I5
IEEE AES MAGAZINE, August 1992
this information can be used to understand the capabilities and batteries, a widely accepted temperature compensation
effects of different battery charge controller specifications. coefficient is - 5 mv/"C/cell[3]. If the electrolyte connection
These descriptions are universal, explaining various has been adjusted for local ambient temperature (increase in
algorithms, how to recognize them, and how they treat a specific gravity for cold environments, decrease in specific
battery. This program also intends to verify, with actual data, gravity for warm environments) and temperature variation of
what it takes to properly maintain lead-acid batteries in peak the batteries is minimal, compensation may not be critical
operating condition in small stand-alone PV systems. factor.
INTRODUCTION TO CHARGE CONTROLLERS Voltage Regulation Hysteresis (VRH): The voltage span or
difference between the VR set point and the voltage at which
The primary function of a charge controller in a stand-alone the full array current is reapplied. The greater this voltage span,
PV system is to protect the battery from overcharge and the longer the array current is interrupted from charging the
overdischarge. Any system that has unpredictable loads, user battery. If the VRH is too small, then the control element will
intervention, optimized or undersized battery storage (to oscillate, inducing noise and possibly harming the switching
minimize initial cost), or other characteristics that would allow element or any loads attached to the system. The VRH has
excessive battery overcharging or overdischarging requires a proven to be an important factor in determining the charging
charge controller and/or low voltage load disconnect or the effectiveness of a controller.
result will be a shortened battery lifetime and decreased load
availability. Low Voltage Disconnect (LVD):The voltage at which the load
Systems with small, predictable, and continuous loads may is disconnected from the battery to prevent overdischarge. The
be designed to operate without a battery charge controller. If LVD defines the actual allowable maximum depth-of-discharge
system designs incorporate oversized battery storage, and and available capacity of the battery. The available capacity
battery charging currents are limited to safe finishing charge must be carefully estimated in the PV system design and sizing
rates ( U 5 0 flooded or C/ 100 sealed) at an appropriate voltage process. Typically, the LVD does not need to be temperature
for the battery technology, a charge controller may not be compensated unless the batteries operate below 0°C on a
required in a PV system [2,3,4,5]. frequent basis. The proper LVD set point will maintain good
Proper operation of a charge controller should prevent battery health while providing the maximum available battery
overcharge or overdischarge of a battery regardless of the capacity to the system.
system sizingldesign and seasonal changes in the load profile
and operating temperatures. The algorithm of a battery charge Low Voltage Disconnect Hysteresis (LVDH):The voltage span
controller determines the effectiveness of battery charging and or difference between the LVD set point and the voltage at
PV array utilization, and ultimately the ability of the system which the load is reconnected to the battery. If the LVDH is
to meet the load demands. Additional features such as too small, the load may cycle on and off rapidly at low battery
temperature compensation, alarms, and special algorithms can state-of-charge (SOC), possibly damaging the load and/or
enhance the ability of a charge controller to maintain the health, controller. If the LVDH is too large, the load may remain off
maximize the capacity, and extend the lifetime of a battery. for extended periods until the array fully recharges the battery.
With a large LVDH, battery health may be improved due to
Basics of Charge Controller Theory reduced battery cycling, but with a reduction in load
While the specific control method and algorithm vary among availability. The proper LVDH selection for a given system
charge controllers, all have basic parameters and will depend on the battery chemistry and size, and PV and load
characteristics. Manufacturers' data generally provide the limits currents.
of controller application such as PV and load currents, operating
temperatures, losses, set points, and set point hysteresis values. CHARGE CONTROLLER ALGORITHMS
In some cases the set points may be dependent upon the
temperature of the battery and/or controller, and the magnitude Two basic methods exist for controlling or regulating the
of the battery current. A discussion of the four basic charge charging of a battery from a PV module or array-series and
controller set points follows: shunt regulation. While both of these methods can be effectively
used, each method may incorporate a number of variations that
Voltage Regulation Set Point (VR): The maximum voltage that alter basic performance and applicability. Following are
a controller allows the battery to reach. At this point a controller descriptions of the two basic methods and variations of these
will either discontinue battery charging or begin to regulate methods.
the amount of current delivered to the battery. Proper selection
of this set point depends on the specific battery chemistry and Shunt Controller
operating temperature. Temperature compensation of the VR A shunt controller regulates the charging of a battery by
set point is often incorporated in controller design, and is interrupting the PV current by short-circuiting the array. A
particularly desirable if battery temperature ranges exceed * blocking diode is required in series between the battery and
5°C at ambient temperatures (25°C). For flooded lead-acid the switching element to keep the battery from being shorted
3 2 0 1-- Irradiance
1 -p. Irradiance -------
---- Battery0 ; =
,e---*--.
I I I I
6AM NOON 6 PM
Time of Day
Fig. 1. Daily Charge Profile for
a Shunt-Interrupting Controller
A
Irradiance ,_.-------
, ------- pv or)-
.........-..
when the array is shunted. This controller typically requires a p.
c
20-- ---- Battery0 { s
large heat sink to dissipate power. Shunt-type controllers are
usually designed for applications with PV currents less than
20 amps due to high-current switching limitations.
