SOLAR CHARGE CONTROLLERS

Prepared By
NAME, P Mgala
Email, Lamsonmgala@[Link]
Phone Number, 0783122125
 INTRODUCTION

• A solar charge controller is a device that regulates the voltage and current
from solar panels to batteries.
• By regulating the voltage and current going to the batteries it therefore
prevent overcharging, over-discharging, and damage to the system.
• It then ensures efficient energy transfer and prolongs battery life.
WHAT DOES SOLAR CHARGE CONTROLLER DO?

• Regulates Voltage and Current: Solar panels produce varying voltage and current
depending on sunlight intensity and temperature. The charge controller steps in to regulate
this output, ensuring that the voltage and current reaching your batteries are within safe and
optimal levels for charging.
• Prevents Overcharging: This is the primary function. Overcharging can cause batteries to
overheat, gas, and eventually fail. The controller monitors the battery's voltage and reduces or
stops the current flow from the panels once the battery reaches its fully charged state.
• Prevents Over-Discharging (in some models): Some charge controllers also monitor
the battery's discharge level and will disconnect the load (appliances connected to the
battery) if the voltage drops too low. This prevents deep discharge, which can also damage
certain types of batteries.
WHAT DOES SOLAR CHARGE CONTROLLER DO?

• Prevents Reverse Current Flow: At night, when the solar panels are not producing
power, some charge controllers have a built-in diode that prevents the battery from
discharging back through the solar panels
• Provides System Information: Many charge controllers have displays that show
important information such as battery voltage, charging current, and system status,
allowing you to monitor the performance of your solar power system
• Maximizes Energy Harvest (in MPPT controllers): More advanced controllers,
called Maximum Power Point Tracking (MPPT) controllers, can optimize the energy
transfer from the solar panels to the batteries. They do this by constantly finding the
"maximum power point" at which the panels are producing the most power and adjusting
the voltage and current accordingly to efficiently charge the batteries.
CONNECTION EXAMPLE
TYPES OF SOLAR CHARGE CONTROLLERS

• There are two types of solar charge controllers namely

PULSE WIDTH MODULATION (PWM) is a device used in solar power

How it works?
o The PWM controller acts as a switch between the solar panel and the battery. It
modulates the power flow by adjusting the duty cycle (the proportion of time the switch
is on) to maintain the desired battery voltage.
o During charging, the solar panel’s voltage is pulled down to match the battery’s voltage,
which can reduce efficiency, especially in systems with mismatched voltages.
o As the battery charges, the controller reduces the current to prevent overcharging, using
short pulses to maintain the battery at the absorption or float voltage
PULSE WIDTH MODULATION (PWM)

Three-Stage Charging: Most PWM controllers use a three-stage charging process to optimize
battery health and extend lifespan.

i. bulk,
ii. absorption
iii. float
• Bulk: Delivers maximum current to quickly charge the battery.
• Absorption: Gradually reduces current to maintain a constant voltage.
• Float: Supplies a low trickle charge to keep the battery fully charged.
KEY FEATURES OF PWM CHARGE CONTROLLERS:

• Cost-Effective: PWM controllers are simpler and less expensive than MPPT (Maximum
Power Point Tracking) controllers, making them ideal for small to medium-sized solar systems.
• Efficient for Small Systems: Best suited for systems where the solar panel voltage is
closely matched to the battery voltage (e.g., a 12V panel with a 12V battery).
• Battery Protection: Includes features like overcharge protection, over-discharge protection,
short-circuit protection, and reverse polarity protection.
• Compatibility: Works with various battery types, including lead-acid (sealed, gel, flooded)
and sometimes lithium batteries, depending on the model.
• Monitoring: Many models feature LCD displays or LED indicators to show battery voltage,
charge current, and system status
ADVANTAGES OF PWM CHARGE CONTROLLERS:

• Affordable: Lower cost makes them suitable for budget-conscious projects or small
systems like solar lighting.
• Simple Design: Easy to set up and operate, with minimal configuration required.
• Reliable in Warm Climates: Performs well in consistent sunlight or high temperatures
where panel voltage (Vmp) is close to battery voltage,
DISADVANTAGES OF PWM CHARGE CONTROLLERS

