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PWM based solar charge controller for inverter/ UPS integration

Introduction to Solar charge controllers:


The solar charge controller is used in off-grid and grid-tie with battery backup systems. The charge controller is an electronic voltage regulator that is used to limit the rate at which electric current is drawn in or out of the batteries. The simplest charge controllers turn off the charge when the battery reaches the optimum charging point and turns on when it goes below certain level. It fully charges the battery without permitting overcharge while preventing from reverse current flow. The overcharge or overvoltage may reduce the battery performance or lifespan and may pose a safety risk.

Technical features of PWM Charge Controller:


PWM based charging control. Charging through Solar panel or Grid supply based on availability of sources. Supplying the load is based on selection of mode in the charge controller. Temperature compensation for better battery charging for various climate and terrain. Two LEDs are provided for indicating solar charge availability and solar charging indication. On Board Grid availability detector along with LED Indicator. Grid connectivity Relay with built in Fuse. 3 Pin Grid Socket on board.

Electrical parameters in 12 Volt mode:


Nominal Battery Voltage: 12V Battery Capacity: 150 Amp Hours Maximum Battery voltage: 14.4V DC Battery Cut-off Voltage: 11V DC. Photovoltaic Panel Voltage Ratings: 12V Nominal (17-21V Open Circuit Voltage). Solar panels required: 5*100W in parallel or 2*250W in parallel. Inverter/UPS rating: 800VA or 1KVA (12V).
Visionary Lighting & Energy India (P) Ltd Ph: +91 40 6457 2220 Email: contact@vleindia.com Url: www.vleindia.com

Grid Supply: 230V AC. Maximum output: 20A @ 12V or 40A @ 12V. Maximum Peak Efficiency of circuit: 98%. Idle Power consumption: 30mW. Load Voltage Ratings: 12V nominal, 11V-14.4V typical range. Maximum load current: 30A.

Electrical parameters in 24 Volt mode :


Nominal Battery Voltage: 24V Battery Capacity: 150 Amp Hours. Maximum Battery voltage: 28.8V DC Battery Cut-off Voltage: 22V DC. Photovoltaic Panel Voltage Ratings: 24V Nominal (30-60V Open Circuit Voltage). Solar panels required: 10*100W in parallel or 4*250W in parallel Inverter/UPS rating: 1400VA (24V). Grid Supply: 230V AC. Maximum output: 20A @ 24V or 40A @ 24V. Maximum Peak Efficiency of circuit: 98%. Idle Power consumption: 30mW. Load Voltage Ratings: 24V nominal, 22V-28.8V typical range. Maximum load current: 30A.

Protections & Switches:


The following are the protections provided in the charge controller
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Battery deep discharge protection which ensures long life of battery. Battery over charge protection. Short circuit protection at load using Fuse. Over load protection using Fuse. Battery reversal protection for protecting battery using Fuse / Solid state automatic resettable fuse (Optional).
Visionary Lighting & Energy India (P) Ltd Ph: +91 40 6457 2220 Email: contact@vleindia.com Url: www.vleindia.com

Solar panel reversal protection using Fuse / Solid state automatic resettable fuse (Optional).

Grid overload Fuse for protection of Relay.

Switches: Two touch switches are provided for the selection of modes 1. Bypass mode selecting switch. 2. Power save mode selecting switch.

Communication port RS-232:


The main features of the communication port provided in the charge controller are For Data logging in future. For changing the battery cutoff levels based on requirement. For energy metering in future.

Description:
The charge controller for inverter/UPS integration is designed for providing proper control for battery charging and supplying the load with the available two sources (Solar & Grid supply). This charge controller having the feature of operating at different modes based on requirement. The modes of operation are described below. The Modes of operation of the charge controller: Normal Mode: During the normal mode of operation the SPV and grid will charge the battery, and the loads are connected to the Grid through UPS. There is no current drawn from the battery even the grid is not available to the load. So, the loads are disconnected when the grid is not available in normal mode. Bypass Mode: 1. When the bypass mode switch is enabled, the LED will glow. (It indicates that the controller will disconnect the grid from load and bypasses the SPV to the load directly through the UPS
Visionary Lighting & Energy India (P) Ltd Ph: +91 40 6457 2220 Email: contact@vleindia.com Url: www.vleindia.com

when battery reaches 14.4V DC at charging condition). 2. During bypass function, if the load is equal or less than SPV Watts then we get free supply from solar. Load will neither draw current from battery nor grid. 3. If the load is greater than SPV watts then the shortage of current will be drawn from the battery, till the battery reaches 11V DC. (This reserve voltage can be changed according to your requirement). 4. If the battery reaches 11V Dc then the Smart CC connects the grid to the Load and SPV will start charging the battery if solar is present. If source is not present then grid will take care of charging and driving the load. 5. During the bye pass function, if the battery hasnt reached 11V DC and the solar source is reduced then the CC will allow the grid supply to UPS. Power save Mode: If the power save mode switch is enabled then even after the sunset the CC will not allow the grid to take over, but it drives the load with the battery current till battery reaches 11V DC.

Operation of charge controller Based on Availability of Sources:


1) When the grid power not available, solar source available :- The charge controller charges the battery; the load will be driven by the UPS once battery reaches 14.4V then the load will take free current available at the battery terminal from the SPV CC. And thus bye passes the DC current from the SPV to the load through the UPS. If the load is less than the SPV watts then we got free supply from the SPV. If the load is more than the SPV watts then the shortage of current is drawn from the battery. We have set a reserve point for the battery (either 11.5 OR 11V), once the battery reaches that point the bye pass operation stops and starts charging the battery. 2) When the grid power available, solar source fully available:- The charge controller charges the battery but the UPS will not charge because the charger section of UPS will switch off by sensing the voltage from CC at the battery terminals. But the load will be driven through the grid. Once the battery reaches full charge level then the CC disconnects the grid to the UPS by a relay in the CC, then the UPS will try to draw the current from the battery, but it will take
Visionary Lighting & Energy India (P) Ltd Ph: +91 40 6457 2220 Email: contact@vleindia.com Url: www.vleindia.com

free ee current available at the battery terminal from the SPV CC. If the load is less than the SPV watts then we get free supply from the SPV SPV. If the load is more than the SPV watts then the storage of current is drawn from the battery. We have set a reserve p point oint for the battery (either 11.5 or 11V) once the battery reaches that point the bye pass operation stops and starts charging the battery. 3) When the grid power available, solar source partially available available:- The CC & Grid both will charge accordingly with h their available source capacity. Since both the chargers operates by sensing the battery voltage there will be no harm for the battery. The load will be driven by the grid till the battery is fully charged, then it bypasses the SPV to load. 4) Once CC bypasses passes the SPV to load it will be in the same mode even after the sunsets, till the battery reaches the reserve point. Once the battery reaches the reserve point then the CC connects the grid power to the UPS.

Connection Diagram:

Visionary Lighting & Energy India (P) Ltd Ph: +91 40 6457 2220 Email: contact@vleindia.com Url: www.vleindia.com

For Details Contact: VLEINDIA Ravi Chambers, Nagarjuna Circle Banjara Hills Road No. 1 Punjagutta, HYD Tel: +91 40 6457 2220 Email: contact@vleindia.com URL: www.vleindia.com

Visionary Lighting & Energy India (P) Ltd Ph: +91 40 6457 2220 Email: contact@vleindia.com Url: www.vleindia.com

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