Chapter 7

Charge Controllers

Types and Characteristics Functions and Features

Specifications and Ratings Sizing

2012 Jim Dunlop Solar

 Overview
Explaining the purpose for battery charge control in PV systems.

Describing the primary functions and features of charge

controllers.

Classifying the different types of controller switching designs

and charging algorithms.

Selecting appropriate charge control set points based on the

types of batteries and controllers used.

Identifying the key specifications and ratings for charge

controllers and their application in circuit design.

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 PV Systems and
Battery Charge Control

A charge controller is required in most PV systems that use

battery storage to regulate battery state-of-charge, optimize
battery and system performance, and help prevent damage to the
batteries or hazardous conditions resulting from the charging
process [690.72(A)].

Charge
PV Array Battery
Controller

Charge controller protects battery

from overcharge by PV array

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 Typical Charge Controllers
Morningstar ProStar controller Outback MPPT controller

Morningstar TriStar controller

Morningstar lighting controller

Xantrex C-series controller

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 Charge Controller
Functions & Features

Functions of charge controllers include:

Battery overcharge and/or overdischarge protection
Control of loads or other energy sources

Features of charge controllers include:

Type of switching and control algorithm
Temperature compensation
Equalization charging
Meters and indicators for system status and operating information

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 Overcharge Protection

Charge controller protects battery

from overcharge by PV array

Charge
PV Array Battery
Controller

Battery is not protected DC Load

from overdischarge by load.

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 Overdischarge Protection

This controller This controller

protects battery protects battery
from overcharge from overdischarge

Charge Load
PV Array DC Load
Controller Controller

Battery

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 Charge Controller Designs

Array switching:
Shunt type
Series type

Regulation algorithm:
On-off (interrupting)
Single- or multi-stage
Linear or constant-voltage
Pulse-width-modulated (PWM)
Array maximum power point tracking (MPPT)
Diversionary control

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 Shunt Charge Controller

Blocking Diode Load Switching Element

PV Regulation LVD DC
Array Control Control Load

Battery
Shunt Element

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 Shunt Charge Controller
Using Zener Diode

R1 D2

+
+ +
PV Load
D1 Battery

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 Series Type Controller

Series Element Load Switching Element

PV Regulation LVD DC
Array Control Control Load

Battery

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 PWM Charge Controllers

Increasing battery state-of-charge >>

Battery current >

Time >

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 Maximum Power Point Tracking
Charge Controllers

MPPT charge controllers operate

the PV array at maximum power,
independent of the battery
voltage.

Can improve array energy

utilization, and permit the use of
more efficient higher-voltage
arrays with lower battery system
voltages.

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 Diversionary Charge Control

This controller protects the battery when

the diversion load is unavailable

Charge
PV Array Battery
Controller

Diversionary controller protects the

battery from overcharge by diverting Diversion Diversion
power to a diversionary load Controller Load

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 Direct-Current
Diversionary Loads
PV systems with using diversionary charge control and DC
diversion loads must meet the following requirements
[690.72(B)(2)]:

The DC diversion load current must be no greater than the controller

maximum current rating.
The DC diversion load must have a voltage rating greater than the
maximum battery voltage.
The DC diversion load power rating must be rated at least 150 percent of
the maximum PV array power output.
The conductors and overcurrent protection for DC diversion load circuits
must be sized for at least 150 percent of controller maximum current
rating.

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 Interactive Inverters
Serving as Diversionary Loads
PV systems with using interactive inverters as diversionary loads
to control battery charging must have a second independent
charge control means to protect the battery if the inverter fails or
the grid becomes unavailable to divert power [690.72(B)(3)].

This controller protects the battery

when the grid is unavailable

Charge
PV Array Battery
Controller Power may flow in reverse
directions if inverter also
includes a battery charger

The inverter normally protects the

Interactive
battery from overcharge by Utility Grid
diverting power to the grid Inverter

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 Charge Controller Set Points
Set points are the battery voltage levels at which a charge
controller performs regulation or control functions, and are
critical parameters affecting battery life and system performance.

Charge regulation set points protect a battery from overcharge

and optimize charging.
Voltage regulation (VR)
Array reconnect voltage (ARV) only applies to interrupting controllers

Load control set points limit allowable battery depth-of-discharge

by disconnecting system loads.
Low voltage disconnection (LVD)
Load reconnect voltage (LVR)

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 Charge Controller Set Points

Voltage Regulation (VR)

Voltage Regulation Hysteresis (VRH)

Battery Voltage

Array Reconnect Voltage (ARV)

Load Reconnect Voltage (LRV)

Low Voltage Disconnect Hysteresis (LVDH)

Low Voltage Load Disconnect (LVD)

Charging Discharging

Time

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 Charge Regulation Setpoints

Battery Type
Regulator Charge Flooded Flooded Sealed, Flooded
Design Type Regulation Lead- Lead- Valve Pocket Plate
o
Voltage at 25 C Antimony Calcium Regulated Nickel-
Lead-Acid Cadmium

On-Off, Per nominal 12 14.6 - 14.8 14.2 - 14.4 14.2 - 14.4 14.5 - 15.0
Interrupting volt battery
Per Cell 2.44 - 2.47 2.37 - 2.40 2.37 - 2.40 1.45 - 1.50

Constant-Voltage, Per nominal 12 14.4 - 14.6 14.0 - 14.2 14.0 - 14.2 14.5 - 15.0
PWM, Linear volt battery
Per Cell 2.40 - 2.44 2.33 - 2.37 2.33 - 2.37 1.45 - 1.50

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 Load Disconnect Set Points

Low-voltage disconnect (LVD) set points are selected based on

the desired battery depth-of-discharge and discharge rates.

