CHARGER CONTROLLER TYPES

Charge controls come in all shapes, sizes, features, and price ranges. They range from the small 4.5 amp (Sunguard) control, up to the 60 to 80 amp MPPT programmable controllers with computer interface. Often, if currents over 60 amps are required, two or more 40 to 80 amp units are wired in parallel. The most common controls used for all battery based systems are in the 4 to 60 amp range, but some of the new MPPT controls such as the Outback Power FlexMax go up to 80 amps.
Charge controls come in 3 general types (with some overlap):

Simple 1 or 2 stage controls which rely on relays or shunt transistors to control the voltage in one or two steps is RENOGY 40 AMP MPPT CHARGE CONTROLLER. These essentially just short or disconnect the solar panel when a certain voltage is reached. For all practical purposes these are dinosaurs, but you still see a few on old systems - and some of the super cheap ones for sale on the internet. Their only real claim to fame is their reliability - they have so few components, there is not much to break.

3-stage and/or PWM such Morningstar, Xantrex, Blue Sky, Steca, and many others. These are pretty much the industry standard now, but you will occasionally still see some of the older shunt/relay types around, such as in the very cheap systems offered by discounters and mass marketers.

Maximum power point tracking (MPPT), such as those made by Midnite Solar, Xantrex, Outback Power, Morningstar and others. These are the ultimate in controllers, with prices to match - but with efficiencies in the 94% to 98% range, they can save considerable money on larger systems since they provide 10 to 30% more power to the battery. For more information, see our article on MPPT.

Most controllers come with some kind of indicator, either a simple LED, a series of LED's, or digital meters. Many newer ones, such as the Outback Power, Midnite Classic, Morningstar MPPT, and others now have built in computer interfaces for monitoring and control. The simplest usually have only a couple of small LED lamps, which show that you have power and that you are getting some kind of charge. Most of those with meters will show both voltage and the current coming from the panels and the battery voltage. Some also show how much current is being pulled from the LOAD terminals.

All of the charge controllers that we stock are 3 stage PWM types, and the MPPT units. (in reality, "4-stage" is somewhat advertising hype - it used to be called equalize, but someone decided that 4 stage was better than 3). And now we even see one that is advertised as "5-stage"....

WHAT IS EQUALIZATION?

Equalization does somewhat what the name implies - it attempts to equalize - or make all cells in the battery or battery bank of exactly equal charge. Essentially it is a period of overcharge, usually in the 15 to 15.5 volt range. If you have some cells in the string lower than others, it will bring them all up to full capacity. In flooded batteries, it also serves the important function of stirring up the liquid in the batteries by causing gas bubbles. Of course, in an RV or boat, this does not usually do much for you unless you have been parked for months, as normal movement will accomplish the same thing. Also, in systems with small panels or oversized battery systems you may not get enough current to really do much bubbling. In many off-grid systems, batteries can also be equalized with a generator+charger.

WHAT IS PWM?

Quite a few charge controls have a "PWM" mode. PWM stands for Pulse Width Modulation. PWM is often used as one method of float charging. Instead of a steady output from the controller, it sends out a series of short charging pulses to the battery - a very rapid "on-off" switch. The controller constantly checks the state of the battery to determine how fast to send pulses, and how long (wide) the pulses will be. In a fully charged battery with no load, it may just "tick" every few seconds and send a short pulse to the battery. In a discharged battery, the pulses would be very long and almost continuous, or the controller may go into "full on" mode. The controller checks the state of charge on the battery between pulses and adjusts itself each time.

The downside to PWM is that it can also create interference in radios and TV's due to the sharp pulses that it generates. If you are having noise problems from your controller, see this page.

WHAT IS A LOAD, OR "LOW VOLTAGE DISCONNECT" OUTPUT?

Some controllers also have a "LOAD", or LVD output, which can be used for smaller loads, such as small appliances and lights. The advantage is that the load terminals have a low voltage disconnect, so it will turn off whatever is connected to the load terminals and keep from running the battery down too far. The LOAD output is often used for small non-critical loads, such as lights. A few, such as the Schneider Electric C12, can also be used as a lighting controller, to turn lights on at dark, but the Morningstar SLC lighting controller is usually a better choice for that. Do not use the LOAD output to run any but very small inverters. Inverters can have very high surge currents and may blow the controller.

Most systems do not need the LVD function - it can drive only smaller loads. Depending on the rating of the controller, this may be from 6 to 60 amps. You cannot run any but the smallest inverter from the LOAD output. On some controllers, such as the Morningstar SS series, the load output can be used to drive a heavy duty relay for load control, gen start etc. The LOAD or LVD output is most often used in RV & remote systems, such as camera, monitor, and cell phone sites where the load is small and the site is unattended.

WHAT ARE THE "SENSE" TERMINALS ON MY CONTROLLER?

Some charge controllers have a pair of "sense" terminals. Sense terminals carry very low current, around 1/10th of a milliamp at most, so there is no voltage drop. What it does is "look" at the battery voltage and compares it to what the controller is putting out. If there is a voltage drop between the charge controller and the battery, it will raise the controller output slightly to compensate.

These are only used when you have a long wire run between the controller and the battery. These wires carry no current, and can be pretty small - #20 to #16 AWG. We prefer to use #16 because it is not easily cut or squished accidentally. They attach to the SENSE terminals on the controller, and onto the same terminals as the two charging wires at the battery end.

WHAT IS A "BATTERY SYSTEM MONITOR"?

Battery system monitors, such as the Bogart Engineering TriMetric 2025A are not controllers. Instead, they monitor your battery system and give you a pretty good idea of your battery condition, and what you are using and generating. They keep track of the total amp-hours into and out of the batteries, and the battery state of charge, and other information. They can be very useful for medium to large systems for tracking exactly what your system is doing with various charging sources. They are somewhat overkill for small systems, but are kind of a fun toy if you want to see what every amp is doing :-). TriMetric's new PentaMetric model also has a computer interface and many other features.

For a complete list of all our charge controllers, to check pricing, or to order online, see our Charge Controller page on our web store. For battery monitors, meters, and shunts see our Meters & Monitors page there.