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 Charge Controller
| GIEE
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Bulk stage: During the Bulk stage, the voltage gradually rises to the
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 Charge Controller
| GIEE
ENGINEERING

PWM Vs. MPPT

12 Volt Module 12 Volt Module

Current vs. Voltage Output Power
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O©GIEE-All rights reserved VA a eo 34

Ww
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Ww
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 Charge Controller
| GIEE
ENGINEERING

PWM Vs. MIPPT

Standard Test Conditions (STC) KYOCERA

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 Charge Controller
| GIEE
ENGINEERING

PWM Vs. MPPT

100W 12V panel

OF ELECTRICAL

18Vmp 5.56A Imp

PWM MPPT
* Low battery : * Low battery :
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OGIEE-AIl rights reserved www.giee.org

 Ww
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 Charge Controller
| GIEE

PWM Vs. PPT

ENGINEERING

MPPT Charge Controller:

Using 12V vs 24V panel
OF ELECTRICAL

12V 100W panel 24V 100W panel

18Vmp 36Vmp
X_5.56A Imp X 2.78A Imp
100W 100W
Voltage and current
INSTITUTE

Voltage and current

adjusted to optimal
adjusted to optimal
battery voltage
battery voltage
13V _
GLOBAL

13V x 7.7A = 100W 13V x 7.7A = 100W

THE

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Le)
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Ls
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c
Which is best?
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a
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-
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a
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== bank ¢ Mismatched nominal
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a
* Cost of increasing solar § Voltages
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°
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©GIEE-All rights reserved www.giee.org

Ww
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Lu)
oO
r Charge controllers could have some features such as:
x
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Ww
4 1. Low voltage warning beeper: When the battery discharges to a preset level,
Oo
z the controller will release a sound as an alarm.
Ww
| 2. Voltmeter: Some controllers use a digital display voltmeter to measure the
i?
4 voltage of the battery and display it on a screen/LED display.
x
= 3. Ammeter: Some controllers use a digital display ammeter to measure the
Oo
WwW
on|
charging current or the load current and display these values on a screen/LED
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rs
display.
Le) 4. Amp-hour meter: This meter will measure the battery capacity used or
Ww
ro remaining and display the value on a screen/LED display.
=)
== 5. Complete charge light: In this feature, a light will be tuned on whenever the
a battery reaches full charge voltage.
z
a 6. Temperature compensation: In this feature, the controller adjusts charging
fe] current in relation to ambient temperature of the battery.
°
|
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ive
— Charge Controller
Le)
Lb)
2 Rated voltage (V) 12
i
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Ww Float voltage (V) 13.8 +0.2
2
U) Over-charging Protection Voltage (V) 14.1-14.5
4
iv)
Load Disconnect Voltage (V) 10.8 - 11.4
a
4 12.2 - 12.6
Load Reconnect Voltage(V)
c
4 Max. Solar Current(A) 15
=
iS)
tT Max. Load Current (A) 15
oo
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rs
Typical Power Consumption (mA) <8
Le)
ive}
Temperature Compensation Factor -3mV/cell*K
a
p> Voltage Drop Between Solar Power and Battery (V) <0.4
=oa
Cy
2 Voltage Drop Between Battery and Load (V) <0.3
|
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Ambient temp. Range(°C) 20°C - 50°C
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Max. Altitude(m) 5000
x
pa

©GIEE-All rights reserved www.giee.org

vy
- Charge Controller
©
LY) MidNite Solar Classic 200-SL Charge Controller
<
x
uy
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Features & Attributes
rs > Dimensions (LxWxH): 14.9 x 6 x 4 inches
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te > Weight: 12 lbs
|
ra >» Solar Only
4
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4 >» 200 operating voltage
iS)
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»79 amps max current at 12VDC
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a > ETL listed to UL1741 and CSA
°
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> Type 1 environmental rating
|
== >» HyperVOC extends VOC limits
n” > 12-72V battery bank voltage
<
oe > Built in DC-Ground Fault Protection
os
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° >» Optional Battery Sensor for temperature
|
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x
= $575.00
©GIEE-All rights reserved www.giee.org
 Charge Controller
| GIEE

