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electrical:solar:charge_controller [2019/05/11 21:10]
frater_secessus [how to choose]
electrical:solar:charge_controller [2024/02/16 23:32] (current)
frater_secessus [how to choose] added video
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 [[lifestyle:words_of_wisdom|Words of wisdom]]:  //"Any Solar is better than no solar, but having too much solar is difficult. The best solar systems are those which can keep the batteries the happiest.  Happy batteries are those which are recharged quickly after depletion."//((http://www.cheaprvliving.com/forums/Thread-Should-I?pid=88971#pid88971)) - SternWake [[lifestyle:words_of_wisdom|Words of wisdom]]:  //"Any Solar is better than no solar, but having too much solar is difficult. The best solar systems are those which can keep the batteries the happiest.  Happy batteries are those which are recharged quickly after depletion."//((http://www.cheaprvliving.com/forums/Thread-Should-I?pid=88971#pid88971)) - SternWake
 +====== Solar charge controllers ======
  
 +===== TLDR =====
  
-====== Solar charge controllers ======+  * solar panels -> solar charge controller (SCC) -> battery bank 
 +  * the SCC's main job is preventing //battery overcharge// 
 +  * The two main types of SCC are PWM and MPPT 
 +    * PWM - Cheaper, less efficient 
 +    * MPPT - More expensive, but more efficient 
 +  * SCC LOAD outputs are vestigial features but may be useful for triggering certain loads
  
-A solar charge controller (CC) regulates the [[electrical:12v:charging|charging]] of a [[electrical:12v:deep cycle battery|battery bank]] from the [[electrical:solar:panels|solar panels]]. 
  
-Counterintuitively, the primary job of the charge controller (CC) is to keep the batteries from being //over//charged.  Solar panels run at higher voltages than batteries, often at voltages high enough to damage the batteries.  The CC provides the correct amount of power the battery needs at the correct time;  this is called [[electrical:12v:charging|smart or three stage charging]].+[[opinion:frater_secessus:pareto|about this summary]]
  
-Charge controllers are generally **rated by the amount of output they can provide**. This output is shared by charging circuits and [[#using_load_output|LOAD circuits]].  For example, a 20A controller might be using 18A for charging and have 2A available for LOAD. 
  
 +==== overview ====
 +
 +
 +
 +A solar charge controller (CC) regulates the [[electrical:12v:charging|charging]] of a [[electrical:12v:deep cycle battery|battery bank]] from the [[electrical:solar:panels|solar panels]].
 +Counterintuitively, the primary job of the charge controller (CC) is to keep the batteries from being //over//charged.  Solar panels run at higher voltages than batteries, often at voltages high enough to damage the batteries.  The CC provides the correct amount of power the battery needs at the correct time;  this is called [[electrical:12v:charging|smart or three stage charging]].
 +Charge controllers are generally **rated by the amount of output they can provide**. This output is shared by charging circuits and [[#using_load_output|LOAD circuits]].  For example, a 20A controller might be using 18A for charging and have 2A available for LOAD.
 Controllers operate based on [[electrical:solar:charge_controller_setpoints|factory- or user-defined setpoints]] (values) stored internally. Controllers operate based on [[electrical:solar:charge_controller_setpoints|factory- or user-defined setpoints]] (values) stored internally.
-===== types of charge controllers ===== 
  
 +Cautionary example:  [[https://www.youtube.com/watch?v=z5RtZe9AW2E|12W Unregulated Panel vs. 220Ah AGM Bank]]
 +===== specs =====
 +
 +Regardless of type, controllers will have several specifications in common. 
 +
 +  * **rating (or "size")** - this is usually the maximum output in A (amps) the controller can produce (charging + loads).((for technical reasons with PWM this will also be the *input* current limit))
 +  * **12v/24v/48v** - this refers to the nominal voltage of the battery bank it will be charging. 
 +  * **Maximum input voltage** - the highest voltage the controller should //ever// see from the solar array.((it is common to leave ~20% margin))  NOTE: a 50v input max does //not// mean a PWM controller can make efficient use of mismatched panel/battery voltages; that requires MPPT.  See [[#how_to_choose|how to choose]] below.
 +
 +
 +
 +===== Types of charge controllers =====
 [note from frater secessus: PWM vs. MPPT debates can get overheated in forums and comments. It's your money and your build so do it the way that meets your needs.] [note from frater secessus: PWM vs. MPPT debates can get overheated in forums and comments. It's your money and your build so do it the way that meets your needs.]
-==== PWM ==== 
-[[http://amzn.to/2hcZaj2|{{ https://images-na.ssl-images-amazon.com/images/I/41pwJOriZHL._AC_US160_.jpg}}]]**PWM** (pulse width modulation) controllers charge by connecting panels to battery until a given voltage setpoint is reached.  When the desired setpoint is reached the controller shuts current on/off to the battery in very fast cycles and in such a duration needed to keep voltage from rising. Excess power is given off as heat. This time slicing power delivery is called is pulse width modulation, or PWM. 
  
