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Charge Controllers!

    Charge controllers come in many versions, from simple to sophisticated, but they all have one basic function in common; they regulate the power from solar panels (or other power sources) into your batteries to charge them efficiently without overcharging.  The simple ones work fine for very small systems, but generally it is truly worth the expense to buy a maximum power point tracking (MPPT) controller.  MPPT controllers actually put more energy into your batteries from the same-size solar array- up to 30% more.  The extra charging energy is like having more solar panels, which easily pays for the extra expense of the controller.  This effect is especially pronounced in the winter months when days are short and more power is needed.  These controls often have deluxe features like data logging, which is useful for troubleshooting, and the ability to control a fan to ventilate your battery compartment.  Most charge controllers can interface with a battery temperature sensor, and it is a very good idea to use a sensor to ensure proper charging in changing temperature conditions.  Many controls are available with optional remote displays, so PV array performance can be monitored from a separate location.

    Some controls can also be used in special situations to divert excess power for things like limited water heating; or as lighting controls; low-battery voltage disconnects; etc.  Another important feature is the ability to connect a higher voltage solar array to a lower voltage battery (48V array to 12V battery, for example).  This voltage conversion capability allows the use of smaller gauge wire from the array to the control, which is especially important for large arrays with a long wire run.  Usually, the choice of which control to buy depends on system size and budget.   Never connect your batteries to a solar array without having a charge control installed.  Always adjust your newly-installed charge controller to suit the recommended voltage set-points for your brand of batteries.... the default settings are almost never right.

OUTBACK FLEXMAX 60 and Flexmax 80

MPPT charge controllers offer all the deluxe features and more, including detailed on-screen system performance information and daily data logging.  It is temperature compensated with the optional battery temp sensor, and it can communicate with the MATE system display/programming interface.  Digital programming is precise and versatile, making it much easier to synchronize multiple controllers on larger systems.  Vent fan control is easy, but it requires a small external relay.  Lighted display for visibility in dim lighting conditions.  These voltage-matching charge controllers will handle series-strings of solar panels up to 110 volts nominal voltage, for great versatility and ease of use.

Outback controls are available in 80-amp and 60-amp versions, and their operation is identical.  They also do array/battery voltage conversion for arrays up to 140Voc MAXIMUM.  These are the controls that I use in my home system.

Model	Part Number	Voltage	Amp Rating	Price
Outback MX60	3500602	12 / 24 / 48	60a	not available	Replaced by Flex Max 60
OutBack FLEXmax 60	3552283	12 / 24 / 36 / 48 / 60	60a	$580	Battery Temp sensor $25
Outback FLEXmax 80	3510605	12 / 24 / 36 / 48 / 60	80a	$650	Auxiliary relay (for fan) $25

APOLLO SOLAR T-80 TurboCharger

is another heavy-duty MPPT controller with many features and excellent value, including a customized system meter similar to the Tri-Metric 2020 that displays net power going to and from your batteries, as well as other useful functions.  This sort of meter is nearly essential for success with an off-grid system, and the T80 has it built-in.  Like the Outback units, this control offers array/battery voltage conversion (140V max), and a full 80 amp output rating.  It also offers TWO on-board relays for controlling vent fans, diversion loads, etc., and the ability to connect to a PC for control and additional data logging. The T80 also has the ability for multiple controllers to be connected together for synchronized charging, providing maximum charging efficiency for multiple arrays under changing conditions. Apollo includes a battery temperature compensation sensor at no extra cost. Apollo Turbocharger is the most advanced charge controller available.

The new Apollo T80HV (high voltage) model allows for nominal array voltages up to 140 volts (180Voc max), offering increased flexibility in designing high-voltage solar arrays.
Click here for more information. 

Model	Voltage	Amp Rating	Price
Apollo T80	12 / 24 /36 / 48	80A	$748	includes built in TriMetric meter
Apollo T80HV	24/36/48	80A	$748	w/ meter, high-voltage model

BLUE SKY

controllers also incorporate MPPT technology to maximize the charging power coming from your array.  These lower cost controllers offer some of the most important features of the more expensive units.  They now feature the ability to have multiple charge controls connect together so they behave as a single unit.  This is a very nice feature if you have a large array with two or more controllers.  The larger units are capable of array/battery voltage matching, but within a smaller range compared to Outback and Apollo.  Blue Sky controls have fully adjustable 3-stage charging. but the fine adjustments require the use of a digital multi-meter and are a bit more hands-on than menu-driven controllers like Outback or Apollo.  The 2512 and 2000E are both flush-mount units, but an optional surface-mount box is available. Overall, these are quality MPPT controls.  I use a model 50DL on one of my arrays and it has been in service for 9 years.
Battery temperature sensors ..... $35.