CLASSIC AND CLASSIC LITE SPECIFICATIONS www.midnitesolar.com 360-403-7207 17722 -67th Ave NE, Arlington, WA 98223
ENGINEERING

Classic and Classic Lite 150, 200 or 250

Nominal Battery Voltage 12 Through 72 volts on Classic's. Lite requires PC or MNGP for advanced feature programming
Maximum Output Current Classic 150 and 150 Lite = 964 on 12V, 944A on 24V and 86A on 48¥ battery
Classic 200 and 200 Lite = 79A on 12V, 78A on 24+48V and 654 on 72V battery
Classic 250 and 250 Lite = 61A on 12V, 62A on 24V, SSA on 48V and 43A on 72V battery
PV Open Circuit Voltage VOC Classic1S0 = 150V + HyperVOC (battery voltage up to 48V) Example 150V + 48V = 198VOC
(NOTE: See HyperVOC at bottom) Classic200 = 200V + HyperVOC (battery voltage up to 48)
Classic250 = 250V + HyperVOC (battery voltage up to48V) = (NOTE: See MyperVOC ot bottom)
Power Conversion Efficiency 98% (Typical systern)
OF ELECTRICAL

Maximum Stand-By Self-Consumption (12V) 2.8W -4W

Reverse Current At Night Zero - Internal relay for reverse current
Low Battery Voltage Low Battery voltage disconnect and re-connect of loads fully programmable with 2 Auxiliary outputs to control external load
disconnect /re-connect switches
Hyper VOC (NOTE: See MyperVOC at bottom) Standard all models - Extended VOC range for cold climates
Arc Fault Protection Standard on Classic, 0.25 second detect and trip speed - Not available on the Lite
Ground Fault Protection Standard all models - resettable, no fuse to blow
Charging Regulation Bulk, Absorb, Float as well as Equalization
Battery Voltage Regulation Set Points 10-100VDC
Equalization Charging Adjustable Voltage and Duration, Manual or Auto
PV Reverse Polarity Protected to Max VOC
Battery Reverse Polarity Fully protected
INSTITUTE

Battery Over Voltage Fully protected

Battery Short Circuit Fully protected
Battery Temp Compensation Autornatic when 8TS is installed, Adjustable mV per degree C per 2V cell
Programmable Auxiliary Control Output 2 Auxiliary outputs, Aux! can be 12V out of dry contact, Aux? is 12 out or Logic IN
Graphic Display Graphical display - MNGP (NOTE: MNGP is an option on the Classic Lites)
Networking Cabling Standard 4 conductor phone cable, no hub needed
Communications RS232, Ethernet and ModBus openly published protocot
Remote Display Display (MNGP) can be relocated and a second display can be added
GLOBAL

The MidNite Solar Classic charge controller conforms to UL 1741, Safety for Inverters,
Converters, Controllers and Interconnection System Equipment for Use With Distributed
Energy Resources,
THE

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 w
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CHARGE CONTROLLER WIRING
r PV Module
oO : Charge
z eecee Controller
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O©GIEE-All rights reserved www.giee.org

 Ww
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Lu)
, s CLASSIC WIRING FLOW
}
- DIAGRAM-REVB-10/3/14
© 10 = Solar Modules (PV) ~.
< 11 = DC Combiner (Like our MNPV6 or MNPV12 for example)
x 12 = MNSPD300-DC (Surge protection)
Ww
Ww 13 = MNSPD300-AC (Surge protection)
r 14 = MNSPD300-DC (Surge protection)
15 = DC breaker for the Inverter (Also serves as a disconnect
©
z for the Inverter)
Ww 16 = DC breaker for the PV into the Classic (Also serves as a
d disconnect for the Classic)
aT
17 = DC breaker for the Battery into the Classic (Also serves as
oS a disconnect for the Classic)
x
ke 18 = AC L1 Input Bus Bar. (This is where the generator L1 input
Oo gets wired)
ee)
ps 19 = AC Neutral Bus Bar. (This is where ALL AC Neutrals get
Ww wired)
ee 20 = AC L1 Output Bus Bar. (This is where the L1 Output to the
Le) Load center for the building would connect)
WwW 21 = Battery Positive Bus Bar. (This is where we would wire
=
=) the Battery positive side of the Classic, as well as where we
== would wire up DC loads. Do NOT wire the battery cable to this
bus bar).
a 22 = Earth Ground Bus Bar. (This is the common Earth Ground
c bus bar where all the grounds get wired back to and it needs
ol to be connected to the building’s ground rod system )
a 23 = PV Positive Bus Bar. (This is where the Solar Panels
+)
° positive lead connects.)
| 24 = Battery negative Bus Bar. This is where the solar panel
Le) negative lead would go as well as the Classics negative lead
WwW
and any negatives from the loads. Do NOT connect the battery
Po
kK negative cable to this bus bar

