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Charge Controller Basics
Solar modules produce electricity when the sun shines. The charge controller regulates the flow of electricity from the solar modules to the battery bank. When the battery bank is low, the charge controller feeds all of the electricity from the array to the batteries. When the batteries reach a state of full charge, the charge controller stops or redirects the supply of electricity to prevent overcharging. Modern charge controllers have the ability to hold the battery bank in a "float" state of charge if the bank is not being used. At night the charge controller prevents a reverse flow of current from the batteries to the modules.
There are three basic types of charge controllers - series, shunt and pulse-width-modulated. A series controller, the most basic type, acts as a switch to disconnect and re-connect the solar modules to the battery bank. A shunt type controller redirects the current from the solar modules - either by simply short circuiting the array or by directing the current to some other load. Pulse-width-modulated charge controllers, the most up-to-date type, maintain the battery bank in a float state of charge. "Float" is the voltage level just below gassing voltage. Keeping the batteries in this state of charge delivers their best possible life without using excessive electrolytic.
Charge controllers are generally selected by their size or ability to control a given amount of current, and by their operating voltage. Listed on this and the
next page are some of the most popular and effective charge controllers on the market.
Note: Trace Engineering has been acquired by Xantrex Engineering in the last year or so. For now most equipment is coming through with the Trace brand name on the box. This could be changed to Xantrex at any time but the equipment will be identical to the existing Trace equipment.
Trace Charge Controllers
C35, C40 and C60
The C35, C40 and C60 charge controllers are 3 stage solid-state, pulse width modulated
devices. They work as charge controllers, DC load controllers or DC diversion regulators. They are electronically protected for short circuit, overload, over-temperature and reverse polarity conditions.
They will control 12V, 24V and in the case of the C40, 48V PV systems. They feature field adjustable set-points, automatic or manual battery bank equalization settings and status LED indicators. As their names suggest, the C35 is rated for 35 amps, the C40 for 40 amps and the
C60 for 60 amps. But they will actually control up to 60 amps before they self limit. They each have automatic high current overload protection which simply turns the unit
 off until the high current condition is removed. Restart is automatic.
Each can be fitted with a digital meter as an option which monitors battery bank voltage, array current and amp-hours. See below for details.
Trace
C12 Charge/ Load Controller
730-012 12 amp, 12 volt
$110
Trace Engineering has introduced the C12, the most advanced small PV system controller available. It performs several functions including:
1. PV Charge Controller - 12 volts, 12 amps
2. DC Load Controller with automatic disconnect/reconnect features and adjustable
set-points
3. Automatic Lighting Controller with field adjustable time durations of 2,4,6,8,10,12 or 14 hours
4. Tri-Color LED Battery Charge/Discharge Condition
The C12 was designed to completely control small systems,
automatic lighting systems and unattended remote systems. All of the above features work at the same time for complete system control and maintenance. The C12 also has excellent regulation features making it a perfect controller for sealed batteries of any type. Its automatic equalization capability makes the C12 an ideal controller for unattended lead acid battery banks. Excellent installation instructions and Trace's standard 2 year warranty are included.
Trace DVM for C35, C40 and C60
Digital Volt/Amp/Power Meter
 The Trace DVM is the perfect accessory for all three charge controllers. The DVM displays volts, amps, and cumulative amp-hours for a solar array. It mounts directly on the C35, C40 or C60. The DVM R/50 or R/100 can be remotely mounted up to 50' or 100' away, respectively. All three versions of the DVM have a backlight LCD display.
The Trace remote meters require a dual-ganged electrical box for mounting.
See page 20 for a surface mount version.
SCI ASC-8/12 Charge Controller
 This is a small, compact, epoxy encapsulated charge controller
that will work with an array output up to 8 amps (two Solarex SX-50's,or one SX75).
The ASC-8 has a red LED which lights while charging and flashes as the battery
bank reaches full charge. This controller is most often used on one module
systems that will not later become large systems.
Note: Charge Controllers are continued on the next web page.
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