230

In this section,
8.6
we
study a charge controller, its function, working, features

Charge Controllers Charge controllers, as the

implies, control the flow of charge from the battery
name
and to the
battery. They protect the battery by preventing over-charge or deep
discharge of batteries to preserve their life and performance. When the battery gets
8.6.1
Function of a Charge overcharged by solar PV module, a charge controller will cut it off from the circuit
so that no more charging is possible. Similarly, if a battery goes into deep discharge
Controller (or overdischarge) due to excessive use of batteries by the load, a charge controller
detects and disconnects the battery from the circuit so that no current can be drawn
O m the dattery. In this way, a controller protects the battery. Note that both
charge
Charge controllers protect the batteries result
circuit in overcharge and deep discharge conditions damage batteries. Both the situations
by disconnecting it from the PV system
case of over charge or over discharge in decrease in the life of batteries. The block diagram of a standalone
controller is shown in Figure 8.10.
(deep discharge). with battery back-up and a charge
by measuringis detected the voltage
The status of over-charge and deep discharge increases beyond a
8.6.2 condition, the battery voltage
level of batteries. In overcharge decreases below
Working of Charge discharge condition, the battery voltage
certain level and in deep conditions, the charge
Controller certain level.In overcharge and deep discharge voltage
a the battery voltage level reaches
the battery. Also, when
cantroller disconnects to the circuit. In case
level, the battery gets connected
within the normal operating voltage
cut-oft due to high voltage of battery. After high
battery gets
of over-charge, load which means some discharge of battery, then
used by
taffif the battery is controller will detect this and connect the
fall. The charge
rminal voltage will
for charging.
the battery gets cut-off due to law
battery again case of deep discharge,
Similarly, in the charoin.
S under charging condition, its terminal
r Now,
Now, Iif the batlery is
the biattery
voltage
of battery. sometume due o cnarging. charge controller will
Ine
increase after
after
will
increase
when voltage inereases above th
votage increases above the low voltage
i n volage and wnc
in voltage
voltage
increase n will the
will connect the battery to the circuit so that
to overetect the controller
connect

cut-off (due the charge

High voltage cut-off (due
cut-off
level,
from the battery by the load.
charge) and low voltag are preset
In
be
e x t r a c t e d

to overdischarg
verdischarge)
levels
power can
charge controllers.
 Solar Photovoltaic Technology and Systems: A Manual for Technicians, Trainers and Engineers
180

Charging
Battery status
Load
Charge controller Lower
Cherge
Solar Panel
Panel Battery Load

Various
O DC Loads

FIGURE 8.10
Basic block diagram of a standalone
Battery
PV system with battery back-up and
charge controller.

8.6.3 The following two types of charge controllers are mostly used nowadays:
Types of Charge 1. Pulse Width Modulation (PWM) charge controller or standard charge
Controllers controller
2. Maximum Power Point Tracking (MPPT) charge controller.

PWM charge controllers have same nominal voltage across battery bank and pV
array. MPPT charge controllers can have different voltages across battery bank and
PV array and operate at the maximum power point tracking (MPPT) of the PV
panel. MPPT charge controller allows us to have a solar panel array with a much
higher voltage than your battery bank voltage.
For the same power flow, when voltage is high, current that will flow in the
wires is small. Power is equal to current
multiplied by voltage. Normaly, it is
desired to keep the current flow to small level.
In solar PV system it is desired to Therefore, a big advantage of having
keep high DC voltage to keep the a higner volage solar panel array 1S that we can use smaller gauge wiring to the
low curent for the same power flow. charge controller, and the use of small
It saves cost. gauge wire reduces the wiring cost. MPPT
concept is further discussed in the next section.