Model	Part Number	Voltage	Amp Rating	Price
Blue Sky Solar Boost 2512i	3925156	12 VDC	25a	$210
Blue Sky Solar Boost 2512iX *	3951212	12 VDC	25a	$225
Blue Sky 2000E w/display	3880012	12 VDC	25a	$240
Blue Sky 3024i	3880102	24 VDC	30a	$310
Blue Sky 3024Di w/display	3931242	24 VDC	30a	$360
Blue Sky 3048L	3880062	24 / 48 VDC	30a	$470
Blue Sky 3048DL w/display	3880072	24 / 48 VDC	30a	$540
Blue Sky 50L	3912243	12 / 24 VDC	50a	$448
Blue Sky 50DL w/display	3980052	12 / 24 VDC	50a	$480
Blue Sky 6024H	3880082	Array 48-Batt 12/24	60a	$540
Blue Sky 6024H w/display	3880092	Array 48-Batt 12/24	60a	$580
* IPN-ProRemote is required to adjust voltage setpoints from factory value.
IPN-ProRemote w/o shunt	3988092	Monitors up to eight IPN charge controllers on a single IPN network.		$189
IPN-ProRemote with 500 amp shunt	3988082			$225

MORNINGSTAR

offers a broad range of charge controllers, and sophisticated lighting control devices at very attractive prices.  Only one model is a true MPPT controller, but all models use PWM (pulse width modulation) technology which transfers maximum charging energy from the solar array (although it does not boost power like MPPT).  Morningstar makes a controller suitable for nearly any array size and use, including larger systems and those requiring diversion loads (wind, hydro).  Tristar controllers can be configured in a number of ways to do specialized tasks, such as disconnecting a load at a specified voltage to prevent battery damage, or as a diversion load control.  Digital display, remote display, and temperature sensors are optional equipment.  
    Some of the smaller units are completely sealed, and particularly suited for charging batteries used in outdoor environments such as remote water pumping locations, gate openers, sign lighting, etc.  The Duo model charges dual battery systems in RV applications. Sunlight controllers are specifically designed to control outdoor lighting.  Larger charge controls can connect to a battery temperature compensation sensor ($30).
    Update:  Beginning late in 2009, Tristar controllers will be available in a full MPPT version (call for pricing)!

Model	Part Number	Voltage	Amp Rating	Price
TriStar 45	3680302	12 / 24 / 48	45a	$195
TriStar 60	3680312	12 / 24 / 48	60a	$235
ProStar PS-30M	3630011	12 / 24 VDC	30a	$240
ProStar PS-15M	3615011	12 / 24 VDC	15a	$215
ProStar PS-15M-48V	3680282	48VDC	15a	$165
Sun Guard SG-4	3600041	12 VDC	4.5a	$45
SunSaver SS-6-12V	3612061	12VDC	6.5a	$55
SunSaverSS-6L-12	3680222	12 VDC	6.6a	$65	w/LVD
SunSaver SS-10-12	3680152	12 VDC	10a	$65
SunSaver SS-10L-12	3610102	12 VDC	10a	$75	w/LVD
SunSaver SS-20L-12	3680192	12 VDC	20a	$95
SunSaver SS-10-24	3610243	24 VDC	10a	$85	w/LVD
SunSaver SS-20L-24	3620242	24 VDC	20a	$105	w/LVD
Sunlight 10L-12V	3680162	12VDC	10a	$95
Sunlight 10L-24V	3624013	24VDC	10a	$110
Sunlight 20L-12V	3680292	12VDC	20a	$150
Sunlight 20l-24V		24VDC	20a	Call
SunKeeper SK-6	3660016	12 VDC	6a	$65
SunKeeper SK-12	3660026	12VDC	12a	$85
SunSaver Duo	3680422	12VDC	25a	$178
SunSaver MPPT	3615155	12/24 VDC	15a	$240

Optional Accessories			Item	Price
MorningStar TriStar Digital Meter Face			3688112	$95
Remote Digital Meter			9401001	$125
Morningstar RemoteTemperature Sensor (RTS)			3688102	$30

XANTREX

charge controllers are a familiar sight at many installations.  The C-Series can be used as a battery charge control, a diversion control, or a load-disconnect control.  The C-12 also has a lighting circuit with a variety of functions, that can turn lights on at night and still protect batteries from over-discharge.  The XW charge control is part of the Xantrex XW product line and is a true MPPT controller.  All Xantrex models can connect to an optional battery temperature sensor ($25-$30 depending on length).  C-Series controls do not include a digital display.  Digital displays and remote displays are available as an option.  Chinese import.

Model	Part Number	Voltage	Amp Rating	Price
Xantrex C 35	3480342	12 / 24 VDC	35 / 35 a	$115	These controllers can operate as charge OR load controllers.
Xantrex C 40	3400402	12 / 24 / 48 VDC	40 / 40 a	$145
Xantrex C 60	3400602	12 / 24 VDC	60 / 60 a	$170
Xantrex XW MPPT	3430302	12/24/36/48/60 VDC	60 a	$580
Xantrex C12	3480332	12 VDC	3a	$98

Model			Item	Price
Xantrex CM Front Digital Meter Face			9488152	$79
Xantrex CM 50' Remote Meter			9488172	$119
Xantrex CM 100' Remote Meter			9488162	$145
Xantrex CM Battery Temperature Sensor 15'			9400432	$25
Xantrex CM Battery Temperature Sensor 35'			9400352	$30

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