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PWM controllers are inexpensive and durable, but typically they cannot extract as much power from a given panel as the more expensive MPPT can. This page is intended to help people get the most out of their PWM system.
Note: much of this information also applies to tweaking shunt controllers.
During charging with a PWM controller the solar panel will be running at the voltage of the battery bank. Unfortunately, this is almost never the voltage at which the panel makes its rated power (Vmp). The panel will make less and less power when battery voltage is low.
17.8v x 5.6A = 99.68w ←- full power, if we could run the panel there. Which we can't with PWM.
14.8v x 5.6A = 82.88w ←- power at a high Absorption voltage, as with flooded lead acid
14.4v x 5.6A = 80.64w ←- power at a lower Absorption voltage, as with AGM
13.8v x 5.6A = 77.28W ←- power at high Float, as with deeply cycled banks
13.2v x 5.6A = 73.92W ←- power at low Float, as with lightly cycled banks
12.7v x 5.6A = 70.61W ←- power at 100% state of charge (SoC)
12.4v x 5.6A = 69.44W ←- power at 75% state of charge; bulk charging
12.1v x 5.6A = 67.76W ←- power at 50% state of charge; bulk charging
This last number shows how far off PWM output can fall when battery voltage is at its lowest.1) It's also when the battery needs the most current to get out of that deep cycle trough.
Here are steps to take to maximize power from the PWM controller, in order from greatest effect to least effect.
During the bulk charging stage the battery needs every bit of power it can get. Any loads applied during this stage slow down charging and, more importantly, prevent the system from reaching power-making voltages as soon as possible.
Wait until your bank is well into Absoroption before using discretionary loads.
Since the panels make more power at higher voltages2) cranking up Vabs and Vfloat to higher-but-still-sane levels will result in more power being harvested.
This may seem obvious, but remember:
In other words, the lower your battery voltage gets the worse the system works. There are two courses of action to take that will help reduce this effect.