8.6.4 For the operation of charge controlers, various voltage and

defined. These levels are as follows: current levels are
Features of Charge
Controller Nominal system voltage: This is the
voltage at which battery and charge
operate in a PV system. controluc
Nominal load current: This is the
maximum load
should be able to handle. current that charge controlic
Nominal PV array current: This is the
controller should maximum PV array curent that
nothing but the Arrav short charge
be able to handle.
This is
curren A safety factor of 1.25 1S used to circunt
current at non STC. account for variation in Short
circu
Charge regulator set
points: Charge controllers regulate the
discharging
discharg"5 of a batlery.
Cnarge rging and
chargi
controller
SoC) and decides either to senses the voltage of the battery (or
his case) to prevent t rom disconnect it from the source (PV
Overcharging or to disconnect the load (from th
 Chapter 8: Charge Controller, MPPT and Inverters 181

battery output) to
prevent
loads are
deep discharging. Such
controllers are mainly used where
unpredictable and the batteries are
initial cost. The charge optimized or undersized to minimize tne
control algorithm has set
upon which it takes decisions. points (threshold values) depending
The commonly used set points are brieily descnocu
below and are shown in
Figure 8.11.
Voltage
Full charge
---- VR

VRH
Recharging
can start

Redischarging
can start LVDH
-

FIGURE 8.11
and their
- - - -

LVD
used set points Full discharge
commonly controllers.
in charge Time
ehaviour

Voltage regulation set point (VR): It is the maximum voltage up to which a

battery can be charged (without getting overcharged). If this threshold is reached,
the controller either disconnects the battery from the source or starts regulating ne
current delivered to the battery.
Voltage regulation hysteresis (VRH): It is the difference between VR and the
voltage at which the controller reconnects the battery to the PV source and starts
charging. If VRH is too small, it will result in tighter voltage regulation but the
control will be oscillatory and may deteriorate the battery life. At the same time, a
large value of VRH may lead to "slight' overcharging of the battery during every
there is a trade-off. VRH also determines how effectively the
cycle. So, in practice,
controller can charge the battery.
Low voltage disconnect (LVD): It is the minimum voltage up to which the battery
without getting deep discharged. It is also defined as the
can be allowed to discharge,
of the battery. The charge controller disconnects
maximum depth of discharge (DoD)
terminals as soon as the battery voltage touches LVD, to
the load from the battery
from overdischarging.
prevent it
hysteresis (LVDH): It is the difference between LVD
Low voltage disconnect
value and the battery
voltage a whiCn
tne
load can be reconnected to the battery
small, or else the load will be switched on and off
terminals, LVDH
is not kept too
affect the and the load adversely battery
which can
frequently
ratings of Nomin
more
for various sy ste
controllers are
available
VOltage and
Charge of 12 V, 6 A rated PWM charge controller
Typical ratings are
6.5 PV array
current.

pical Specifications of Table 8.6.

shown in
of 12
al Ratings of 12 V, 6 A Rated PWM Charge Controller
WM Charge Controller 8.6 Typical Ratings
TABLE

Nominal system voltage

12 V
current 6 A
PV array
Nominal
Nominal load current
6 A
14 volts
Regulation voltage
L o w v o l t a g e d i s c o n n e c t
11 volts
L o w v o l t a g e r e c o n n e c t
13 volts
Series PWM
Type of charging

-20°C to 55°C
Temperature

10 mA maximum
Self-consumption
 182 Solar Photovoltaic Technology
and Systems: A Manual tor Technicians, Irainers an
lechnicians, Trainers and
Engineors
datashect 4.5 A, 12 V rated ch:ar
An example
Corportion is shown in Figure 8.12. ontroller from m
Eloctrlcal Spoclflcatlons
Rated solar input 4.5 A

MOROS
Maximum input (5 min.) 5.5 A
12 V
System voltage
Maximum solar voltage
Regulation voltage
Accuracy
Self-consumption
30 V
14.1 V
60 mV
6 mA
SUNGUARD
s0LA OnOt
ArtD 4 1

Temperature compensation -28 mV/°C

FIGURE &12 Reverse current leakage <10 A
Example datasheet of 4.5A, 12 V rated
PWM charge controlle. Operating temperature -40°C to 85°C

EXAMPLE 8.7 A house has the following DC loads rated at 12 V.