-[[http://www.electronics-tutorials.ws/blog/pulse-width-modulation.html|{{ http://www.electronics-tutorials.ws/articles/pwm2.gif }}]]+=== The quick and dirty === 
  
-This runs the panels at((or very close to)) battery voltage (Vbatt).  Vbatt is usually much lower than the panels' Vmp((unless the panels are very hot)) and so PWM generally cannot capture the panels' maximum available power((adjusted for temperature, insolation, etc)) under typical conditions.  A side effect of this is the PWM controller will have **highest power output when Vbatt is highest**: Absorption (Vabs) and Float (Vfloat) Setpoints can be tweaked for longer duration Absorption and higher Vfloat to [[electrical:solar:pwm tweaking|maximize power output of a PWM controller]].+**PWM** is much less expensive, and typically makes less power over the course of the dayPanel voltage and battery bank voltage need to be matched
  
 +**MPPT** is more expensive and but typically makes more power, especially when battery voltage is low.   Panel voltage and battery bank voltage can diverge. 
 +
 +The more power / less power dynamic is highly dependent on the setup and use case; there are no definite answers about which is right for you.  For example, there are edge scenarios where PWM can make more power than MPPT.((like high ambient temps + low Vmp panels))
 +
 +
 +==== PWM ====
 +[[http://amzn.to/2hcZaj2|{{ https://images-na.ssl-images-amazon.com/images/I/41pwJOriZHL._AC_US160_.jpg}}]]**PWM** (pulse width modulation) controllers charge by connecting panels to battery until a given voltage setpoint is reached.  When the desired setpoint is reached the controller switches current on/off to the battery in very fast cycles and in such a duration needed to keep voltage from rising.  This time slicing power delivery is called is pulse width modulation, or PWM.  Some heat will be generated by the switching. Counterintuitively, the PWM may be cooler the touch when it is running full open because there is no switching going on to limit voltage.
 +[[http://www.electronics-tutorials.ws/blog/pulse-width-modulation.html|{{ http://www.electronics-tutorials.ws/articles/pwm2.gif }}]]
 +This runs the panels at((or very close to)) battery voltage (Vbatt).  Vbatt is usually much lower than the panels' Vmp((unless the panels are very hot)) and so PWM generally cannot capture the panels' maximum available power((adjusted for temperature, insolation, etc)) under typical conditions.  A side effect of this is the PWM controller will have **highest power output when Vbatt is highest**: Absorption (Vabs) and Float (Vfloat).  Setpoints can be tweaked for longer duration Absorption and higher Vfloat to [[electrical:solar:pwm tweaking|maximize power output of a PWM controller]].
 PWM controllers are **simple, inexpensive, and sufficient** for many uses, particularly if ambient temperatures are fairly high, paneling is ample, and batteries are not [[electrical:depth_of_discharge|deeply cycled]]. PWM controllers are **simple, inexpensive, and sufficient** for many uses, particularly if ambient temperatures are fairly high, paneling is ample, and batteries are not [[electrical:depth_of_discharge|deeply cycled]].
 +
 +Note that there are some simple PWM controllers like Morningstar's [[https://amzn.to/3lvk0Ze|SunGuard]] that [[electrical:12v:eternal_absorption|run at a single voltage]].
 +
 +[[https://diysolarforum.com/threads/why-is-mppt-better-than-pwm.24892/post-295861|For technical reasons]] PWM can deliver more current than the panels' Imp, even nearing Isc.
 +
 +=== panel selection for PWM ===
 +
 +PWM makes the most power when coupled with panels whose operating [[electrical:solar:panels#specifications|Vmp]] is very close to the controller's Absorption ("boost") voltage [[electrical:solar:charge_controller_setpoints|setpoint]].  Since [[electrical:solar:output#panel_temperature|ambient temperatures affect operating Vmp]] the panel's Vmp spec on the label should be about 10% higher than Absorption voltage.  
 +
 +Examples:
 +
 +  * 16.28v Vmp panel spec would be optimal for 14.8v Absorption, as we might use for flooded lead acid.  14.8v x 1.1 = 16.28v.
 +  * 15.62v Vmp panel spec would be optimal for 14.2v Absorption, as we might use for Gel or LiFePO4.  
 +
 +
 +Some [[electrical:solar:panels#thin_film|thin-film]] panels have Vmp in that range but most panels are much higher.  So we find the lowest Vmp practical.  17Vmp panels would perform better on PWM than 18v or 19v.
 ==== MPPT ==== ==== MPPT ====
 [[http://amzn.to/2iD3WKf|{{ https://images-na.ssl-images-amazon.com/images/I/51bi9IjcsRL._AC_US160_.jpg}}]] [[http://amzn.to/2iD3WKf|{{ https://images-na.ssl-images-amazon.com/images/I/51bi9IjcsRL._AC_US160_.jpg}}]]
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   - discover (track) and utilize various power points along [[http://samlexsolar.com/learning-center/solar-panels-characteristics.aspx|the panel's power curve]].  Sometimes this is the maximum power point (MPP);  often in a 'dweller context the system needs less power and the controller runs the panels at some other power point.  It might be more accurate to call them PPT controllers.      - discover (track) and utilize various power points along [[http://samlexsolar.com/learning-center/solar-panels-characteristics.aspx|the panel's power curve]].  Sometimes this is the maximum power point (MPP);  often in a 'dweller context the system needs less power and the controller runs the panels at some other power point.  It might be more accurate to call them PPT controllers.   
-  - DC-DC downconvert excess voltage to amps +  - DC-DC downconvert excess voltage to amps - this is possible because MPPT decouples panel voltage (Vpanel) from charging voltage (Vbatt) 
 +   
 When maximum power is required((in Bulk or at other time when loads + charging >= panel output)) the controller will run the panels at Vmp (the maximum power point).   At other times the controller will find a less-than-maximum power point to match panel output to system needs. When maximum power is required((in Bulk or at other time when loads + charging >= panel output)) the controller will run the panels at Vmp (the maximum power point).   At other times the controller will find a less-than-maximum power point to match panel output to system needs.
- 
 [[http://amzn.to/2yP01Ob|{{https://images-na.ssl-images-amazon.com/images/I/512x3hbc6jL._AC_US160_.jpg }}]] [[http://amzn.to/2yP01Ob|{{https://images-na.ssl-images-amazon.com/images/I/512x3hbc6jL._AC_US160_.jpg }}]]
-Since panel voltage at a given power point is usually too high for system needs((particularly with higher than nominal 12v panels )) the controller performs a DC-DC conversion to bring the voltage down to a directly usable level.  Because **current through a conductor is directly proportional to voltage**((https://en.wikipedia.org/wiki/Ohm%27s_law)) this downconversion effectively turns excess voltage into increased amps.(minus conversion losses).   
  
