Charge Controllers

The following information on charge controllers is taken from: Polar Powe Inc. unless otherwise indicated.

The primary function of a charge controller in a stand-alone PV system is to protect the battery from overcharge and over discharge. Any system that has unpredictable loads, user intervention, optimized or undersized battery storage (to minimize initial cost), or any characteristics that would allow excessive battery overcharging or over discharging requires a charge controller and/or low-voltage load disconnect. Lack of a controller may result in shortened battery lifetime and decreased load availability.

Systems with small, predictable, and continuous loads may be designed to operate without a battery charge controller. If system designs incorporate oversized battery storage and battery charging currents are limited to safe finishing charge rates (C/SO flooded or C/1OO sealed) at an appropriate voltage for the battery technology, a charge controller may not be required in the PV system.

Proper operation of a charge controller should prevent overcharge or over discharge of a battery regardless of the system sizing/design and seasonal changes in the load profile and operating temperatures. The algorithm or control strategy of a battery charge controller determines the effectiveness of battery charging and PV array utilization, and ultimately the ability of the system to meet the load demands. Additional features such as temperature compensation, alarms, and special algorithms can enhance the ability of a charge controller to maintain the health, maximize capacity, and extend the lifetime of a battery.

Basics of charge controller theory

While the specific control method and algorithm vary among charge controllers, all have basic parameters and characteristics. Manufacturer's data generally provides the limits of controller application such as PV and load currents, operating temperatures, losses, set points, and set point hysteresis values. In some cases the set points may be intentionally dependent upon the temperature of the battery and/or controller, and the magnitude of the battery current. A discussion of the four basic charge controller set points follows:

Regulation set point (VR): This set point is the maximum voltage a controller allows the battery to reach. At this point a controller will either discontinue battery charging or begin to regulate the amount of current delivered to the battery. Proper selection of this set point depends on the specific battery chemistry and operating temperature.

Regulation hysteresis (VRH): The set point is voltage span or difference between the VR set point and the voltage when the full array current is reapplied. The greater this voltage span, the longer the array current is interrupted from charging the battery. If the VRH is too small, then the control element will oscillate, inducing noise and possibly harming the switching element. The VRH is an important factor in determining the charging effectiveness of a controller.

Low voltage disconnect (LVD): The set point is voltage at which the load is disconnected from the battery to prevent over discharge. The LVD defines the actual allowable maximum depth-of-discharge and available capacity of the battery. The available capacity must be carefully estimated in the system design and sizing process. Typically, the LVD does not need to be temperature compensated unless the batteries operate below 0°C on a frequent basis. The proper LVD set point will maintain good battery health while providing the maximum available battery capacity to the system.

Low voltage disconnect hysteresis (LVDH): This set point is the voltage span or difference between the LVD set point and the voltage at which the load is reconnected to the battery. If the LVDH is too small, the load may cycle on and off rapidly at low battery state-of-charge, possibly damaging the load and/or controller. If the LVDH is too large, the load may remain off for extended periods until the array fully recharges the battery. With a large LVDH, battery health may be improved due to reduced battery cycling, but this will reduce load availability. The proper LVDH selection will depend on the battery chemistry, battery capacity, and PV and load currents.

Charge controller algorithms

Two basic methods exist for controlling or regulating the charging of a battery from a PV module or array - series and shunt regulation. While both of these methods can be effectively used, each method may incorporate a number of variations that alter basic performance and applicability. Following are descriptions of the two basic methods and variations of these methods.

Shunt controller

A shunt controller regulates the charging of a battery by interrupting the PV current by short-circuiting the array. A blocking diode is required in series between the battery and the switching element to keep the battery from being shortened when the array is shunted. This controller typically requires a large heat sink to dissipate power. Shunt type controllers are usually designed for applications with PV currents less than 20 amps due to high current switching limitations.

Shunt-linear: This algorithm maintains the battery at a fixed voltage by using a control element in parallel with the battery. This control element turns on when the VR set point is reached, shunting power away from the battery in a linear method (not on/off), maintaining a constant voltage at the battery. This relatively simple controller design utilizes a Zener power diode which is the limiting factor in cost and power ratings.

Shunt-interrupting: This algorithm terminates battery charging when the VR set point is reached by short-circuiting the PV array. This algorithm has been referred to as "pulse charging" due to the pulsing effect when reaching the finishing charge state. This should not be confused with Pulse-Width Modulation (PWM).

Series controller

Several variations of this type of controller exist, all of which use some type of control element in series between the array and the battery.

Series-interrupting: This algorithm terminates battery charging at the VR set point by open-circuiting the PV array.

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