Charge Controllers (Overview)

Charge Controllers

In general, charge controllers regulate the power of solar panels and charge your batteries safely.
They have sensors that determine battery status and keep them from over-charging or adjusting
the charge when the environment plays a role. Some also come with predetermined algorithms for
major battery types commonly used such as Sealed Lead Acid, Gel, and Flooded.

Two major types of controllers exist for usage in the solar power industry: PWM (Pulse Width
Modulation) and MPPT (Maximum Power Point Tracking). In order for these controllers to
commence charging a battery, the voltage going into the controller needs to be higher than the
battery so that the charge controllers can regulate the voltage. Both PWM and MPPT controllers
charge deep cycle batteries but handle the charging algorithm differently which contributes to their
efficiency differences.The main differences between PWM and MPPT are the charging efficiency
and cost. MPPT (90% and above efficient) controllers are more efficient than PWM (70%-80%
efficient) at battery charging, and PWM controllers are more inexpensive than MPPT controllers
(About 1/3 price).

In summary:

Charge controllers are a complex electronic equipment that is essential to the operation of
an off-grid solar system.

The following summarizes the key points of this section:

Charge controllers typically come in two major varieties, Pulse Width Modulated (PWM)
andMaximum Power Point Tracking (MPPT)

MPPT controllers are much more efficient than PWM controllers and are sometimes the only
logical option especially when preventing excessive power losses in larger systems.

PWM controllers work the best when panel array voltages are paired closely with the battery
charging voltages

Battery pairing with controllers is important to ensure battery health

Charge controllers typically exhibit three-stage charging which allows for the best battery
health compensation and power conservation for charging
PWM Charge Controllers

PWM charge controllers are the least efficient controllers of the two main types used in the solar
industry. The reason for this being is the method of regulation. For a PWM controller, it acts as a
constant voltage regulator for reducing the voltage required to a battery bank. Since the PWM
controller is a voltage regulator, it does not change the output current until the battery is close to
being full. Additionally, the output voltage will depend on the charging voltage required by a
battery. As with current output, this varies throughout the charging cycle, but for the bulk of this
cycle, it remains constant. PWM controllers emit a pulsing signal to the battery to determine the
level of charge(setpoint) to completely charge the battery and maintain it. Based on the setpoints
within the controller, it can determine the general state of charge of the battery, charge it to full,
and maintain it. In PWM, once the controller reaches the set-point, it ceases proportional control
and enters the pulse width modulation. Pulse width is a type of on/off control meaning once the
set-point is achieved the signal is shut off to the plant. However, it turns the signal on and off
frequently rather than shutting completely off. This is a great feature for battery charge control
because once charging ceases, a battery will tend to slowly discharge itself. By continuously
pulsing a signal to the battery once it is full, it will maintain the battery at the set-point. This would
be akin to holding a cup under a faucet that has a leak in the bottom. You would then attempt to
maintain the full water level by rapidly shutting the faucet on and off. Essentially this signal
approximates keeping the battery at a constant voltage while ensuring that it is not overcharged.
When PWM regulate the voltage, the step down to match the battery bank is lost to heat, hence
why they are less efficient. PWM controllers generally have a lower input voltage which means you
have to wire solar panels in parallel. Lastly, PWM controllers are typically used on smaller systems
where applications are not so critical. A rule of thumb is 400W or less should use a PWM charge
controller.