-This ability to decouple panel and bank voltage can result in 10%-30% more power harvested from 12v nominal panels than with a PWM controller.  Marketers like to call this "boost" or "gains" but it really just full capture of whatever power the panel[s] can provide under given conditions.+Since panel voltage at a given power point is usually too  
 +high for system needs((particularly with higher than nominal 12v panels )) the controller performs a DC-DC conversion to bring the voltage down to a directly usable level.  Because **current through a conductor is directly proportional to voltage**((https://en.wikipedia.org/wiki/Ohm%27s_law)) this downconversion effectively turns excess voltage into increased amps.(minus conversion losses).   
 + 
 +This ability to decouple panel and bank voltage can result in 10%-30% more power harvested from 12v nominal panels than with a PWM controller, depending on conditions.  //Average// daily production with MPPT is typically ~+15%((https://web.archive.org/web/20221012213623/https://www.redalyc.org/journal/849/84959429001/html/)), which may or may not justify the added cost on its own  
  
  
 === "boost" effect === === "boost" effect ===
 {{ https://media.licdn.com/mpr/mpr/AAEAAQAAAAAAAAwtAAAAJGJhNjE1OGY3LTM3OWQtNGQ2Mi05NWEwLTI2Mzc3MGY3MDk3MA.png?150}}When compared apples-to-apples on identical systems with //only the controller being different//, the "boost" effect is most pronounced:   {{ https://media.licdn.com/mpr/mpr/AAEAAQAAAAAAAAwtAAAAJGJhNjE1OGY3LTM3OWQtNGQ2Mi05NWEwLTI2Mzc3MGY3MDk3MA.png?150}}When compared apples-to-apples on identical systems with //only the controller being different//, the "boost" effect is most pronounced:  
- 
   * during bulk stage and the early part of absorption stage when the battery can take in the most power   * during bulk stage and the early part of absorption stage when the battery can take in the most power
 +  * anytime the system is fully loaded down (charging and/or loads)
   * when the battery is most depleted (ie lowest resting voltage).  This is the result of a cascade of factors:   * when the battery is most depleted (ie lowest resting voltage).  This is the result of a cascade of factors:
-    * When a battery is deeply discharged it will go into Bulk charging mode until it reaches the Absorption voltage (Vabs).  For the purpose of illustration we will assume the bank is depleted to 12.2v (~50% [[electrical:depth_of_discharge|state of charge]]), a commonly recommended lower limit for deep cycle batteries. +      * When a battery is deeply discharged it will go into Bulk charging mode until it reaches the Absorption voltage (Vabs).  For the purpose of illustration we will assume the bank is depleted to 12.2v (~50% [[electrical:depth_of_discharge|state of charge]]), a commonly recommended lower limit for deep cycle batteries. 
-    * PWM controllers can only run the panel at whatever voltage they are charging at right now.  In our example that is 12.2v. +      * PWM controllers can only run the panel at whatever voltage they are charging at right now.  In our example that is 12.2v. 
-    * Nominal 12v panels usually have max power output (Vmp) around 17v.((https://www.altestore.com/howto/solar-panels-pv-and-voltages-a98/)) +      * Nominal 12v panels usually have max power output (Vmp) around 17v.((https://www.altestore.com/howto/solar-panels-pv-and-voltages-a98/)) 
-    * when a typical 100w panel((Iop = 5.6A)) is run at 12.2v in lab conditions it puts out **~68.32W**. The same panel run at Vmp (~17v) would put out **100W**.  **MPPT is capturing more power than the PWM when the battery needs it most**.((there are minor inefficiencies not considered here))+      * when a typical 100w panel((Iop = 5.6A)) is run at 12.2v in lab conditions it puts out **~68.32W**. The same panel run at Vmp (~17v) would put out **100W**.  **MPPT is capturing more power than the PWM when the battery needs it most**.((there are minor inefficiencies not considered here))
   * during times of greatest PV efficiency((i.e. highest voltage)) (clear, cold weather)   * during times of greatest PV efficiency((i.e. highest voltage)) (clear, cold weather)
-  * during times of low irradience (low light levels due to low angle or overcast conditions)((this is a function of higher input voltages))((https://www.victronenergy.com/upload/documents/White-paper-Which-solar-charge-controller-PWM-or-MPPT.pdf Section 7.3)) +  * during times of low irradience (low light levels due to low angle or overcast conditions)((this is a function of higher input voltages)),((https://www.victronenergy.com/upload/documents/White-paper-Which-solar-charge-controller-PWM-or-MPPT.pdf Section 7.3)) 
 +   
 There are some considerations when [[electrical:solar:mppt design|designing a system around an MPPT controller]]. There are some considerations when [[electrical:solar:mppt design|designing a system around an MPPT controller]].
 +
 +== panel selection for MPPT ==
 +
 +MPPT thrives on voltage.  In general, we should select panels that have the highest-practical Vmp while staying safely under the controller's voltage input limit.   MPPT efficiency tends to be greatest when panel voltage is ~twice the charging voltage. The exact ratio varies by controller so read the docs for specifics.  
 +
 +Note that [[electrical:solar:series_vs_parallel|panels can be run in series]] to increase their voltage. 
 +
 +
 +== when PWM beats MPPT ==
 +
 +There are edge cases where an optimal PWM setup can make //more// power than MPPT for a time.  This can happen because MPPT has DC-DC losses that PWM does not, typically ~5%.  Since MPPT harvest from the panel is typically 10-30% greater than PWM the DC-DC losses are hidden.  
 +
 +But when PWM controllers and panels are optimally matched (difference between panel Vmp((actual, not spec)) and Absorption(("boost")) voltage is <5%) then PWM will make a bit more power during Absorption.  
 +
 +
 +
 +
 +
  