) Three 40 W lights
(ii) A 50 W fan
All the loads are to be powered simultaneously
using two parallel connected
Each module has a peak current of
2.5 A and Short circuit current of 3.5 d module.
the appropriate charge controller? A.
Solution Total DC Load estimation:

Load Wattage
Quantity Total load
Light W 3 120 N
Fan 50 W 1 50W
170 W
Nominal system voltage of
and PV array, i.e. 12 V. charge controller: Same as rated voltage of lou

Nominal PV array current:

Nominal PV array current 2 x 3.5 A 1 A = =
Therefore, at the input side, the
current. charge controller should be able to handle 7
3

Nominal load current:

Nominal load current =. Total DC load

Nominal system voltage
170 14.17A
12 V
Therefore,the output side, the
14.17 A current. charge controller should be able to
adout

na
Problem 8.8: A house
has the following
DC loads rated at 12
. Four 30 W
lights Y.|
2. A 40 W
fan
All the loads
are to be
Each module
has a peak
powered simultaneously
using two paralies
n n e c t e dm o d u l e s

f 4 A. Choo
the current of 3.5 A and
appropriate charge controller? Short circuit curre
 183
Chapter 8: Charge Controller, MPPT and Inverters

PV
ORKSHEET
8.4: Complete Table 8.7 choosing PWM charge controller ratings for given load and
arrary.

TABLE 8.7 To Obtain

Missing Quantities
Loed voltage Module Nominal system Nominal PV Rating of charge
LoBd(W rating (V) aray current controller
Voltage
= W 12 Three modules of short circuit
lights
10 W current of 3.5 A each.
Two W
fan
ASO W
Totalload

=
W 12 Two modules of short circuit current
four
15 W lights of 3.5 A each.
fans= W
W
Two 25
Total load

FOwer delivered by a module depends on the load connected to the module. Consider
8.7 a module whose I-V characteristics and the corresponding power drawn are shown
Maximum Power Point in Figure 8.13. At short circuit conditions (V = 0), current delivered by the module
1S maximum and is 5.1 A. As voltage across the load is increased (by varying load)
Tracking (MPP)
up to T7.3 V, power delivered to the load increases to 84 W (17.3 V x 4.86 A).
decreases as the
Beyond this point, though the voltage is increased, power delivered
current decreases very sharply. So, the power delivered by the module has a point
on -V characteristics corresponding to maximum power and is called Maximum

Power Point (MPP).

In order to extract the maximum power from PV modules, the load connected
point or the operating point of PV
to the modules should work at maximum power
module-load combination should be at maximum power point. The operating point
to a load
is the of intersection of 1-V characteristics of a source (PV modules)
point
(a fan, a TV, a resister, etc).

F140
5 Current (A) MPPT
120

100

-80

Power (W) 60
FIGURE 8.133 2
Definition of maximum power point AO
(MPP) 0
in the -V
There is only point module at which
0
characteristics of PV 8 12 16 20
the module 0
the power delivered by Voltage (V)
IS maximum, called maximum power

poln The output power of P

are rated
for
peak powe Oulput.
Solar PV modules nult solar radiation
solar
on Oner
radiation but also on operating point (combination
on input
8.7.1 depends under
under Very
very bright
not only For
instance even sun light condition
PV and voltage). open circuit mode oorr hshort circuit mode the
rating in open
Power Output from a
of current operating in
module is
also, if
PV cThere is .one operating point of a PV module at which
There is
Module will be
zero.
(maximu (maximum power point) and his
this operatine
power
output
is
maximum

radiation fallin
af solar radiation operating point
the power
output
in intensity
or solar falling on PV modules.
There
with change
changes
 184 Solar Photovoltaic Technology and Systems: A Manual tor Technicians, Trainers and Engineer

are electronic devices which ensure that at all light

operate at maximum power point. This concept of maximum
conditions, solar PVPV moule
is discussed in the following paragraphs. power point track
8.7.2 In practice, because of the changing
radiation. the 1-v ambient solar
Need for Maximum Power of PV modules change throughout the day. Therefore, itit isis not nhaces
Point Tracking? a load such that the
not
operating point eristucs
is always at
,

maximum power ssible

characteris
to cho
maximunm power point. or point close t
Intensity of solar radiation varies throughout the day. On a typical das
is less intense at 9 a.m. and increases till noon. As the
characteristics of the module also change as shown in Figure
intensity chane ti
8.14, As.
As aresult.
a given load characteristics, the
operating point also changes.
As an
example, the operating point of a PV module and a resistive
I p.m., 1l a.m. and 9 a.m. is
schematically shown in Figure 8.14 and is denou. Sor
p.m., 11 a.m. and 9 a.m., the maximumnoted by
Z. Y and X respectively. But for 1
point Z',
is Y' and X respectively. In order to deliver maximum
operating points X, Y and Z should be made as close as possible power, the actual
to X, Yand 7.
1 p.m.