High discharge rates (current) will lower battery voltage by a

greater amount than lower discharge rates at the same battery
state-of-charge.

For a typical lead-acid cell, a LVD set point of 1.85 to 1.91 VPC
corresponds to a depth-of-discharge of 70 to 80% at discharge
rates C/20 and lower.

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 Equalizing Charge

Some charge controllers can

provide manual or automatic
equalizing charge functions.

Charge regulation voltage is

periodically increased for a
certain period of time to equalize
battery cells.

Equalizing charge is typically

performed on flooded, vented
batteries, and some types of
AGM batteries.

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 Set Point Adjustments
Means for charge controller adjustment must only be accessible
to qualified persons [690.72(A)].

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 Temperature Compensation

Temperature compensation adjusts charge regulation voltage

based on battery temperature.
Increases regulation voltage when battery is cold, improving ability to
charge battery.
Decreases regulation voltage when battery is warm, decreasing electrolyte
loss and battery overcharge.

The standard temperature compensation coefficient for lead-acid

cells is -5 mV/C.

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 Temperature Compensation Sensors

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 Temperature Compensation:
Example
A charge controller for a nominal 24-volt VRLA battery has a
regulation voltage of 28.2 volts at 25C. What should the charge
regulation voltage be if the battery operates at 0C?

Vcomp = Vset (Cvcell [25 Tbat ] ns )

= 28.2 (0.005 [25 Tbat ] 12)

Vcomp

Vcomp = 28.2 + 1.5 = 29.7 V

Conversely, if the battery temperature is 40C, the charge

regulation voltage will be reduced to 27.3 volts.

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 Shunt-Interrupting
Charge Controller
15 25
V bat, avg
Vbat, max
V bat, min
20
14 V bat, max

PV Array Voltage (V)

Vbat, avg
Battery Voltage (V)

V pv, avg
15

13
Vbat, min
10

12
5

Vpv, avg
11 0
4 8 12 16 20 24

Time of Da y (EST)

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 Series-Interrupting
Charge Controller
15 25
V bat, avg
V bat, min Vpv, avg
Vbat, max 20
14 V bat, max

PV Array Voltage (V)

Battery Voltage (V)

V pv, avg Vbat, avg

15

13

10
Vbat, min

12
5

11 0
4 8 12 16 20 24

Time of Da y (EST)

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 Series PWM
Charge Controller
15 25
V bat, avg Vbat, max
V bat, min Vbat, avg
20
14 V bat, max Vbat, min

PV Array Voltage (V)

Battery Voltage (V)

V pv, avg

15

13
Vpv, avg
10

12
5

11 0
4 8 12 16 20 24

Time of Da y (EST)

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 Three-Stage Charging

Bulk Stage Absorption Stage Float Stage

Increasing Bulk Charge -

Voltage Constant Voltage Float Voltage
Battery Voltage

Maximum
Charge Current

Reducing
Battery Current Absorption
Current
Float Current

Time

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 Multiple Charge Controllers

PV Subarray #1 Charge
Controller #1

PV Subarray #2 Charge Battery

Controller #2

PV Subarray #3 Charge
Controller #3

DC Load
PV Subarray #4

One subarray may be directly connected Note: No overdischarge

to battery without charge control if protection shown.
charge current x 1 hr is less than 3% of
battery capacity.

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 Battery Voltage Sensing
Battery voltage sense leads are available on some charge
controllers to counter the effects of voltage drop on charge
regulation set points.

Charge
Controller
Sense(+) Power(+) Power(-) Sense(-)

Positive(+) Negative(-)

Battery

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 Self-Regulating Systems
Self-regulating PV systems operate without charge battery
charge control. Certain design requirements help ensure that the
battery is neither overcharged nor overdischarged.

PV Array Battery DC Load

PV maximum charge Battery must be Load must be well-

current x 1 hour must be oversized in relation to defined, operate daily
less than 3% of the PV array charge rates and not subject to user
battery capacity. Lower and load energy. control.
voltage modules are
typically used for self-
regulating effect.

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 Self-Regulating Systems
Self-regulating PV systems use lower-voltage PV modules to
naturally limit the array current as battery voltage increases.

Battery voltage range

Isc
Imp High-Voltage Module:
Current remains high over
battery voltage range

Low-Voltage Module:
Current limits as battery
voltage increases

Voltage (V) Vmp Voc

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 Charge Controller Ratings

Electrical ratings for charge controller are used to properly

specify equipment and size circuits and include:

Nominal and maximum PV array and battery voltages.

Maximum and continuous PV array and load currents.

Charge controllers used in PV system must be listed to UL 1741.

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 Charge Controller Sizing
Conductors, overcurrent protection devices and other equipment
must normally be sized for at least 125% of the maximum PV
output circuit current, or 156% of the short-circuit current for the
PV output circuit [690.8].

For example, a PV array with rated short-circuit current of 16 A

requires a charge controller with at least a 24 A continuous rating
(16 A x 156%). The conductors in the PV output circuit must be
sized for at least 24 A after deratings for conditions of use have
been applied.

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 Summary

Charge controllers are used to protect batteries from overcharge

and may perform other system functions.

There are a variety of charge controller designs and regulation

methods.

Charge controller set points trigger functions such as charge

regulation or load control, and are key to maximizing battery
health and system performance.

Listed charge controllers are rated for certain electrical

parameters that are used to properly size the controller for
specific system applications.
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 Questions and Discussion

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