 ==== shunt  ==== ==== shunt  ====
 +
 +see article below
 +
 +
 +==== single-stage chargers ====
 +
 [[http://amzn.to/2yQppTX|{{ https://images-na.ssl-images-amazon.com/images/I/41Gwyw0BT5L._AC_US160_.jpg}}]] [[http://amzn.to/2yQppTX|{{ https://images-na.ssl-images-amazon.com/images/I/41Gwyw0BT5L._AC_US160_.jpg}}]]
-Shunt controllers are very simple devices that charge to given voltage [[electrical:solar:charge_controller_setpoints|setpoint]] (Vdisconnect) then stop charging.  If/when voltage falls to some lower voltage (Vreconnectcharging begins again.  This is sometimes called [[electrical:12v:charging#charge-and-stop|charge and stop charging]] or on/off charging.+Single-stage chargers hold the bank at a [[electrical:solar:charge_controller_setpoints|setpoint]] (Vdisconnect)((whether generally or exactly)) as long as sufficient solar harvest is present.  When the setpoint voltage is achieved the controller current is turned off for some amount of time.((In a hydro or windpower scenario the power cannot be turned off and is diverted (shunted) instead to a diversion load like water heating, water pumping, etc.)) There are several different ways of turning off the current:
  
-> ...PWM [and] shunt controllers apply full panel voltage, or something close to it, across the battery terminals, at duty cycle (fast for PWM, slow for shuntthat keeps the battery happy, and the controller monitors the battery voltage and then adjusts the PWM duty cycle accordinglyor in the case of a shunt, it clamps the panel output. -- Tx2Sturgis((http://www.cheaprvliving.com/forums/showthread.php?tid=29896&pid=373640#pid373640))+  * PWM - open circuit the panels very rapidly (tens-to-thousands times second)and for varying lengths of time to hold the voltage setpoint more precisely.  Same as PWM controllers abovebut in this market range the modulation tends to be cruder/slower and there is only one charging voltage setpoint. 
 +  * shunt - shorts the panels ON/OFF (charge-and-stopless common)  
 +  * series - open circuits the panels ON/OFF (charge-and-stop, less common)
  
 +Simple versions use simple electronics((as with [[https://www.flexcharge.com|Flexcharge]])) or relays to turn charging on until Vdisconnect is reached, at which point charging is turned off off. If/when voltage falls to some lower voltage (Vreconnect) charging begins again.  This is sometimes called [[electrical:12v:charging#charge-and-stop|charge and stop charging]] or on/off charging.  Voltage tends to wander a bit as the charging stops and starts.  They are often used where extreme simplicity/robustness is required, or where more complex electronics might cause electrical interference.((as in a ham shack))
  
 +More complex shunts use electronic components((like FETs)) to hold the single voltage setpoint with finer accuracy, dissipating switching heat through the backplate or other heatsink.  The difference is mainly one of time and therefore stability of the setpoint;  a relay shunt might go ON/OFF 1x/second every few seconds if the loads were neatly balanced with solar harvest.  The electronic shunt might switch power tens, hundreds or thousands of times each second and may be PWM or quasi-PWM. It would take an oscilloscope to know for sure what's happening under the hood.  
  
 +For the purposes of this discussion the two types will be grouped together. 
  