MPPT Charge Controllers

With an MPPT controller, rather than regulating voltage, it actually behaves as a DC voltage
converter. By doing this it essentially acts as a power regulator. This allows the controller to accept
any input of power (within its voltage/current range) and convert it to the appropriate voltage for
the battery bank. DC voltage converters typically have an efficiency above 90%, depending on the
level at which the converter is run. Depending on the input, the efficiency can actually range
from90% to 99%. The output current of an MPPT controller will always produce more current flow
to the battery than a PWM controller will. Since we know on average that the PWM controllers
have an average efficiency of around 79% (max) and MPPT has an average efficiency of 94%, an
MPPT will produce a current of about 1.2 that of the array current or 20% higher than the array. it
maintains a higher efficiency and boosts the array current to more quickly charge the battery
rather than wasting energy as heat. In addition, MPPT controller typically supports a higher
voltage input which allows for the wiring of the panels in series. This can be advantageous in
systems with long panel to-controller wire runs as it will overcome voltage losses in the wiring.
MPPT controllers attempt to ensure maximum power conversion and for that reason are typically
used in critical power applications and are essential for bigger systems. 500W solar power
systems and more should use an MPPT charge controller.
Troubleshooting ACr
Troubleshooting ACr on Charger
Controllers
Lithium Battery Activation
Lithium batteries with a battery management system (BMS) typically have a protection feature against abuse or
inoperable conditions. They will lock out and disengage the battery from the circuit and slip into a low power
discharged state that gradually depletes if not charged or activated. The Renogy charge controllers or battery
chargers are equipped to activate batteries under this scenario and recharge batteries so that they can be
serviceable again.

The following causes highlight the different scenarios where a battery may need to be activated as well as their
respective troubleshooting procedure. It is important to verify the causes so that the correct action could be
taken to clear the ACr code since some locked batteries due to user error connection have the potential to not
clear ACr until the circuit is fixed.

The following fixes require a multi-meter to better understand your system and to properly troubleshoot your
system. If you do not have one, it is advised to get one. In addition, Lithium activation requires the assistance of
PV charging power. For activation to work, the solar panel(s) must be connected correctly and providing charge
power for lithium activation to take place.

Cause 1: Break in the Circuit

1. The controller is connected to PV and a battery set to Lithium but is not properly connected to the battery
because it might be experiencing a break in the connection. The ACr code is shown because it is powered by
the PV circuit and not the battery circuit during this time. ACr will remain until the connection to the battery
is fixed.
Fix 1: Restore the Broken Connection
To check for a break in the connection, use a multi-meter to measure the battery voltage and get that reading.
Then, measure the battery terminals on the charge controller to see if they are roughly the same. Drastic
reading differences indicate a bad connection.

In addition, certain meters will have a continuity tester; refer to your meter for those instructions. Measure
continuity between the controller and battery positive connections to verify no breaks in the connection.
Repeat for the negative connections. The beeps indicate a connection. No beeps indicate a missing connection
and could be the root cause. Once the connection break has been restored, the controller will be able to send a
charge and clear the ACr code automatically.
Cause 2: 12V Lithium Incorrectly set to 24V on
Controller
Renogy Lithium batteries are nominally 12V and need to be manually selected on Renogy charge controllers.
The charge controller is set to Lithium and incorrectly set to 24V, resulting in the controller believing the 12V
Battery Lithium battery is depleted and needs to be activated.

Fix 2: Manually set your controller to 12V Lithium

Renogy controllers require manual programming of lithium batteries, including their voltage. The controllers
will usually have an option for a 12V or 24V system as well as the specified charging voltage. When first
connecting your battery, change the battery type to Lithium and select 12V. Different controllers might have
different instructions on selecting your 12V lithium battery, but the concept is the same. When changing from
24V to 12V, the ACr code will clear automatically upon detecting the battery and starting normal PV charging.
For those batteries that are too discharged to meet the minimum voltage of the controller, then you should
connect a separate 12V Battery (perhaps a vehicle battery) and change the settings from 24V to 12V.
Cause 3: Your Demand is higher than your Lithium
Battery Capacity
The controller and lithium battery are correctly set to 12V; however, the battery was not able to keep up with
power demand and is now out of power resulting in disconnecting from the charge controller via BMS
protection.