O©GIEE-All rights reserved www.giee.org

 WwW
~ Charge Controller
Le)
2 ~ CLASSIC WIRING FLOW
‘ Sete Ow DIAGRAM REWB- 10/3/14
Lb) 25 = DC Shunt. (The Shunt measures the amperage in
< or out of the battery. You connect the battery to one
x
ve side and everything else to the other side.)
Ww
26 = Earth Ground system of the building
c 27 = Classic Charge controller.
Le)
r 28 = AC Generator
WwW
29 = Batteries. (The Voltage must match the voltage
a
cs4 of the inverter. Typically 2-3 strings of batteries
c would be considered the max.)
x 30 = Optional Battery temperature sensor. (This is ‘ ; imme’)
7
is) used to compensate for the temperature of the 417 | “ie

KKAKA
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| battery. If a battery is cold it has to be charged to a -
Ww slightly higher voltage and when it is hot it will be

a
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Ls
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©GIEE-All rights reserved www.giee.org

 Charge Controller
| GIEE

Parallel C.C
Parallel TSMPPT System
ENGINEERING

PV Array PV Array
TSMPPT TSMPPT
OF ELECTRICAL

s + - +

= s —
& | = < —= a
a <> 4v ys ay

Array 1 - Array 2 -
INSTITUTE

Battery -
Battery +
GLOBAL

Note: This diagram does not Battery +

include fusing/disconnects. Battery -
Fusing/disconnects should be
Note: Each TSMPPT controller
installed as local electric code
must be wired to its own isolated
requires
PV array (as above). A single
array Cannot be paralleled into
THE

both controllers

©GIEE-All rights reserved www.giee.org

Ww
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[4 Equalization
Ww
ie)
cs The Equalization function can be manually initiated or can be set up
Lu)
z
to Auto Equalize. The intent of an Equalization charge is to bring all
WW
a
battery cells to an equal voltage by a controller deliberate
4 overcharge. The goal is to return each battery cell to its optimum
4
x
7
condition through a series of voltage controlled chemical reactions
is) inside the batteries.
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oa
°
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2 MidNite Solar Classic 200-SL Charge Controller
==
Default preset voltages for the different nominal battery voltages.
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| wm 12v 24v 36v 48v 60v Tv
os
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| Float 13.6v 27.2v 40 8v 54 4v 68.0v 81.6v
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x
-