-They may be hardcoded with setpoints or allow user configuration. If configurable, you can get better results by [[electrical:solar:shunt tweaking|choosing setpoints to fit your situation]].+ 
 +> ...PWM [and] shunt controllers apply full panel voltage, or something close to it, across the battery terminals, at a duty cycle (fast for PWM, slow for shunt) that keeps the battery happy, and the controller monitors the battery voltage and then adjusts the PWM duty cycle accordingly, or in the case of a [relay-based] shunt, it clamps the panel output. -- Tx2Sturgis((http://www.cheaprvliving.com/forums/showthread.php?tid=29896&pid=373640#pid373640)) 
 + 
 + 
 + 
 +They may be hardcoded with setpoints or allow user configuration. If configurable, you can get better results by [[electrical:solar:shunt tweaking|choosing setpoints to fit your situation]].  Usually on cheap shunts there is one setpoint, which we can think of as the absorption voltage (Vabs).  Holding Vabs as long as the sun shines might seem weird but to quote Sternwake again: 
 + 
 +> If your charge controller only holds [absorption] voltage for an hour or two, that is likely not enough time. As long as [there is a load] and you cycle the battery daily, you could set float voltage to 14.8v [to match absorption] without worry. Only when you stop cycling the battery do you need to return float voltage to more regular 13.2v levels. Premature application of float voltage by automatic charging sources is a battery killer.((http://www.cheaprvliving.com/forums/Thread-Solar-or-Battery-Problem?pid=229883#pid229883)) 
 + 
 +Also see [[https://goughlui.com/2020/06/05/teardown-tested-generic-kw12x0-w88-solar-charge-controller-10-30a-versions/|this comprehensive teardown]] that assesses: 
 + 
 +> ....a rather inexpensive piece of equipment but it doesn’t do a terrible job of being a basic solar charge controller. On the whole, it behaves as one may expect – protecting the battery from excessive voltage and overdischarge, with an integrated dusk timer function and USB outputs...what do you expect for $10-20? Something that works is already a big surprise to me. 
 + 
 +=== with Bnn settings === 
 + 
 +Units with Bnn settings purport to have Absorption((which they often call Equalization)) profiles for various batteries and configurable Float setpoints.  
 + 
 +  * B01 - Sealed lead acid (AGM), typically 14.4v 
 +  * B02 - Gel, typically 14.2v 
 +  * B03 - flooded lead acid, typically 14.6v 
 +  * B04 - 4S LiFePO4 <-- like [[electrical:12v:drop-in_lifepo4|drop-in LFP]] 
 +  * B05 - 5S LiFePO4 (uncommon) 
 +  * B06 - 3S Li-NMC 
 +  * B07 - 4S Li-NMC 
 + 
 +Absorption duration is unknown. 
 + 
 +Example manual for controller with [[https://www.botnroll.com/img/cms/FAL09014-Solar-PWM-10A-USB-Manual.pdf|B01-B03]] and [[https://www.solorder.se/image/data/uploads/KLD1210.pdf|B01-B07]]. 
 + 
 + 
 +Further viewing: 
 + 
 + 
 +  * [[https://www.youtube.com/watch?v=Fmfnxkh1IFo|basic setup]] by Scott 
 +  * [[https://www.youtube.com/watch?v=v-iLu9DS558|setting up the LOAD functions]] by Scott 
 + 
 +==== USB converters ==== 
 +[[https://amzn.to/3msdCUU|{{ https://m.media-amazon.com/images/I/71EmsM+loWL._AC_SY200_.jpg?50}}]]  
 +These aren't controllers in the normal sense, but there are [[https://amzn.to/3msdCUU|modules]] that connect to your panel's MC4 connectors and output USB power.   
 + 
 +If you only need 5v USB power up to 2.5A per port this may be a workable solution
  
 ==== DDCCC ==== ==== DDCCC ====
 [note:  this is a placeholder for a possible new entry.] [note:  this is a placeholder for a possible new entry.]
- 
 There are //DC-DC converting charge controllers// (DDCCC) appearing on the market that claim to be MPPT but do not actually track power points (maximum or otherwise).  They do downconvert some excess voltage into amperage.  See [[https://boondockplan.wordpress.com/2017/12/15/backchannel-dc-dc-converting-charge-controllers/|this blog post]]. There are //DC-DC converting charge controllers// (DDCCC) appearing on the market that claim to be MPPT but do not actually track power points (maximum or otherwise).  They do downconvert some excess voltage into amperage.  See [[https://boondockplan.wordpress.com/2017/12/15/backchannel-dc-dc-converting-charge-controllers/|this blog post]].
-==== how to choose ==== 
  
-**PWM is the default choice** in most situations because they get the job done in most scenarios and are inexpensive. PWM controllers can cost half or a third of their MPPT workmates for any given rated output.((10A, 20A, 40A, etc)) 
  
-If more power is needed (and there is physical space) additional PV can be added to match the charging output of an MPPT charger, often at a lower cost.  [There are no prizes for fanciest or most expensive charge controller!  Do what is best for you -- frater secessus]+==== boosting ====
  
-MPPT controllers also tend to consume more power to run themselves than PWM models due to additional processing and electronic components.+Most charge controllers that convert voltage do it by //bucking// (reducing) panel voltage down to the appropriate charging voltages.((normal PWM don't reduce/convert voltage in the normal sense;  they run the panels ~at bank voltage))
  
-**MPPT may be better fit** when:+//Boosting// (voltage-increasing) controllers do exist ([[https://amzn.to/3Rh6QSu|example]]) but they are niche products.  In most cases it makes more sense to increase panel voltage with serial wiring.  
 +==== how to choose ==== 
 +**PWM is reasonable default choice** in typical scenarios((12v house power, 12v panels)); they work well enough and are inexpensive. PWM controllers can cost half or a third of their MPPT workmates for any given rated output.((10A, 20A, 40A, etc)) 
 +If more power is needed (and there is physical space) additional PV can be added to match the charging output of an MPPT charger, often at a lower cost.  [There are no prizes for fanciest or most expensive charge controller!  Do what is best for you -- frater secessus]
  
-  * battery banks are cycled deeply on a regular basis so more time is spent in Bulk +There are also edge cases where //PWM can actually make more power than MPPT// An example of this might be low-Vmp poly [[electrical:solar:panels|panels]] during Absorption stage in very hot weather, due to MPPT DC-DC conversion losses and [[electrical:solar:output#panel_temperature|temperature derating]].
-  * nominal 12v panels have a relatively high Vmp (>=18v) for [[https://www.reddit.com/r/vandwellers/comments/bmlosu/is_vandwelling_a_frugal_lifestyle/emz5lsf/?context=1|reasons discussed here]]+
-  * [[https://www.wholesalesolar.com/solar-information/sun-hours-us-map|areas of low insolation]] +
-    * high latitudes +
-    * overcast or rainy weather +
-  * if the camper will be used in areas of partial shade((http://forum.solar-electric.com/discussion/comment/250936#Comment_250936)) +
-    * canyon or "urban canyon" areas +
-    * forested areas +
-  * if temperatures are very low (greater harvest) +
-  * the increase in cost is not an undue burden+
  