Series Controller
There are several variations of this type of controller, all o f
which use some type of control element in series between the
array and the battery.
cell and also compensated for the rate at which the battery is 1 114.361I 1.33 Il1.00 11.48 I No . -
ISeries-intaUDtincl
Field Evaluations
Several sites with stand-alone PV lighting systems were
visited to perform evaluations and gain a better understanding
of charge controller operation in real systems. Each system was
completely evaluated to expose conditions that may have been
contributing to poor system performance. In general most
2 " c1 m c3 c4 Is w c7 #a systems were functional, however at a non-optimal
Battery performance. Typically, the systems evaluated had operated
Start 3 Months 4.5 Months for about a year and the batteries were found in generally poor
6 Months a9 Months condition due to lack of maintenance and improper charging.
Fig. 5. Nine Month Battery Capacities at Sandia Both design and hardware-related problems were found in most
40 systems. A few of the more typical problems related to charge
controllers are listed below [7,8,9].
A common problem found in field evaluations was a
30
mismatch of the charge controller VR set point and the battery.
8 = At one site where identical systems (and controllers) were
0 installed, voltage regulation set points varied from 13.4 to 15. I
S2O volts. Battery capacity tests proved the effects of the different
0 15
set points and showed the lower VR set point systems to have
10
a lower available battery capacity. Where captive-electrolyte
5 batteries were used, they have been typically overcharged due
0 to a high VR set point. The sealed batteries have less tolerance
#I #2 #3 #4 #5 #6 #7 #0
to overcharging because once excessive gassing has occurred
Battery
and electrolyte is lost, it cannot be replenished, hence reducing
3 Months @j6 Months 9 Months battery lifetime.
Fig. 6. Nine Month Battery Water Additions at Sandia Flooded batteries, both lead-antimony and lead-calcium,
were usually found to be undercharged and sulfated. This was
experienced a stabilization of water loss. Those systems without caused by the VR set point being adjusted too low. This results
temperature compensation experienced significant increases in in lower water requirements, although coupled with reduced
water loss. battery capacity and lifetime.
Both under and overcharge situations can be detrimental to Catalytic recombination caps have proven very effective in
the lifetime of a battery. As shown in Fig. 5, system # I is reducing battery water requirements to minimal levels. At one
suffering from severe undercharging and systems # 2 , 5 , 6 and site where half of the systems have recombination caps and
7 are somewhat undercharged. System #8 is overcharging the half do not, no water was required for the batteries with
battery, as shown by the water additions and specific gravity recombination caps over a six month period, while batteries
readings. The cumulative effects of these situations will be without these caps required approximately one-half gallon of
analyzed by an inspection of internal battery parts when the water per 6 - ~ o l t 220
, amp hour battery.
testing is completed. Load controls (timers and photocells) and LVDs have shown
Controllers without low-voltage load disconnects have shown some problems during the field evaluations. Several system
both recoverable and non-recoverable behavior when low- designs with oversized loads with respect to the PV array have
voltage battery conditions occurred. PV systems incorporating relied on the LVD to function as a load control. In these systems
controllers without an LVD are vulnerable to excessive the batteries remained at a low SOC almost continuously, resulting
overdischarge of the battery if either the load exceeds the design in a low load availability. The most trouble free lighting controls
conditions or during extended periods of below average sense array voltage or current to turn the lights on and off at dusk
insolation. Two systems without an LVD experienced and dawn. This eliminates the need to use photocells, which have
overdischarge of the batteries down to 1.5 volts per battery at been found to be unreliable in the field evaluations. All of the
both FSEC and Sandia. One controller allowed the PV array load timers evaluated functioned as expected. Several controllers
to remain connected to the battery without sufficient voltage are commercially available with light control/timersbuilt-in, thus
being applied to operate the controller. After a few days, the eliminating the need for additional components. A few controllers
PV array was able to recharge the battery without user were found with a non-functional LVD. One situation was
intervention. The controller in the other system required a encountered where the LVDH was too small, causing the load
battery voltage of six volts to connect the PV array, which to cycle on and off rapidly at low battery SOC. A small LVDH
without, did not allow the PV array to recharge the battery. may be desirable to increase load availability if battery lifetime
User intervention was required to disconnect the load and allow is a secondary consideration.
[5] Allen, W.R. et al. Prepared for Sandia National Labs, July 1991. Internal report,
“Evaluation of Solar Photovoltaic Energy Storage for Aids not available.
to Navigation, ”
Steve Harrington’s work includes the investigation of all aspects of combining photovoltaic (PV) energy sources with loads, batteries, and electronic
power processing hardware. He is employed by Ktech Corporation who contracted in-house to Sandia National Laboratories’ Photovoltaic Systems
Research Division.
Mr. Harrington’s specific responsibilities include research into the various methods of charging battery storage systems, power processing hardware
(battery charge controllers), and batteries in PV powered small stand-alone systems. He is primary and co-author on several research papers regarding
the characterization and the effect of PV/battery charge controllers on batteries in PV systems.
He is also involved in the evaluation of stand-alone PV systems in the field, where he provides troubleshooting and technical information to users
to increase the understanding and reliability of those systems. He is familiar with all of the test and evaluation disciplines used in the photovoltaic
industry from solar cells, modules, power conditioning, and control equipment. He has been with the Photovoltaic Systems Research Division since
1990 and has been involved with photovoltaics since 1982.
James P. Dunlop is a senior research engineer at the Florida Solar Energy Center (FSEC) and has been involved with photovoltaic systems development
for 8 years. He has been primary and contributing author of numerous photovoltaic applicationidesign manuals and research papers. Mr. Dunlop
is principal investigator for the Southeast Regional Experimental Station (SERES) project, a multi-year photovoltaic systems research contract with
U.S. Dept. of Energy and Sandia National Laboratory. He is also responsible for a number of other photovoltaic programs at FSEC, including PV
applications development for the Florida Department of Transportation.