Solar Charge Controller |
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General Information
A photovoltaic charge controller or regulator is a device that prevents solar panels from over charging your batteries by regulating the current flowing from your solar panels to the battery bank. When your batteries are fully charged, the controller stops the flow of current or slows it to a slow trickle. Connecting your solar array to your batteries without a controller seriously risks damaging your batteries and potentially causing safety problems. Charge controllers are rated and sized according to the systems they protect and to the amount of current flowing from your solar array.
Most common are 12, 24 and 48-volt controllers. Amperage ratings range from 1 amp to over 100 amps.
For safety reasons it is best to oversize your controller by at least 25%.
For example, if your 12-volt system has four solar panels rated at 4.0 amps each, total output would be 16 amps. Adding 25%, you would need at least a 20- amp controller.
There is no problem going with a larger controller other than additional cost and it's something you may want to consider if you think you may be adding more solar panels in the future.
Other than protecting your batteries from over charging, there are several other features that should be included in your controller.
A few of these options are:
• Reverse Current Leakage Protection - This keeps current from flowing backward from your
batteries to your array.
• Low Voltage Disconnect - This reduces damage to your batteries by avoiding deep
discharges.
• System Monitoring - meters, indicating lights and/or warning alarms.
• Temperature Compensation - The charging voltage is adjusted to the temperature if your
batteries are not in a climate-controlled space.
Remember Always Use Proper Sized Wiring and Connectors.
Any time the sun is shining, a PV array is ready to produce electricity. All that's needed to get the electrons in those wires moving is a complete circuit. But in off-grid battery-based systems, overcharging will occur if the batteries are full and if more energy is being generated than is being consumed by loads. This can permanently damage the batteries.
That's where controllers come in—to protect the batteries. The simplest PV controller is a manual switch that's flipped to disconnect the PV array when the battery bank is full. However, since battery damage can happen quickly, an automated solution is needed. Modern PV charge controllers can:
• prevent overcharging and coddle the battery bank with a strict regime of healthy charging cycles;
• equalize the batteries on a set monthly schedule or on command;
• log, store and send detailed charging information to a computer or the Internet;
• automatically control other equipment in the system according to battery bank voltage;
• and even communicate with other system components to deliver the best system performance.
Advances in Controllers
The earliest PV charge controllers were voltage-controlled switches that disconnected the PV array when a certain voltage was reached. When voltage fell to another, lower point, it reconnected the array. These controllers protected the batteries from overcharging, but were unable to provide
the three-stage charging regime recommended by battery manufacturers for longest battery life, since the controller output was either "on" or "off."
The advent of pulse-width-modulated (PWM) controllers made efficient three-stage charging from a PV array possible.
This technology charges batteries with high-frequency electrical pulses, and can continuously change the amperage being delivered by varying the length of the pulses. When the batteries are discharged, the PWM controller senses this from the battery bank voltage and stays on to deliver the full current available, called the "bulk" stage of charging.
The next stage of charging is "absorption" and occurs as the batteries approach a full state of charge (SOC). The controller holds battery bank voltage constant for a period of time, and the "off" time of the pulses is increased to gradually reduce current as the bank is topped off.
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EPIP-60 SERIES SOLAR CHARGE CONTROLLER
60 Amp Charger
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Characteristics
●PWM or ON/OFF series charging
●Over-load, short circuit, polarity reverse protection, electronic fuse.
●State of charge(SOC) battery regulation
●Battery Ah setting, boost, equalizing and float charging
●Automatic load reconnection
●Automatic selection of voltage（12/24V or 24/48V）
●Temperature compensation
●Accurate clock show
●Lighting control, timer setting options during night time
●Field adjustable parameters by four buttons
●LCD display: SOC as a fuel gauge, all system parameters in digital value, system status as symbols
View Installation Manual (pdf )
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EPIP30R SERIES SOLAR CHARGE CONTROLLER
30 Amp Charger
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Characteristics
●PWM or ON/OFF series charging
●Over-load, short circuit, polarity reverse protection, electronic fuse.
