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.
Xantrex Charge Controllers
C35, C40 and C60
| 730-035 | C35 35A, 12 or 24 volt | $119 |
| 730-040 | C40 40A, 12, 24 or 48 volt | $159 |
| 730-060 | C60 60A, 12 or 24 volt | $199 |
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.
C12 Charge/ Load Controller
| 730-012 | 12 amp, 12 volt only | $110 |
The C12 was designed to completely control small systems, automatic lighting systems and unattended remote systems. It can function as a charge controller, load controller and lighting controller at the same time. The C12 can regulate either wet or sealed lead-acid batteries. Its automatic equalization capability makes the C12 an ideal controller for unattended lead acid battery banks. Excellent installation instructions and Xantrex's standard 2 year warranty are included.
SCI ASC-8/12 Charge Controller
| 731-008 | 12 volts, 8 amps | $49 | |
| 731-009 | 24 volts, 8 amps | $59 | |
Xantrex CM for C35, C40 and C60
Digital Volt/Amp/Power Meter
| 730-041 | CM/C35,C40,C60 | $99 |
| 730-042 | CM R/50' Remote | $126 |
| 730-043 | CM R/100' Remote | $146 |
Battery Temperature Sensors |
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| 741-032 | 15' BTS/15 | $29 |
| 730-033 | 35' BTS/35 | $32 |
The Xantrex CM displays volts, amps, and cumulative amp-hours for the solar array. It mounts directly on the C35, C40 or C60. The CM R/50 or R/100 can be remotely mounted up to 50' or 100' away, respectively. All three versions of the CM have a backlight LCD Display. The Xantrex remote meters require a dual-ganged electrical box for mounting.
C35 Charge Controller with CM Meter attached.
CM R/50 Remote
Maximum Power Point Tracking
Many people have asked about power point tracking and whether it has any real advantages. Maximum Power Point Tracking
(MPPT) converts the difference between a solar modules rated voltage, (usually 17 volts) and a battery banks charging voltage (up to 14.7 volts) into usable charging current. Often claims are made for up to a 30% increase in charging current. This
gain, however, is possible under a very limited set of conditions. The "extra" module voltage is there for a reason:
to allow for real world use of the solar module,
i.e. the voltage drop caused by the array wiring and other components, including the charge controller, between the solar array and batteries. Also, high ambient temperatures cause the solar module to drop in voltage further reducing this "extra" voltage.
Having said that, there are times when the voltage difference will be high enough to provide extra current to a battery bank utilizing this type of charge controller. Cold weather comes to mind, as well as low battery bank voltage. Under these conditions, it can be possible to get as much as 10% to 30% more current from your solar modules.
| 730-061 | XW MPPT60 Charge Controller | $685 |
The XW charge controller features maximum power point tracking (MPPT) which allows all available energy to be extracted from the solar array. (See the side bar for a more detailed description of MPPT).
The XW can be used with 12, 24, 36, 48 and 60 volt battery systems. It is also capable of charging a lower voltage battery bank with a higher voltage array. This allows longer array wiring runs without the higher cost of larger wire while still maintaining maximum array output. The MPPT power points are constantly adjusted to maintain maximum array output for all sunlight conditions. The XW 60 is capable of 60 amps charging current into the battery bank and can withstand 150 VDC open circuit voltage from the array.
Features:
- 5 Year Warranty
- Integrated PV Ground Fault Protection
- Three Stage Controller: Bulk, Absorption and Float
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Reverse Current Protection
- Over and Under Voltage Protection
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Output Over Current Protection
- Digital Display Option showing Battery Bank Voltage,
Array Current and Battery Charging Current - Battery Temperature Sensor Included
- Programmable Output for Battery Box Vent Fan
- UL 1741 and CSA Certified
Outback Charge Controller
| 730-060 | Outback FLEXmax60 |
$699 |
| 730-080 | Outback FLEXmax80 |
$749 |
The Outback FLEXmax Series charge controllers are maximum power point tracking charge controllers with the ability to charge lower voltage battery banks with higher voltage arrays. That means it could charge a 12VDC battery bank with a 48V or 24V array.
This ability to work on a 12V to 60V battery bank with an open circuit voltage of up to 150V allows your system to achieve its greatest possible performance. (See the sidebar for a description of Maximum Power Point tracking.)
The FLEXmax60 and 80 have a backlit LCD display which monitors system performance and is also used for programming system operation. These are among the finest charge controllers on the market.
- Output Current 60A, 80A
- Nominal Battery Voltage 12,24,32,36,48,60 VDC
- PV Open Circuit Voltage 150V Rated
- Charging regulation Methods Bulk, Absorption, Float, Silent and Equalization
- Voltage Regulation Set-points 10 to 80 VDC
- Equalization Voltage Up to 5V above Absorption
- Digital Display 4 Line, 80 character
- Warranty Standard 5 Year
- Dimensions Fm 60 13.5” H x 5.75” W x 4” D
Fm 80 16.5” H x 5.75” W x 4” D
Morningstar Charge Controllers
TriStar TS-45
| 736-045 | TriStar TS-45 45A 12 to 48V | $174 |
| 736-060 | TriStar TS-60 60A 12 to 48V | $224 |
| 736-047 | TriStar Digital Meter | $102 |
| 736-003 | TriStar Remote Digital Meter | $136 |
| 736-001 | Remote Temperature Sensor | $32 |
| 736-210 | SunSaver 10A 12V | $57 |
| 736-210L | SunSaver 10A 12V w/LVD | $72 |
| 736-310L | SunSaver 10A 24V w/LVD | $79 |
| 736-406 | SunGuard 4A 12V | $34 |
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SunSaver10 w/LVDWe now carry the full line of Morning Star charge controllers: the TriStar, ProStar, SunSaver and SunGuard charge controllers as well as the SunLight lighting control. The TriStar will fit into any of our pre-wired power panels or charge controller panels. It is fully protected (short circuit,, reverse polarity and overload) and is rated at 45 or 60 amps at 12 to 48 volts. Both remote and attached meters are available for the TriStar. The ProStar and Sunsaver offer low battery disconnect from 6 to 30 amps and 12 to 48 volts. The SunGuard is an inexpensive 4.5A 12V controller and the SunLight Controller allows 10 lighting options at 10 to 20A at 12 or 24V. Morningstar has many more options in their charge controller line than we have room to list here. Please call for more details about this versatile line of charge controllers.
Steca Charge Controllers
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| 737-010 | PR 1010 12/24V 10A |
$150 |
| 737-015 | PR 1515 12/24V 15A |
$279 |
Steca charge controllers are made in Germany and incorporate all the aspects of German engineering that one would expect. The controllers include a load controller as well as a charge controller. They feature an LCD meter which monitors state-of-charge in percent, array current and battery bank voltage. The meter also monitors load current. The current rating is for both charge and load control. The included manual guides you through very thorough installation and operation procedures. A very nice charge controller for someone who wants excellent control for a smaller system.