SOLAR CHARGE CONTROLLER SYSTEMS

If you have batteries in your system, you'll almost surely need a charge controller to prolong battery life. The only exceptions are very small systems using PV panels of 5 watts or less. Charge controllers sense the battery state of charge by monitoring its voltage. Lead-acid batteries gradually rise in voltage as they charge. But batteries are like buckets, you can only fit just so much into them. Overcharging will use excess water, and if severe, will cause physical battery damage. So a charge controller's primary duty is to limit, and eventually shut off input as the battery approaches full.

Controllers are rated by what voltage or voltages they can operate at, and by how many amps of current they can pass at maximum. Be sure your controller can handle the maximum rated amps of your array. Most controllers will sustain permanent damage (read crispy critter) if significantly over-amped for more than a few minutes.

Optional Charge Controller Duties

Beyond the basic duty of preventing overcharging, you'll find many controllers offering other bells and whistles, many of them very useful. The most common are:

• Voltage Indicators using simple LED lights, often red/yellow/green, that give a rough idea of the system state of charge.
• Volt or Amp readings using more sophisticated LCD displays that can show how many amps are flowing in or out through the controller.
• Load Terminals with automatic Low Voltage Disconnect to shut off all, or parts of the household power, if battery voltage gets too low. This isn't very nice to the users, but it's very nice for the batteries and their life expectancy. The more polite LVDs will blink the lights 5 minutes before shutoff to allow the user a chance to reduce power. Once triggered, LVD won't turn back on till the batteries get at least some modest charging.
• Lighting Controllers to automatically turn on lights at night. Often used for sign and security lighting. Can be set to run dusk to dawn, or for a certain number of hours. Triggered by sunset, not time, so seasonal adjustment is automatic.

Controller Operation, PWM Vs MPPT

There's a major change underway in how controllers operate. Standard controllers simply open and close the circuit between the PV array and the batteries, usually with a power transistor using PWM (pulse width modulation) control that switches hundreds of times per second. This pulls the PV voltage down to whatever voltage the battery is operating at. PV modules are designed to always make more voltage than the battery wants, because electrons only flow from higher to lower voltage. But if we could run the PV module at its Maximum Power Point, we could get more wattage out. This is what the new generation of MPPT controls do. They run your array at whatever voltage delivers the most wattage, with the excess voltage that would toast the batteries converted to amps the batteries can happily absorb. MPPT controllers typically extract about 15% more energy year round. They do their best work in winter, up to 30% boost, when PV temperatures are low, and battery voltages are generally lower. At this time, the OutBack MX60, Apollo Solar, and the BZ Products controllers are MPPT types, others are standard PWM.

Apollo solar

Apollo Solar is an experienced and highly skilled design and manufacturing organization committed to bringing innovative, reliable, and cost-effective power electronics technology to the customers of DC Power Systems. Apollo Solar has over 35 years of engineering expertise in providing industrial strength solutions and unique power management systems for NASA, the United States Government, the US military, as well as numerous Fortune 500 clients. Building on the proven success in designing and manufacturing sophisticated custom electronics based on robust thermal design, Apollo Solar is now developing new products that have innovative features, are more reliable especially in extreme temperatures, and are more efficient at harvesting power from any PV modules. These new products are now being integrated into the residential and commercial solar-energy systems supplied by DC Power Systems.

From decades of experience in designing products exactly as industrial clients specified, Apollo Solar learned how to listen carefully to the users and installers of energy systems when they state what they require and how they want to meet those requirements. The Apollo Solar product line is the direct result of listening to installers and end-users of inverters, charge controllers, and system monitoring capabilities. Solar installers and end-users now expect problem-free electronic equipment that is easy to install, that optimizes power production, and that offers advanced communication features. Apollo Solar is dedicated to meeting each and every one of those expectations.

Morningstar Corporation

Founded in 1993, is the world’s leading supplier of photovoltaic (PV) controllers. In 2007 Morningstar shipped over 200,000 controllers and inverters to the industry’s leading PV companies. Their products have set new standards in the industry for quality, high reliability and extended battery life.

Morningstar is an independent, privately owned U.S. corporation. Their commercial office is located near Philadelphia, and their engineering lab is based near Baltimore. Morningstar's products are manufactured in an ISO 9001 facility and are shipped to their customers worldwide from a warehouse in Los Angeles.
ADVANCED PWM Charging

The Key to Longer Battery Life:

• Typically 30% more solar energy into the battery per day
• Average battery State-of-Charge is 90 - 95% compared to 55 - 60% for other controllers
• Ability to recover lost battery capacity and desulfate a battery