●State of charge(SOC) battery regulation
●Battery Ah setting, boost, equalizing and float charging
●Automatic load reconnection
●Automatic selection of voltage（12/24V）
●Temperature compensation
●Accurate clock show
●Lighting control, timer setting options during night time
●Field adjustable parameters by four buttons
●LCD display: SOC as a fuel gauge, all system parameters in digital value, system status as symbols
View Installation Manual (pdf )
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C12 Charge Controller
Description
12 Amp 3-stage Solar Charge, DC Load and Auto Lighting Controller
The C12 charge, lighting, or load controller is uniquely sophisticated. As a charge controller, it features three-stage charging, user definable voltage parameters, and automatic equalization. Standard in the C12's load control circuitry are field adjustable low voltage disconnect and reconnect points, along with a five minute low battery disconnect warning. The C12 also functions as a lighting controller. Lighting run time is adjustable from 2 to 8 hours or can be set from dusk to dawn operation. It is used worldwide in a variety of applications, including remote village lighting systems and automatic outdoor lighting in Africa, Latin America, and Asia. An optional battery temperature sensor ensures precise battery charging regardless of battery temperature fluctuations.
Product Features
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Ensures your batteries are always charged
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Silent, pulse width modulated microprocessor control (maximizing battery life)
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Field adjustable voltage and battery set points
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Electronic protection against short-circuit, overload, over temperature and reverse polarity conditions.
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Electrical Specifications
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PV Amps (Max.)
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12 A at 12 VDC only
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DC Load (Max.)
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12 A with auto reset
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Operating Voltage (Min.)
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6 V
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Voltage Drop - PV to Battery (Max.)
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0.3 V
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Voltage Drop - Battery to DC Load (Max.)
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0.15 V
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Regulation Setting
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13 to 15 VDC
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Equalize Setting
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Bulk plus 1 V for two hours
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Consumption while charging (typical)
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0.007 A
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Consumption at night (typical)
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0.003 A
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Consumption with load disconnected (typical)
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0.003 A
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Stranded wire size (Max.)
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#10 AWG stranded (5.4 mm2)
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General Specifications
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Allowed Temperature Range
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32° F to 104° F (0° C to 40° C)
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Enclosure Type
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Powder coated steel with strain relief for wiring and knockouts for up to three 1/2" conduits
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Unit Weight
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2 lb (0.9 kg)
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Shipping Weight
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2.5 lb (1.13 kg)
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Dimensions (H x W x D)
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6.25 x 4.3 x 1.5" (16.5 x 11 x 4 cm)
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Shipping Dimensions (H x W X D)
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8 x 4.6 x 1.6" (20.3 x 11.7 x 4 cm)
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Mounting
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Vertical wall mount - indoor
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Warranty
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Two years
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Part Numbers
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C12 - charge controller
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BTS - optional battery temperature sensor
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Features & Options
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Regulation Method
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Standard - three stage (bulk, absorption and float), solid state, pulse width modulation
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Field Adjustable Control Setpoints
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Standard - removable knobs and calibrated scales
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Setting Protection
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Standard - knobs can be removed to prevent tampering
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Testpoints
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Standard - provided for each setting
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Automatic Equalization
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Standard - every 30 days or after voltage reaches low voltage disconnect - can be disabled
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External Battery Temperature Compensation
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Optional - battery temperature sensor (BTS)
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Short Circuit Protection
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Standard - fully electronically protected with auto reset and manual reset switch, protects both the loads and PV array from damage from short circuits - a fuse for the battery is still advised to protect the battery wires if located separately
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Reverse Polarity Protection
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Standard - fully protected
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Low Voltage Disconnect
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Standard - adjustable automatic or manual operation, manual reconnection includes warning flash of loads five minutes before and ten minutes grace period
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C Series Charge Controllers
Description
A Controller for Virtually Any DC Charging Source
The C Series, including the C35, C40 and C60, is the benchmark of our charge controller lineup. The C35 and C60 are field configurable for 12 and 24 VDC operation. The C40 may be configured for 12, 24, or 48 VDC operation. All can be used as a charge, diversion, or load controller and come with a standard multi-color charge status LED.