Resistive load, R
11 a.m.

FIGURE 8.14 9 a.m.

X PV R
Operating points (X, Y, and Z) of a Module
solar PV module under various day- Maximum power
light conditions when connected to a point trajectory
resistive load. The X, Y and Z must
be the operating point for maximum
power transfer. 4 3 12 16 20
Voltage (V)
The MPPT device There is a device whose function is to
maximum power point under differentbring
the operating
PV modue -V curve
changes through-
the point of a load close to
out the day as the operating
sunlight intensity maximum power point tracking or MPPT. n this conditions. This device is called
changes, hence the maximum point to extract maximum available way, the function of MPPT is
also changes throughout the day. power from PV modules under
(less radiation, any given condition
more radiation, high
temperature, etc.)
The maximum power
tracking mechanism makes use of an
electronic circuitry. The mechanism is based on
the principle of
algorithm and an
between load and PV module which is impedance matching
Thus, in theory, whenever the necessary for maximum transrer.
of source, maximum
impedance of loacd is matches with power
the
power transfer takes place impedane
between source and load. In this
way, the presence olf MPPT between the
source
maximum available power is extracted from PV(PV Module) and load, ensures that
modules.
8.7.3 Many manufacturers combine the function of
MPPT Charge Controller single device which is called MPPT charge charge controller and MPPT in one
controller and is shown in
Figure 8.19.
 Chapter 8: Charge Controller, MPPT and Inverters 185

Solar panel
ction o f M P P T PT device is to
point of a load
hhe operating power point of
the maximum MPPT
different operating
under Charge controller
module order to extract
ondihons in

M a x i m u m p o O w e r .
Panel Battery Load
controller
and charge
h MPPT
Tindependent functions, many
ovide these two
facturers

ons in
a single electronic
MPPT chargge
Varlous
DC loads
are called
iry and
antroers.

FIGURE 8.15

PT charge
atner system components.
controller along with Battery
T and Sun-tracking for MPPT device is used to extract maximum power possible from a PV module in a
MPPT
operating conditions. The sun-tracking is referred as mechanical tracking ofasolar
more power PV module in such a way that it is always perpendicular to the sunlight. In this

IC nodule should face eastward in the morning, southward in the noon time
MPPT is electronic tracking and Sun-ay,
ana westward in the evening directly see the sun.
to When the PV modules are
reding is mechanical tracking, both all the time, they receive more solar radiation and,
therefore,
taving the objective of generating directly facing the sun
more power using solar PV moauies they generate more power.
same as the Sun-tracking of
Here it should be noted that the MPPT is not the
MPPT and char controller
Though are rotated mechanically
so that the
ae two independent Tunctions, solar PV modules. In Sun-tracking, PV modules electronic
provide these radiation absorbed while in the case of MPPT,
many
manufacturers
electronic by a module is maximum, is transferred
bwO functions in a single used to that maximum amount of generated power
and
arcuitry are called MPPT charge circuitry is ensure

CorntrollersS. to the load.

the charge controller
is the maximum power that
Maximum power: This
input
8.7.4 can handle
from a PV array.
Specifications of MPPT This is the maximum open
circuit voltage that
circuit voltage:
Maximum open
Charge Controller controller can
handle.
the charge
range: These are the voltage levels that the charge
voltage
PV input MPPT tracking
controller can handle.
in a system.
This is the voltage at which battery operates
voltage:
Nominal battery It is the maximum voltage up to
which a
DC output to battery set point (VR
Voltage
regulation
thout
(witho getting overcharged). If this threshold is reached
be charged starts regulating the
ttery
can
disconnects the battery from the source or
either
controller
he
the to the
battery.
delivered
current It is the minimum voltage up to which the battery
(LVD)
It is also defined as the
disconnect

Low
voltage without getting deep discharged.
discharge
allowed to battery. The charge controller disconnects
of the battery
(DoD)
can be discharge
maximum
depth of terminal nals as soon as the battery voltage touches LVD, to
battery
from the
load
the o v e r d i s c h a r g i n g .

from
it
prevent 1rrent or
current « maximum charging current: This is the maximum
Nominal
PV array
charge controller should be able to handle. This is nothing
«
that a
array
current

circuit
current. safety factor of 1.25 is used to account for
PV short
array current at non STC.
but
the
variation in Short
ircuit
 186 Solar Photovoltaic Technology and Systems: A Manual for Technicians, Trainers and Engineers

DC load control Nominnl voltage: This is the maximum load voltage that a
should be able to handle. charge controller
cha.