Fix 3: Limit Load Use or Increase PV or Batt Size

The battery has been over-discharged, whether it was intentional or accidental, and needs to recharge. Make
sure to disconnect any loads from the battery and make sure the above causes are not the issue. The battery is
currently locked out and upon no loads being connected, the controller will attempt to send a small charge to
the battery to activate it assuming adequate PV charging. Some batteries will need to have a voltage of at least
10V to be recognized by the charge controller. The ACr will automatically clear upon the battery being
activated.

Limiting your load use will be effective in not draining the battery as quickly. This may not be a favorable
solution so the next best would be to increase the battery capacity as well as increasing the charging rate
through your solar panels. Having a larger capacity will slower the rate of discharge and can be better sized to
your application so that you have a sustainable system. Contact Renogy for sizing your specific application to
ensure this does not happen.
Cause 4: Lithium Reverse Polarity w/ Solar
Connected
WARNING! Prolonged reverse polarity connections with lithium batteries will likely cause permanent damage
to the controller

The controller is connected to PV and a battery set to Lithium but is reversely connected to the battery
terminals. The ACr code is shown because it is powered by the PV circuit and not the battery circuit during this
time. ACr will remain and has will not clear for the duration of solar power since the battery circuit can not be
detected.

WARNING! The controller may experience permanent damage in this scenario

Fix 4: Fix the Poles, then Observe for Change

Disconnect the solar panel first just in case. To check for reverse polarity, use a multi-meter to align the positive
meter pole to the battery positive pole and the negative meter pole to the battery negative pole to get a
voltage reading. Using the same convention on the charge controller battery terminals to measure the
respective battery poles. If the voltage indicates a negative number, the poles are reversed. Positive indicates
correct polarity.

If your poles are reversed, restore the proper battery poles to the controller and the controller may/may not
turn on depending on your battery voltage. Once this has been checked with a meter as being correct, you can
then connect your PV source again to restore charging and activate the battery. Long-term (after a few days)
ACr code indicates internal controller damage and you may need to contact our Tech Support Team for next
steps.
Connecting the Battery before Solar
Panels
When connecting to a Renogy charge controller it is likely you have seen a warning like the
following:

WARNING! Connect the battery terminal wires to the charge controller FIRST, then connect
the solar panel(s) to the charge controller. NEVER connect solar panel to charge controller
before the battery.

You might be asking yourself why? Or if there are any exceptions? The purpose of this article is to
answer those questions and shed light on connecting solar order of operations.

Why is this the rule?

Renogy charge controllers may turn on if they detect solar power (PV) or battery power. However,
the battery source defines the system voltage (for auto recognition), is a stable supply that allows
programming of the charge controller, and most importantly, is how the controller receives its
operating power to regulate solar power. Though a controller may turn on with PV input, the power
source is unstable, and in some cases can damage the charge controllers if they lack certain
protections.

Wanderer 30 LI (Model: RNG-CTRL-WND30-LI)

In previous years, the protections did not apply to all charge controllers. Over the years, Renogy
controllers have improved on their electronic protections to the point where the controller would be
fine if PV is connected before battery power. If you find that you connected it in this fashion and
the controller is operating fine, then there is nothing to worry about. However, each controller may
have a different threshold for this protection so above all else, it is always good practice to connect
the battery first and then the solar panels to ensure system success and ability to program your
controller.

Exceptions
As mentioned above, it is always good practice to connect the battery first to ensure system
success. The unique exception to the rule is the Renogy Solar Suitcase with Controller. This
product is uniquely designed to have the PV panels prewired to the charge controller and have it
readymade for battery connections for plug and play. The controllers used in the suitcase, whether
it be the Adventurer or Voyager are equipped with electronic protections to avoid
damage. However, to navigate the controller, the rule is the same in that it needs a battery
source. Ultimately, the suitcase is the exception to the rule because the panels are prewired and
the controller has electronic protections in place, but the convention is the same in that in order to
use or navigate the controller, it needs a battery connection.

100W Solar Suitcase (Model: RNG-KIT-STCS100D-VOY20)

We hope to have addressed concerns regarding the order of operations when connecting to solar
charge controller.