All three of these fully solid state, microprocessor-driven controllers are UL and cUL listed. Whatever the charging source, a C Series controller is sure to meet your DC controller needs.
Product Features
- Ensures your batteries are always charged
- Silent, pulse width modulated microprocessor control (maximizing battery life)
- Field adjustable voltage and battery set points
- Electronic protection against short-circuit, overload, over temperature and reverse polarity conditions.
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C35
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Electrical Specifications
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Voltage Configurations
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12 and 24 VDC
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Max. PV Open Circuit Array Voltage
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55 VDC
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Charging / Load Current (at 25 °C)
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35 amps DC
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Max. Peak current
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85 amps
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Max. Voltage Drop through Controller
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0.30 volts
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Typical Operating Consumption
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15 ma
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Typical Idle Consumption
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3 ma
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Recommended Breaker Size
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45 amps
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Recommended Wire Size
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#8 AWG
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Lead Acid Battery Settings
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Adjustable
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NiCad Battery Settings
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Adjustable
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Load Control Mode
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Low Voltage Reconnect - Adjustable (sticker provided with unit) all models
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Low Voltage Disconnect - User selectable manual or automatic reconnection - includes warning flash before disconnect and provides a one time, user selectable grace period) all models
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General Specifications
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Specified Temperature Range
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32° F to 104° F (0° C to 40° C)
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Enclosure Type
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Indoor, ventilated, powder coated steel with 3/4" and 1" knockouts
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Unit Weight
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2.5 lb (1.2 kg)
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Shipping Weight
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3.0 lb (1.4 kg)
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Dimensions (H x W x D)
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8.0 x 5.0 x 2.5" (20.3 x 17.8 x 6.4 cm)
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Shipping Dimensions (H x W x D)
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12.4 x 7 x 2.5" (31.5 x 17.8 x 6.4 cm)
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Mounting
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Vertical wall mount - indoor only
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Altitude - Operating
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15,000' (4,572 m)
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Altitude - Non-Operating
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50,000' (15,240 m)
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Warranty
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Two years
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Part Numbers
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C5, C40, C60 - Controllers
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CM - Front Display Panel
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CM/R-50, CM/R-100 - Remote Display Panel
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BTS - Battery temperature sensor
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Features & Options
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Regulation Method
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Solid stage, three-stage (bulk, absorption, and float), pulse width modulation
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Field Adjustable Control Setpoints
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Two user adjustable voltage setpoints for control of loads or charging sources - setting retained if battery is disconnected
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Display Panel
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CM, CM/R-50, or CM/R-100 - optional LCD - backlit, alphanumeric display showing battery voltage, DC amperage, cumulative amp hours, and amp hours since last reset - remote includes 50' (15 m) or 100' (30.5 m) cable
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Equalization Charge
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User selectable manual or automatic equalization - every 30 days
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Battery Temperature Sensor
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BTS - optional remote battery temperature sensor for increased charging precision
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Regulatory Approvals
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UL Listed to UL 1741 - 1999 and to CSA 22.2 No. 107.1-95 Standards, CE compliant
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C40
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Electrical Specifications
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Voltage Configurations
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12, 24 and 48 VDC
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Max. PV Open Circuit Array Voltage
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125 VDC
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Charging / Load Current (at 25 °C)
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40 amps DC
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Max. Peak current
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85 amps
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Max. Voltage Drop through Controller
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0.30 volts
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Typical Operating Consumption
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15 ma
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Typical Idle Consumption
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3 ma
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Recommended Breaker Size
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50 amps
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Recommended Wire Size
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#8 AWG
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Lead Acid Battery Settings
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Adjustable
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NiCad Battery Settings
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Adjustable
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Load Control Mode
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Low Voltage Reconnect - Adjustable (sticker provided with unit) all models
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Low Voltage Disconnect - User selectable manual or automatic reconnection - includes warning flash before disconnect and provides a one time, user selectable grace period) all models
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General Specifications
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Specified Temperature Range
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32° F to 104° F (0° C to 40° C)
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Enclosure Type