 **MPPT is effectively required** when: **MPPT is effectively required** when:
-  * using panels with nominal voltages higher than 12v+  * when one needs to squeeze every watt out of the panel 
 +  * using panels with nominal voltages higher than the battery bank voltage, like 24v panels with a 12v bank.   To be fair, [[http://mouse.mousetrap.net/blog/2021-07-09-solar-back-online-.html#pwm-spare-saved-my-bacon|one really can use higher-voltage panels with PWM and 12v banks]] -- they just end up running at about half power.  [[https://www.youtube.com/watch?v=V2b7z2eTb5o|Demonstration video from AltE]].
   * space available for panels is limited, as on a sailboat or small vehicle   * space available for panels is limited, as on a sailboat or small vehicle
 +  * daytime loads are hampered by [[electrical:solar:pwm_tweaking|PWM Vbatt hobbling]]
   * [[#overpaneling|overpaneling]]   * [[#overpaneling|overpaneling]]
   * making [[electrical:converter#diy_converters|DIY converters]]   * making [[electrical:converter#diy_converters|DIY converters]]
  
-We say "effectively required" because one //can// use 24v panels with PWM and 12v banks -- it just doesn't work very well.  The 24v panels will be run at 12v voltages, yielding about half the power you would get with MPPT.  
- 
-**Shunt controllers are useful for [[electrical:solar:shallow_cycling|shallow-cycling configurations]]** or for battery chemistries that are not damaged by [[electrical:depth_of_discharge|partial state of charge (PSoC)]].  Their relative inexpense makes them useful for even very small systems and test configurations. 
- 
-Their simple ON and OFF setpoints may also make them useful for charging [[electrical:12v:lifepo4_batteries_thread|lithium]] chemistries. 
  
  
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 [[https://www.victronenergy.com/upload/documents/White-paper-Which-solar-charge-controller-PWM-or-MPPT.pdf|an excellent and readable whitepaper by Victron]] (PDF). [[https://www.victronenergy.com/upload/documents/White-paper-Which-solar-charge-controller-PWM-or-MPPT.pdf|an excellent and readable whitepaper by Victron]] (PDF).
  
-===== multiple charge controllers  =====+**MPPT may be a better fit** when:
  
-[[electrical:12v:multipoint_charging|Multiple controllers (with separate arrays) can be used to charge a common bank]].  The controllers should be configured with similar charging setpoints for the greatest efficiency.((http://www.morningstarcorp.com/parallel-charging-using-multiple-controllers-separate-pv-arrays/))+  * the existing PWM system is not providing enough output but is close (like 10%-20% shortfall) 
 +  * nominal 12v panels have a relatively high Vmp (>=18v) for [[https://www.reddit.com/r/vandwellers/comments/bmlosu/is_vandwelling_a_frugal_lifestyle/emz5lsf/?context=1|reasons discussed here]]. 
 +  * battery banks are cycled deeply on a regular basis so more time is spent at low Vbatt where PWM struggles. 
 +  * with deeply-discharged banks of low internal resistance (AGM and especially lithium).  Their voltage will take more time to rise from deeply-cycled levels.((https://marinehowto.com/mppt-vs-pwm-solar-controllers/))  
 +  * charging is by solar //only//;  no [[electrical:generator|generator]], [[electrical:shore_power|shore power]], or alternator charging to help. 
 +  * if temperatures are very low (rising Vmp means increasing output which PWM could not capture) 
 +  * the increase in cost is not an undue burden
  
 +**Shunt controllers** are extremely inexpensive, making them useful for even very small systems, test configurations, and backups. 
  
  
  
 +Shunt may be the best fit::
  
-===== sizing your charge controller =====+  * when price point is critical, as in [[electrical:solar:shallow_cycling|shallow-cycling configurations]] 
 +  * when very little space is available to mount the controller 
 +  * when used off-grid with deeply-cycled lead banks ([[electrical:12v:eternal_absorption|eternal absorption]]) 
 +  * Their simple ON and OFF setpoints may also make them useful for holding [[electrical:12v:deep_cycle_battery#lithium_chemistries|lithium]] chemistries at quasi-Float voltages.
  
-As with [[electrical:inverter|inverters]], sizing the controller correctly will help system efficiency.  An oversized CC will have unnecessarily high parasitic drains as it powers itself.  An undersized CC will not be able to put all the rated solar wattage to use and will leave no room for expansion.+See also [[electrical:solar:shunt_tweaking|shunt tweaking]].
  
-For PWM controllers, the formula is something like (panel wattage / 13) * (1.2 oversize for safety) charge controller amps.((https://www.altestore.com/howto/sizing-pwm-solar-charge-controllers-a91/)) +==== should I upgrade my PWM to MPPT? ====
  
-MPPT controllers have more leeway in sizing since they can control the output of the panels independently of battery voltage +If the system has changed and now MPPT is required for one of the reason above, then yes.
  