Maximum current: This is the maximum load current

that aa chars.
that
should be able to handle. charge controlle
MPPT charge controller is rated by the output current
that they can
not by the input current from the solar
panel array as it is done in stand handle nd
controllers. Typical specifications of 12 V, 6 A MPPT
in Table 8.8. charge controller charge
TABLE 8.8 Typical Specifications of 12 V, 6 A MPPT
Charge Controllar
PV input
Maximum input power
Maximum open circuit voltage 80 W
MPPT 95 V
tracking voltage range 26 75 V
DC output to battery
Nominal battery voltage
12 V
Voltage regulation set point (VR)
Low voltage disconnect 12.6 0.2
(LVD) 10.5 0.2
Maximum charging current
6 A
DC load control
Nominal voltage
12 1
Maximum current
10 A

EXAMPILE 8.8 Consider a 1000 watt solar panel array that

bank at 24
operates at 48 volts DC and battery
volts DC. Choose the MPPT
Solution
charge controller ratings for this system?
Following parameters are given for MPPT:
Wattage of solar PV modules = 1000 W
PV array operating voltage = 48 V
Battery bank operating voltage = 24 V
Wattage input by solar
panel MPPT charge controller is 1000 W. In this
to
case, the solar PV modules are connected to
the input side of MPPT and the
is connected to the
output side. Therefore, load for batteryy
the MPPT is the battery. The
specification for the MPPT is given in terms of the
it can handle. Therefore, we
output
should calculate the current voltage
and output current
for its load. requirement of the MPPT
The input power the MPPT is 1000 watt
to
efficiency, power battery bank terminals would(PValsomodules),
at
be
and assuming 100%
is at 24 V, current to the 1000 W. As battery bank
battery bank can be found in
Power
following way:
=
Voltage x Current
Power 1000
or Current=
Voltage 00
24
41.67 A
Thus a 24 V, 41.6 A MPPT would
work well in this
case. As a
increase the estimated current value by 25% to
take into precaution, we may
that could occur causing the Solar account special conditions
panel array to
narmally rated for. This gives current as sI A. produce more power than it is
controller suits well for this system. So, 24 V, 51 A
MPPT charge
Huever. the chosen MPPT charge controller
should be able
Voe and Vmp to handle the array
 Chapter 8: Charge Controller, MPPT and Inverters 187

Problem 8.9 Consider a 3000 watt solar panel array that operates at 36 volts DC
and battery bank at 36 volts DC. Choose the MPPT charge controller ratings for
this system?

8.5: Complete Table 8.9.

WORKSHEET

TABLE 8.9 To Obtain Missing Quantities

Battery bank voltage Battery bank current Battery bank current MPPT ratings
Solar planes operating
Solarpanel wattage (A) +25%
voltage (V) (V) (A) 24 V, 51 A
(W) 51
24 24 41.67
1000
36 36
3000
48 36
4800

150 watt peak

Consider using the following PV module and battery for designing
EXAMPLE 8.9 controller ratings for this system?
solar home system. Choose the MPPT charge

12 V battery

Pm 78 W
Voc 22 V
Vmp= 17.4V Battery

series:
be connected in
Let the PV modules
Solution 2 x 22 =
44 V =
(system)
Voc
17.4 = 34.8 V
(system)
= 2 x
Vmp
Pm (system)
= 78 x 2 =156 W and assuming 100%
watt (PV modules),
MPPT is 156
to the
would also be 156
W. As battery bank
The input power bank terminals
at battery in the following way:
efficiency, power bank can be found
curent to the battery
is at 12 V, the
x Current
Power = Voltage

Power 156
=13 A
Current Voltage 12
mav
As a precaution, we
work well in this case.
MPPT would conditions
12 V, 13
A
25% to take into account special
Thus, a value by it is
power than
current
more
the estimated panel array to produce
increase thee solar
occur
causing 16.25
16.25 A. So 24 V. 16.25 A MPPT
that
could the amperage as
rated for. This gives
normally for this system.
suits well
controller should be able to handle the arr
charge
the
chosen PT charge controller
However

accordingly.

Voe
and Vmp