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Indoor, ventilated, powder coated steel with 3/4" and 1" knockouts
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Unit Weight
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3.0 lb (1.4 kg)
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Shipping Weight
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3.5 lb (1.6 kg)
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Dimensions (H x W x D)
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10 x 5 x 2.5" (25.4 x 12.7 x 6.35 cm)
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Shipping Dimensions (H x W x D)
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12.4 x 7 x 2.5" (31.5 x 17.8 x 6.4 cm)
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Mounting
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Vertical wall mount - indoor only
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Altitude - Operating
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15,000' (4,572 m)
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Altitude - Non-Operating
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50,000' (15,240 m)
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Warranty
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Two years
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Part Numbers
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C5, C40, C60 - Controllers
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CM - Front Display Panel
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CM/R-50, CM/R-100 - Remote Display Panel
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BTS - Battery temperature sensor
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Features & Options
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Regulation Method
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Solid stage, three-stage (bulk, absorption, and float), pulse width modulation
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Field Adjustable Control Setpoints
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Two user adjustable voltage setpoints for control of loads or charging sources - setting retained if battery is disconnected
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Display Panel
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CM, CM/R-50, or CM/R-100 - optional LCD - backlit, alphanumeric display showing battery voltage, DC amperage, cumulative amp hours, and amp hours since last reset - remote includes 50' (15 m) or 100' (30.5 m) cable
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Equalization Charge
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User selectable manual or automatic equalization - every 30 days
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Battery Temperature Sensor
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BTS - optional remote battery temperature sensor for increased charging precision
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Regulatory Approvals
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UL Listed to UL 1741 - 1999 and to CSA 22.2 No. 107.1-95 Standards, CE compliant
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C60
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Electrical Specifications
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Voltage Configurations
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12 and 24 VDC
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Max. PV Open Circuit Array Voltage
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55 VDC
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Charging / Load Current (at 25 °C)
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60 amps DC
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Max. Peak current
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85 amps
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Max. Voltage Drop through Controller
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0.30 volts
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Typical Operating Consumption
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15 ma
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Typical Idle Consumption
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3 ma
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Recommended Breaker Size
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60 amps rated at 1000% continuous duty
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Recommended Wire Size
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#6 AWG rated at 90 °C
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Lead Acid Battery Settings
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Adjustable
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NiCad Battery Settings
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Adjustable
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Load Control Mode
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Low Voltage Reconnect - Adjustable (sticker provided with unit) all models
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Low Voltage Disconnect - User selectable manual or automatic reconnection - includes warning flash before disconnect and provides a one time, user selectable grace period) all models
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General Specifications
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Specified Temperature Range
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32° F to 104° F (0° C to 40° C)
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Enclosure Type
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Indoor, ventilated, powder coated steel with 3/4" and 1" knockouts
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Unit Weight
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Shipping Weight
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Dimensions (H x W x D)
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Shipping Dimensions (H x W x D)
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Mounting
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Vertical wall mount - indoor only
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Altitude - Operating
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15,000' (4,572 m)
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Altitude - Non-Operating
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50,000' (15,240 m)
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Warranty
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Two years
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Part Numbers
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C5, C40, C60 - Controllers
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CM - Front Display Panel
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CM/R-50, CM/R-100 - Remote Display Panel
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BTS - Battery temperature sensor
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Features & Options
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Regulation Method
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Solid stage, three-stage (bulk, absorption, and float), pulse width modulation
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Field Adjustable Control Setpoints
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Two user adjustable voltage setpoints for control of loads or charging sources - setting retained if battery is disconnected
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Display Panel
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CM, CM/R-50, or CM/R-100 - optional LCD - backlit, alphanumeric display showing battery voltage, DC amperage, cumulative amp hours, and amp hours since last reset - remote includes 50' (15 m) or 100' (30.5 m) cable
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Equalization Charge
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User selectable manual or automatic equalization - every 30 days
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Battery Temperature Sensor
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BTS - optional remote battery temperature sensor for increased charging precision
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Regulatory Approvals
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UL Listed to UL 1741 - 1999 and to CSA 22.2 No. 107.1-95 Standards, CE compliant
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