Advantages

• The Best Overall Value – Combination of performance, features and competitive price results in the best controller and inverter value on the market.
• Extremely High Reliability – Failure rates of less than 1 per 1,000 units shipped.
• Outstanding Battery Charging – PWM charging can double the life of the battery and recover capacity in a sulfated battery. Series design (not shunt) reduces heating and stress on the electronic components.
• Highest Quality – Manufactured in a fully automated, world-class ISO 9001 factory. Quality control using the latest computerized test equipment.
• Electronic Protections – Fully protected against reverse polarity, short circuit, overcurrent, high temperature and reverse current at night. No mechanical fuses.
• Environmental Protections – Rated for ambient temperatures of –40°C to +60°C. Epoxy encapsulated or conformal coating to protect printed circuit boards from corrosion.
• No Need to Derate – Designed with a 25% safety margin, controllers and inverters may be used up to their full “nameplate” ratings.
• Expected 15 Year Life – 5-year warranty, with an expected operating life of 15 years or more. The Suresine inverter and SHS controller have a 2-year warranty.
• Easy to Use – Large clearly marked wire terminals, LED and meter displays, well-written manuals and timely technical support.
• Multiple Languages – Product documentation available in five languages: English, French, German, Portuguese and Spanish.

Mission Statement

To develop enduring relationships with our customers by providing innovative power conversion products supported by personal customer service.

About Samlex

Samlex America has manufactured and distributed power supply products to more than 90 countries worldwide since 1991. Innovative product designs, strict quality control, and responsible after sales service provide customers with high quality power conversion products at extremely competitive prices.

OEM services are available to companies that require high quality, low cost alternatives to manufacturing finished goods in their own facilities. Samlex can assist in all areas of product development from initial design to final assembly and packaging. You will work directly with our OEM team and develop a plan to have your product manufactured to your precise specifications or to develop cost saving strategies by modifying your existing product for mass production in one of our assembly factories.

BZ Products

MPPT 250
25 Amp MPPT Current Boosting Solar Charge Control

The MPPT 250 is a fully automatic, current boosting, 25 amp solar control. The MPPT 250 incorporates an advanced microprocessor design that brings outstanding performance and many new features to the medium power systems.

Solar inputs of up to 50 volts may be used to charge a 12 volt battery. With the MPPT 250, up to 30% current boost is possible. It is ideal for campers, recreational vehicles and small cabin systems. The solar charger control provides up to 250 watt solar input.

Standard Features

• Current boosting
• Digital volt and amp meter
• 12 volt operation
• 25 amp charge current
• PWM float control
• Fully automatic operation
• Easy installation
• Low voltage disconnect
• Five-year warranty
• Auxiliary battery charger included
• Flush mount
• Battery temperature sensor standard

MX60
MPPT Charge Controller

The OutBack MX60 Maximum Power Point Tracking (MPPT) charge controller enables your PV system to achieve its highest possible performance.

Rated for up to 60 amps of DC output current, the OutBack MX60 can be used with battery systems from 12 to 60 VDC with PV open circuit voltage as high as125 VDC. The MX60's setpoints are fully adjustable to allow use with virtually any battery type, chemistry and charging profile.

The OutBack MX60 allows you to use a higher output voltage PV array with a lower voltage battery - such as charging a 24 VDC battery with a 48 VDC PV array. This reduces wire size and power loss from the PV array to the battery/inverter location and can maximize the performance of your PV system.

The OutBack MX60 comes standard with an easy to use and understand display of the PV system’s performance. The four line, 80 character, backlit LCD display is also used for programming and monitoring of the system’s operation.

The OutBack MX60 can also be connected to the OutBack MATE system controller and display to allow monitoring of up to eight MX60 controllers froma distant location - up to 300 feet away. The MATE also includes an opto-isolated RS232 port for connection to a PC computer for data logging and system monitoring.
Specifications

• Output Current Rating: 60 amps DC maximum at 12,24 or 48 VDC
• Nominal Battery Voltage: 12, 24, 32, 36, 48, 54 or 60 VDC (programmable)
• PV Open Circuit Voltage: 125 VDC maximum
• Standby Power Consumption: Less than 1 watt typical
• Charging Regulation Methods: Five Stage: Bulk, Absorption, Float, Silent, Equalization
• Voltage Regulation Setpoints: 13 - 80 VDC
• Equalization Voltage: Adjustable 1.0 to 5.0 VDC above bulk setpoint
• Temperature Compensation: Programmable slope -2.0mV/oC/cell to -5.0mV/oC/cell
• Voltage Step-Down Capability: Can charge a 12 or 24 VDC battery from a 48V nominal PV array
• Power Conversion Efficiency: 99.1% @ 40 amps output / 97.3% @ 60 amps output
• Digital Display: 4 line 80 character backlit LCD display
• Remote Interface: RJ 45 modular connector CAT5 cable 8 wire
• Operating Temperature Range: -40 to 60oC power derated above 25oC
• Environmental Rating: Indoor Type 1
• Conduit Knockouts: Two 3/4 - 1” on the back; One 1” - 1 1/2 “ on each side; Two 1” - 1 1/2” on the bottom
• Warranty: Two years parts and labor; optional extended warranty
• Dimensions: Enclosure - 14.5 “ H x 5.75” W x 5.75” D / Shipping box - 17.75” H x 10” W x 7” D
• Shipping Weight: 12 lbs. - 5.4 kg

Specifications subject to change without notice