• Lower Efficiency: Compared to other type PWM is less efficient (typically 70-80% vs. 94-98% for
MPPT) because it cannot capture excess voltage from the solar panel. This results in 10-30% less energy
harvest, especially in cold climates or with mismatched panel-battery voltages
• Voltage Matching Required: The solar panel’s voltage must be close to the battery’s voltage (e.g., 18V
Vmp for a 12V battery), limiting flexibility for larger or complex systems. Not Ideal for Oversized Arrays:
• Potential Interference: The rapid switching can cause electromagnetic interference, affecting nearby
radios or TVs.
• Less Effective in Cold Weather: In cold weather, solar panel voltage increases. PWM controllers can't
utilize this higher voltage to charge the battery more efficiently.
• Not Ideal for Larger Systems: For larger systems where maximizing energy harvest is crucial, PWM
controllers may not be the best choice.
 MPPT (MAXIMUM POWER POINT TRACKING) CHARGE
CONTROLLERS

• MPPT controllers are more advanced and act as smart DC-to-DC converters. They
actively track the maximum power point (MPP) of your solar panels – the voltage and
current combination at which the panels produce the most power under given conditions.
The MPPT controller then converts this higher voltage input from the panels into the correct
voltage needed to efficiently charge your batteries, often at a higher current
• MPPT controllers use sophisticated algorithms to continuously monitor the voltage and
current output of your solar panels.
• They dynamically determine the optimal operating voltage (Vmp) of the panels that will
yield the maximum power output under the current sunlight and temperature conditions. This
MPP constantly changes throughout the day
 MPPT (MAXIMUM POWER POINT TRACKING)
CHARGE CONTROLLERS
• Unlike PWM controllers, MPPT controllers don't directly connect the panels to the
battery. Instead, they use a DC-to-DC converter.
• This allows them to take the higher voltage (at the MPP) from the solar panels and
convert it down to the lower voltage required by the battery bank.
• Importantly, when the voltage is stepped down, the current is stepped up (minus some
conversion losses), resulting in more amperage going into your batteries compared to a
PWM controller in the same situation.
 MPPT (MAXIMUM POWER POINT TRACKING)
CHARGE CONTROLLERS
Stages of Charging (Similar to PWM but More Efficient):
• Bulk Stage: The MPPT controller harvests the maximum power from the panels and
delivers the highest possible current to the battery.
• Absorption Stage: Once the battery reaches the absorption voltage, the MPPT
controller regulates the voltage at this set point while gradually reducing the current as
the battery charges fully. It's still operating at the MPP of the panels during this stage.
• Float Stage: Similar to PWM, the voltage is reduced to a float level to maintain the
charge.
ADVANTAGES OF MPPT CONTROLLERS:

• Increased Energy Harvest: MPPT controllers can extract significantly more energy from your solar
panels (typically 10-30% more, and sometimes even higher in colder conditions or with deeply
discharged batteries) compared to PWM controllers.
• Greater Flexibility in Panel Configuration: You can use solar panels with a higher voltage than your
battery bank. The MPPT controller will efficiently step down the voltage. This allows for more flexible
system designs, such as wiring panels in series to reduce voltage drop over long distances
• Improved Performance in Cold Weather: Solar panels produce higher voltage in cold temperatures.
MPPT controllers can utilize this higher voltage to deliver more power to your batteries.
• Better for Larger Systems: For larger off-grid and hybrid systems where maximizing energy
production is critical, MPPT controllers are the preferred choice.
• Effective with Higher Voltage Panels: MPPT controllers are essential when using grid-tie solar panels
(which typically have higher voltages) to charge lower voltage battery banks.
DISADVANTAGES OF MPPT CONTROLLERS:

• Higher Cost: MPPT controllers are generally more expensive than PWM controllers
due to their more complex electronics.
• Can be Larger in Size: MPPT controllers often have more components and can be
physically larger than PWM controllers.