Email: [email protected] Rome, via Ticino 14
Website: www.microgridacademy.org 24 www.res4med.org
www.resafrica.org