SOLAR PV TECHNICIAN’S

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Module 7: Charge Controller

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Charge Controller
Always obtain data sheet.
 Functions of Charge Controller No datasheet, Poor quality

 Types of Charge Controller

 Methods of Charging Controll
 Set point voltage
 Connecting sequence
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Functions of Charge Controller

– Charge Controller (C/C) protects batteries from

Overcharging and Over discharging
− Overcharge: C/C disconnects the PV module
− Over Discharge: C/C disconnects the Load

– Charge controller does NOT regulate current and voltage.

− C/C is only a switching device

– Charge Controller does NOT protect the battery from overuse.

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Functions of Charge Controller

Overcharge Protection
Charging Charging stopped
(Switch A is ON) (Switch A is OFF)

Charge Controller Charge Controller

A A
PV PV
Modul Charging
Modul Charging
stopped
e e
Full

Battery Battery
Empty
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Functions of Charge Controller

Over discharge Protection

Discharging Discharging stopped
(Switch B is ON) (Switch B is OFF)

Charge Controller Charge Controller

B
B
Load Load
Discharging Discharging
stopped

Full
Battery Battery
Before
empty
Empty
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Types of Charge Controller

 Two types of over charge protection :
 Series Type : PV is disconnected as Open
 Shunt Type : PV is disconnected as Shorted

Series type : PV is Open Shunt type : PV is Shorted

Charge Controller Charge Controller

Control Circuit Control Circuit

Over charge Over Over

protection discharge Over discharge
protection charge protection
A1 B protection B

PV PV
Loa A2 Loa
Module Module
d d

Battery Battery
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Functions of Charge Controller

 Function of Charge controller
– Charge controller protects batteries from Overcharging and Over discharging
– Charge controller does NOT regulate current and voltage.
 Over charge protection :
– Sense battery voltage
– When battery voltage is high (fully charged, ~14.1-14.4V : High Voltage
Disconnect, HVD, applicable only for ON/OFF Charge Controller)
 Charge Controller automatically disconnects the PV module from battery
( Stops Charging )

– While battery voltage is not high (not fully charged, below 13.5V : High Voltage
Reconnect, HVR, applicable only for ON/OFF Charge Controller)
 Always connect PV module to battery ( Normal status for charging)
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Methods of Charging Control

 There are two methods of charging control.
– On-Off method
– PWM (Pulse Width Modulation) method
 Most of new charge controllers use PWM.

Types of Charge
Charging Method Discharging Method
Controller
Series Type (On-Off) On-Off On-Off

Series Type (PWM) PWM On-Off

Shunt Type (On-Off) On-Off On-Off

Shunt Type (PWM) PWM On-Off

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Charging Control (On – Off)

 Over charge Protection
– When Battery voltage reached to the final voltage , PV is disconnected (High Voltage Disconnect)
– When Battery voltage decreased to the reconnect voltage, PV is reconnected (High Voltage
Reconnect)
– Interval is in minutes
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Charging Control (PWM)

 Over charge Protection

– When Battery voltage reached to close the float voltage , PV is disconnected and
connected by pulse width, by interval of milliseconds.
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Discharging Control
 Under normal operation, LVD is not triggered except if system is
overused or at the end of battery life
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Additional functions
PWM charge controller has additional functions
to prolong battery life and for efficient charging.
 Boost charging mode
– Boost charging mode is triggered automatically (low battery
voltage, after several charging cycles, etc.). Once boost charging
is completed, it will automatically back to its normal charging
mode.
 Equalize charging mode
– To equalize cell voltages, high voltage is implied. This mode is
triggered automatically (low battery voltage, after several charging
cycles, etc.). Once boost charging is completed, it will
automatically back to its normal charging mode
– Do NOT use this function for sealed (maintenance free) battery
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Boost Charging Mode

Example of boost charging mode
15.0
14.8 Boost charging (14.4V) for 2hours
14.6 → Then exit Boost charging mode
14.4
14.2
14.0
13.8
13.6
13.4
13.2
13.0
Battery Voltage (V)

12.8
12.6
Trigger voltage (12.6V)
12.4 for boost charging mode
12.2
12.0 Weather condition is not good or
11.8 energy is consumed more than instructed Battery voltage reached trigger voltage
11.6 → Entering Boost charging mode
11.4
11.2
11.0
0 3 6 9 12 15 18 21 0 3 6 9 12 15 18 21 0 3 6 9 12 15 18 21
Time (hrs)
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Set point voltages

 Set point voltages slightly differs for each model
– Choose charge controller with the right set point voltages
according to battery type.
 Temperature compensation is necessary (built-in)
– Approx. -3mV to -5mV / ºC per cell
– Approx. -0.18V at 12V battery when 10 ºC increased
Set point voltages for over discharge protection
Types of battery LVD LVR
Automotive type 11.6V – 11.7V 12.4V – 12.5V
Industrial type (factory setting) 11.3V – 11.5V 12.4V – 12.5V

On-Off charging PWM charging

Types of battery
HVD HVR Float Boost Equalize
Flooded type (factory
14.3V – 14.4V 13.0V – 13.5V 13.8V – 13.9V 14.4V – 14.7V 14.8V – 14.9V
setting)
Maintenance Free type 14.0V – 14.2V 13.0V – 13.5V 13.4V – 13.6V 14.2V – 14.4V disabled
Values are @ 20 ºC, reference
ONLY
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Set Points Voltages

 Set point voltages for HEP Charge Controller

 Temperature Compensation is -4mV/ ºC

PWM charging
Types of battery
LVD LVR Float Boost HVD
Flooded type (factory
N/A N/A N/A N/A N/A
setting)
Maintenance Free type
11.5 V 12.6 V 13.7 V 14.4V disabled
(Industrial/Deep Cycle)

Values are @ 20 ºC, reference

ONLY
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Connecting Sequence
 Connecting / Disconnecting cables to C/C
Connect Battery First, Disconnect Battery Last

Connecting Sequence Disconnecting Sequence

Battery PV Load Load PV Battery

First Last

If battery is not connected,

high voltage (18-21V) of PV
module may damage
Load (Max input is ~14.5V)
PV Load

Battery
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Additional Function
Some charge controllers have additional function
to prolong battery life and efficient charging
 Boost charging mode
– To equalize cell voltage, high HVD setting By changing HVD,
– Boost charging mode is triggered automatically (low battery
voltage, after several charging cycles, etc.). Once boost charging
is completed, it will automatically back to its normal charging
mode.
– Do NOT use this function for sealed (maintenance free) battery
END OF MODULE 7:
Charge Controller