 +But most people consider this switch to make "more power", forgetting that **solar only makes power when it is demanded**.((for loads or charging))  //If you are presently consuming every watt the system can make// then, yes, replacing PWM with MPPT will likely increase your harvest by ~15%. If you aren't hammering the system then +15% is immaterial; there is no difference in the performance of a 150mph car and a 165mph car in a school zone.
 +
 +So the questions are:
 +
 +  -  do you need more power than you are getting now?
 +  -  would +15% be enough to meet your needs
 +  -  if so, would you pay [whatever the MPPT costs] to get that +15%?
 +
 +There is a saying in solar circles that "adding another panel is a better deal than upgrading from PWM to MPPT."  This may or may not be true in your particular use case.   
 +
 +===== multiple charge controllers  =====
 +[[electrical:12v:multipoint_charging|Multiple controllers (with separate arrays) can be used to charge a common bank]].  The controllers should be configured with similar charging setpoints for the greatest efficiency.((http://www.morningstarcorp.com/parallel-charging-using-multiple-controllers-separate-pv-arrays/))
 +===== sizing your charge controller =====
 +As with [[electrical:inverter|inverters]], sizing the controller correctly will help system efficiency and save money.  An oversized CC will have unnecessarily high parasitic drains as it powers itself and will cost more.  An undersized CC will not be able to put all the rated solar wattage to use and will leave no room for expansion.
 +For PWM controllers, the formula is something like (panel wattage / 13) * (1.2 oversize for safety) = charge controller amps.((https://www.altestore.com/howto/sizing-pwm-solar-charge-controllers-a91/)) 
 +MPPT controllers have more leeway in sizing since they can [[electrical:solar:overpaneling|control the output of the panels]] independently of battery voltage.  
 See also [[electrical:solar:sizing|Sizing a Solar Installation]] See also [[electrical:solar:sizing|Sizing a Solar Installation]]
 ===== overpaneling ===== ===== overpaneling =====
Line 124: Line 256:
 ===== Using LOAD output ===== ===== Using LOAD output =====
  
-It is common for charge controllers to have a LOAD output for powering (or switching) loads.  One benefit to doing this is you can define a [[electrical:12v:lvd|Low Voltage Disconnect]] (LVD) setpoint and Low Voltage Reconnect to protect the battery from excessive discharge.+It is common for charge controllers to have a LOAD output for powering (or switching) loads.  A common-and-understandable misperception is that it is there to run your loads.  Kinda 
  
-Not all types of loads should be run from these terminals, though.  Morningstar says:+ 
 +==== historical use ==== 
 + 
 +LOAD terminals were originally used to control nighttime lighting, like pathway or garden lights.  These are relatively small, resistive loads.  Power to the LOAD terminal could be associated with sun (or lack of sun) and/or battery voltage.  
 + 
 +==== present use ==== 
 + 
 +In practice the LOAD terminals typically are either ignored((some well-respected controllers don't have them anymore)) or used as [[electrical:12v:lvd|low voltage disconnect]] power relays.  You can define Low Voltage Disconnect (LVD) and Low Voltage Reconnect (LVR) [[electrical:solar:charge_controller_setpoints|setpoints]]  to protect the battery from excessive discharge. 
 + 
 +==== why loads aren't powered from LOAD terminals ==== 
 + 
 + 
 +> The load outputs take power from the battery terminals.... the only advantage in using the load terminals is displayed info and the ability to disconnect the load at programmable voltage levels. -- mikefitz((https://diysolarforum.com/threads/epever-solar-charge-controller-false-measurements-on-the-load.23995/post-283823)) 
 + 
 +Some loads are inappropriate for the LOAD output.  Morningstar says:
  
 >  Heavily inductive or capacitive loads such as **pumps, motors, compressors, and  >  Heavily inductive or capacitive loads such as **pumps, motors, compressors, and 
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 >  Inductive loads can generate large voltage spikes that may damage the controller’s lightning protection devices.((http://www.morningstarcorp.com/wp-content/uploads/2014/02/TS.IOM_.Operators_Manual.04.EN_1.pdf))  >  Inductive loads can generate large voltage spikes that may damage the controller’s lightning protection devices.((http://www.morningstarcorp.com/wp-content/uploads/2014/02/TS.IOM_.Operators_Manual.04.EN_1.pdf)) 
- 
 although an exception is made for the SunSaver MPPT which "Handles inductive loads without problems."((http://support.morningstarcorp.com/wp-content/uploads/2014/07/SunSaverMPPT-FeaturesBenefits.pdf)) although an exception is made for the SunSaver MPPT which "Handles inductive loads without problems."((http://support.morningstarcorp.com/wp-content/uploads/2014/07/SunSaverMPPT-FeaturesBenefits.pdf))
  
Line 143: Line 288:
 Note:  in wind and hydro power applications the output can be sequenced so that LOAD is activated only when batteries are fully charged.  This is called a "dump load" because those power sources need to be able to "dump" excess current to prevent damage to themselves.  Dump loads are not necessary in solar because panels can be open- or short-circuited without damage. Note:  in wind and hydro power applications the output can be sequenced so that LOAD is activated only when batteries are fully charged.  This is called a "dump load" because those power sources need to be able to "dump" excess current to prevent damage to themselves.  Dump loads are not necessary in solar because panels can be open- or short-circuited without damage.
  