©GIEE-All rights reserved www.giee.org

 Ww
= Charge Controller
Lu)
Lu)
Outback Power FlexMax FM80 Charge Controller
<
x (a a ae
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ite)
z Features & Attributes a
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>» Dimensions (LxWxH): 16.3 x 5.6 x 4 inches
I
4
> Weight: 14 Ibs
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4
7
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>» Rated to 80 A DC output current
a
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re
°
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> Allows use with virtually any battery type
ro
- >» An optional Mate can be added to allow
==
n”
monitoring and control from up to 300 feet
z away
a
a
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o}
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> 12/24/48 V
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©GIEE-All rights reserved www.giee.org
 Ww
— Charge Controller
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r Outback Power FlexMax FM80 Charge Controller
i
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te
cA OFLEXmeax-
BO -FM80-150VD0C OFLEXmex
6O -FM60-150VDC
Lu) Nominal Battery Voltages 12, 24, 36, 48, or 60 VDC (Single model - selectable via field programming at start-up)
z
ive Maximum Output Current 80A @ 104°F (40°C) with adjustable current limit 60A @ 104°F (40°C) with adjustable current limit
i NEC Recommended Solar 12 VDC systems 1000 Watts / 24 VDC Systems 2000 Watts 12 VDC systems 750 Watts / 24 VDC Systems 1500 Watts
ae Maximum Array STC Nameplate 48 VDC systems 4000 Watts / 60 VDC Systems 5000 Watts 48 VDC systems 3000 Watts / 60 VDC Systems 3750 Watts
2
[rg PV Open Circuit Voltage (VOC) 150 VDC absolute maximum coldest conditions / 145 VDC start-up and operating maximum
ro
iS) Standby Power Consumption Less than 1 Watt typical
Ty Power Conversion Efficiency 97.5% @ 80 Amps DC in a 48 VDC System - Typical 98.1% @ 60 Amps DC in a 48 VDC System - Typical
|
WwW Charging Regulation Five Stages: Bulk, Absorption, Float, Silent and Equalization
Lk
° Voltage Regulation Set points 13 to 80 VDC user adjustable with password protection
Ww Equalization Charging Programmable voltage setpoint and duration - automatic termination when completed
a
= Battery Temperature
Automatic with optional RTS installed / 5.0 mV per °C per 2V battery cell
=~ Compensation

ty) Down convert from any acceptable array voltage to any battery voltage.
Voltage Step-Down Capability
< Example: 72 VDC array to 24 VDC battery; 60 VDC array to 48 VDC battery
| Programmable Auxiliary 12 VDC output signal which can be programmed for different
oa Control Output control applications (maximum of 0.2 Amps DC)
a
°
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O©GIEE-All rights reserved www.giee.org

 Ww
— Charge Controller
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Lu)
é Outback Power FlexMax FM80 Charge Controller
4
Ww
te)
z Models:
oO
z >» FLEXmax 80: 80 amps maximum continuous
Ww output current (up to 40°C without thermal derating)
a
a >» FLEXmax 60: 60 amps maximum continuous
S output current (up to 40°C without thermal derating)
x
kb
iS)
TE) Features:
ps|
Ww > Maximum Power Point Tracking
Le
o > Supports 12, 24, 36, 48, and 60 Vdc
Ww battery voltages
-
a) > Backlit display screen (LCD) with 80 characters
=FE (4 lines, 20 characters per line)
Cy)
2 > Last 128 days of operational data logging
| >» Voltage step-down capability allowing a higher PV
a
Lf) array voltage configuration
Le]
a > Manual and automatic equalize cycles
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it8)
Ps
-

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 Charge Controller
| GIEE

Outback Power FlexMax FM80 Charge Controller

ENGINEERING

Maximum PV Input Wattage

per Charge Controller
OF ELECTRICAL

Battery Maximum PV | Maximum PV

Bank Input Wattage | Input Wattage
for the for the
Voltage | FLEXxmax 80 | FLEXmax 60
12 Vde 1000 W 750 W

24Vde | 2000W 1500 W

INSTITUTE

36Vde | 3000 W 2250 W

48 Vde 4000 W 3000 W

5000 W 3750 W
GLOBAL

60 Vdc
THE

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 Charge Controller
| GIEE

Outback Power FlexMax FM80 Charge Controller

ENGINEERING

FLEXmax Charge
Controlier [AS contguratons
must compy aM cea ac Ur
Sect Codes. Consult your local electric authorty b
OF ELECTRICAL
INSTITUTE
GLOBAL
THE

©GIEE-All rights reserved www.giee.org

 Charge Controller
| GIEE

Outback Power FlexMax FM80 Charge Controller

ENGINEERING

f
1'
j
'
;i~ ~ ~ ~

i
OF ELECTRICAL
INSTITUTE
GLOBAL
THE

O©GIEE-All rights reserved www.giee.org

 ue
— Charge Controller
Oo
LY) Temperature Compensation
rs
x
ue
ive)
<
Lu)
r
pt > Temperature compensation adjusts charge regulation voltage
4
q based on battery temperature.
- Increases regulation voltage when battery is cold, improving ability to
4
a charge battery.
is)
Ww
—
Decreases regulation voltage when battery is warm, decreasing electrolyte
Ww loss and battery overcharge.
Le
°
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a >» The standard temperature compensation coefficient for lead-acid
a
== cells is -5 mV/°C.
Cy)
<
oo
os
a
°
|
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x
=