-===== positive ground controllers ===== 
  
-Some controllers are labeled or described as "positive ground", often by their competitors.  The term is incorrect and misleading:+===== connection order =====
  
-... "positive ground" terminology is wrong.  There is nothing connecting positive supplies to chassis ground, earth ground, or any other ground. -- Trebor English((PM correspondence with frater secessus))+Solar charge controllers use the battery bank to provide a reference voltage for operation For this reason **the battery should always be present when solar panels are connected**.  This suggests a particular order for connection/disconnection/resetting:
  
-A more accurate term would be **Low Side Switched Controllers** (//**LSSC**// hereafter).  A how and why of low side switching is found [[#low_side_switching|at the end of the article]].+  - disconnect solar panels 
 +  - disconnect battery 
 +  - wait a moment 
 +  - connect battery, wait for controller to power on 
 +  - connect solar panels
  
  
 +For an overview of official procedures by manufacturer, see [[https://www.reddit.com/r/vandwellers/comments/12fmyrl/solar_system_is_not_functioning/jfm66y0/|this post]]. 
 +
 +
 +===== positive ground controllers =====
 +Some controllers are labeled or described as "positive ground", often by their competitors.  The term is incorrect and misleading:
 +> ... "positive ground" terminology is wrong.  There is nothing connecting positive supplies to chassis ground, earth ground, or any other ground. -- Trebor English((PM correspondence with frater secessus))
 +A more accurate term would be **Low Side Switched Controllers** (//**LSSC**// hereafter).  A how and why of low side switching is found [[#low_side_switching|at the end of the article]].
 **These LSSC can be incorporated into your camper's electrical system** as long as: **These LSSC can be incorporated into your camper's electrical system** as long as:
- 
   -  anything powered by the LOAD output does not ground the negative wiring to the vehicle.((https://www.altestore.com/store/charge-controllers/solar-charge-controllers/pwm-solar-charge-controllers/positive-ground-pwm-charge-controllers-c1143/))     -  anything powered by the LOAD output does not ground the negative wiring to the vehicle.((https://www.altestore.com/store/charge-controllers/solar-charge-controllers/pwm-solar-charge-controllers/positive-ground-pwm-charge-controllers-c1143/))  
   - any communications i/o (like ethernet or other jacks) do not connect to devices that are grounded to the vehicle.((http://forum.solar-electric.com/discussion/comment/291317#Comment_291317))   - any communications i/o (like ethernet or other jacks) do not connect to devices that are grounded to the vehicle.((http://forum.solar-electric.com/discussion/comment/291317#Comment_291317))
   - solar panels are wired directly to the controller and do not use the vehicle as an electrical path((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=302146#pid302146))   - solar panels are wired directly to the controller and do not use the vehicle as an electrical path((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=302146#pid302146))
- 
 If you are not using the LOAD output, communicating with the controller, or using the vehicle as an electrical path for the solar panels, LSSC (so-called "positive grounding") doesn't matter.((http://www.irv2.com/forums/f56/renolgy-starter-kit-positive-vs-negative-ground-244437.html#post2557817)) If you are not using the LOAD output, communicating with the controller, or using the vehicle as an electrical path for the solar panels, LSSC (so-called "positive grounding") doesn't matter.((http://www.irv2.com/forums/f56/renolgy-starter-kit-positive-vs-negative-ground-244437.html#post2557817))
- 
 ==== use of LOAD output on an LSSC ==== ==== use of LOAD output on an LSSC ====
- 
 If some basic steps are not taken the device may not turn off/on as expected.   If some basic steps are not taken the device may not turn off/on as expected.  
- 
 Here are some appropriate ways to use the LOAD output with LSSC: Here are some appropriate ways to use the LOAD output with LSSC:
- 
   * run all positive and negative wires back to the LOAD output; or   * run all positive and negative wires back to the LOAD output; or
   * run them through buses that lead back only to the LOAD output; or   * run them through buses that lead back only to the LOAD output; or
   * put a relay on the LOAD output and run all the loads through that.((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=307516#pid307516))   * put a relay on the LOAD output and run all the loads through that.((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=307516#pid307516))
- 
 ==== low side switching ==== ==== low side switching ====
- 
 LSS means //switching// (turning on-off) is done on the negative (or //low//) side rather than on the positive (or //high//) side.  Referring to a low side switched PWM controller, Trebor says: LSS means //switching// (turning on-off) is done on the negative (or //low//) side rather than on the positive (or //high//) side.  Referring to a low side switched PWM controller, Trebor says:
- 
 > All three plus connections, solar panel, battery, and load, are tied together.  Loads are turned on with a switch (transistor) between the load minus terminal and the battery minus terminal.  Charging is turned on (bulk) or pulsed with a switch between panel minus terminal and battery minus terminal.((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=307539#pid307539))  > All three plus connections, solar panel, battery, and load, are tied together.  Loads are turned on with a switch (transistor) between the load minus terminal and the battery minus terminal.  Charging is turned on (bulk) or pulsed with a switch between panel minus terminal and battery minus terminal.((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=307539#pid307539)) 
- 
 He goes on to explain why this is the case: He goes on to explain why this is the case:
 +> The reason for the low side switching is the intersection between physics and economics.  N-channel field effect transistors are faster, better, cheaper than P-channel parts.  The designer can A) use good parts in a simple circuit or B) use more expensive not so good parts or C) make a complicated circuit that uses 18 volts to control a 15 volt switch.((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=307539#pid307539))
  
-> The reason for the low side switching is the intersection between physics and economics.  N-channel field effect transistors are faster, better, cheaper than P-channel parts.  The designer can A) use good parts in a simple circuit or B) use more expensive not so good parts or C) make a complicated circuit that uses 18 volts to control a 15 volt switch.((http://www.cheaprvliving.com/forums/showthread.php?tid=24605&pid=307539#pid307539))+===== further reading =====
  
 +  * [[https://www.solar4rvs.com.au/buying/buyer-guides/choosing-the-right-solar-charge-controller-regulat/|exceptional article on charge controllers]] by Solar4RVs
electrical/solar/charge_controller.1557623417.txt.gz · Last modified: 2020/10/11 19:48 (external edit)