©GIEE-All rights reserved www.giee.org

Ww
— Charge Controller
o
oO
< Temperature Compensation-Example
x
Ww
Ww
4 » A charge controller for a nominal 24-volt VRLA battery has a
oO
Fo regulation voltage of 28.2 volts at 25°C. What should the charge
Ww
al regulation voltage be if the battery operates at 0°C?
<
4
4
= Vp comp” =- Vu set — (Cv, x(25—T,_.
]x0,)
is)
ive
oo
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°
Ww V__,comp —= 28.24+1.5=29.7 V
-
|
==
2)
>» Conversely, if the battery temperature is 40°C, the charge
< regulation voltage will be reduced to 27.3 volts.
|
4
fe)
°
|
Le)
uy
=
=

O©GIEE-All rights reserved www.giee.org

 ue
— Charge Controller
Oo
LY) Charge Controller Sizing
rs
x
ue
ie)
<
Lu)
r >» Electrical ratings for charge controller are used to properly
pt
4
q
specify equipment and size circuits and include:
-
4
a Nominal and maximum PV array and battery voltages.
is)
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—
Ww
hw
°
Ww >» Charge controllers used in PV system must be listed to UL 1741.
a
a
==
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a
°
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x
=

©GIEE-All rights reserved www.giee.org

vey
= Charge Controller
Lu)
Lu)
<
x
uy
ive)
Charge Controller Sizing-Example
cs
Lu) >» Conductors, overcurrent protection devices and other equipment
z
uy must normally be sized for at least 125% of the maximum PV
|
as output circuit current, or 156% of the short-circuit current for the
o PV output circuit [690.8].
4
7
oO
Ww
/
Ww
re
For example, a PV array with rated short-circuit current of 16 A
° requires a charge controller with at least a 24 A continuous rating
Ww
ro (16 A x 156%). The conductors in the PV output circuit must be
- sized for at least 24 A after deratings for conditions of use have
=FE
been applied.
2)
z
a
a
ie]
o}
od
oO
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x
FE

©GIEE-All rights reserved www.giee.org

 Charge Controller
| GIEE

Morningstar String Calculator: http://string-calculator.morningstarcorp.com/

ENGINEERING

Morningstar String Calculator

OF ELECTRICAL
INSTITUTE

Select PV Module (module search)

Select manufacturer Select model

GLOBAL

Select a Morningstar Product

Select product
THE

OGIEE-AIll rights reserved www.giee.org

 Charge Controller
| GIEE

Design Example: PWM C.C.

ENGINEERING

What is the right size of a charge Controller to charge a battery bank form
1320W PV array (330W/Module).
C.B PV Module
PV Array (4 panels in parallel)

330W i PWM C.C Imp = 8.85A

OF ELECTRICAL

Isc = 9.26A
xOg JauIquio) Voc = 45.9V
Vmp = 37.3V

a
330W
INSTITUTE

a0 <[—_
GLOBAL

Ic,rated = Isc*1.56 = (9.26*4)*1.56 = $7.78 A

System Voltage must be 24V. The C.C. must be rated for 24V battery voltage.
THE

O©GIEE-All rights reserved aA

ee ae eee
 Charge Controller
| GIEE

Design Example: MPPT C.C.

ENGINEERING

What is the right size of a charge Controller to charge a battery bank form
1320W PV array (330W/Module).
C.B PV Module
PV Array (4 panels in parallel)

330W i PWM C.C Imp = 8.85A

OF ELECTRICAL

Isc = 9.26A
xOg JauIquio) Voc = 45.9V
Vmp = 37.3V

a
330W
INSTITUTE

a0 <[—_
GLOBAL

Ic,rated = Isc*1.56 = (9.26*4)*1.56 = $7.78 A

System Voltage must be 24V. The C.C. must be rated for 24V battery voltage.
THE

O©GIEE-All rights reserved aA

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