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A charge controller is used to keep the voltage across the battery within acceptable limits. The charge controller automatically tapers, stops, or diverts power when batteries become fully charged. Charge controller capacities range from 4 A to 100 A and multiple charge controllers can be used in parallel for larger systems. Some charge controllers offer additional features including charge status display, data logging, automatic battery equalization charging, generator starting, and even lighting controls.
The simplest charge controllers disconnect the power source when the battery reaches a set voltage, and turn it on when a low voltage set point is reached. Pulse Width Modulated (PWM) charge controllers turn on and off very rapidly, maintaining the batteries at full charge voltage, which results in quicker and more complete battery charging. Maximum Power Point Tracking (MPPT) charge controllers optimize the voltage of the PV array to maximize total power output then convert that to the correct voltage to charge the battery. This process significantly increases the power from a solar array, particularly in low temperatures when battery voltage is significantly below the PV array voltage. Most MPPT charge controllers work with higher array voltages, which can greatly reduce the required wire size between the array and the charge controller. While more expensive than PWM controllers, MPPT charge controllers can boost system performance by up to 30% making them very cost effective.
The table below shows recommended maximum nameplate PV array sizes. The wattages shown can be exceeded by up to 20% without damaging the controller, but some “clipping” of potential peak current may occur under cool, clear conditions at the peak of the day. While exceeding these wattages may reduce power harvest at peak times of the day, the total daily amp-hours delivered to the battery bank will be greater because the larger array will produce more power in less-than-peak conditions such as mornings, afternoons, and in hazy or cloudy weather.
MPPT Charge Controllers at a Glance | ||||||
Model | Max output current | Maximum recommended PV array size | Max PV array voltage (V )
OC |
Item code | ||
12 VDC | 24 VDC | 48 VDC | ||||
OutBack FLEXmax 60 | 60 A | 750 W | 1,500 W | 3,000 W | 150 VDC | 020-02017 |
OutBack FLEXmax 80 | 80 A | 1,000 W | 2,000 W | 4,000 W | 150 VDC | 020-02020 |
OutBack FLEXmax Ultra FM100 | 100 A | — | 3,000 W | 6,000 W | 300 VDC | 020-02031 |
MidNite Classic 150 Or Classic SL | 96 A at 12 VDC
94 A at 24 VDC 86 A at 48 VDC |
1,350 W |
2,700 W |
5,000 W |
150 VDC | 020-02405
020-02404 |
MidNite Classic 200 Or Classic SL | 79 A at 12 VDC
78 A at 24 VDC 76 A at 48 VDC |
1,100 W |
2,200 W |
4,500 W |
200 VDC | 020-02407
020-02406 |
MidNite Classic 250 Or Classic SL | 61 A at 12 VDC
62 A at 24 VDC 55 A at 48 VDC |
900 W |
1,800 W |
3,200 W |
250 VDC | 020-02409
020-02408 |
MidNite KID | 30 A | 450 W | 900 W | 1,800 W | 150 VDC | 020-02400 |
Magnum PT-100 | 100 A | 1,500 W | 3,000 W | 6,000 W | 200 VDC | 020-06371 |
Schneider XWMPPT60-150 | 60 A | 875 W | 1,750 W | 3,500 W | 150 VDC | 020-08040 |
Schneider XWMPPT80-600 | 80 A | — | 2,560 W | 4,800 W | 600 VDC | 020-08048 |
Morningstar TS-MPPT-30 | 30 A | 440 W | 880 W | 1,760 W | 150 VDC | 020–01116 |
Morningstar TS-MPPT-45 | 45 A | 650 W | 1,300 W | 2,600 W | 150 VDC | 020-01109 |
Morningstar TS-MPPT-60 | 60 A | 875 W | 1,750 W | 3,500 W | 150 VDC | 020–01110 |
Morningstar TS-MPPT-60-600 | 60 A | — | 1,750 W | 3,500 W | 600 VDC | 020–01103 |
Blue Sky SB3000i | 30 A w / 36-cell input 22 A w / 60-cell input | 400 W
290 W | — | — | 50 VDC | 020-03121 |
Blue Sky SB2512i-HV | 20 A w / 60-cell input | 264 W | — | — | 50 VDC | 020-03164 |
Blue Sky SB1524iX | 15/20 A at 12 VDC
15 A at 24 VDC | 270 W w / 36 cell 200 W w / 60-72-cell | 400 W w / 72-cell | — | 57 VDC | 020–03118 |
Blue Sky SB3024iL | 30/40 A at 12 VDC
30 A at 24 VDC | 540 W w / 36-cell 400 W w / 60-72-cell | 900 W w / 72-cell | — | 57 VDC | 020-03158 |
It is important to note that PWM charge controllers have limited voltage correction capabilities and should only be used with 36 or 72-cell modules (See Solar Modules) in series or parallel to match the battery voltage.
NOTE: The nominal PV array wattages listed assume 36-cell modules with an 18.0 VDC maximum power voltage (Vmp), installed in a location with nominal 1000 W per square meter solar irradiance.
Higher or lower rated module voltages, and high altitude or other locations which regularly see higher solar irradiance requires adjustment to the wattages shown. The wattages shown also include the derating to 80% required by the National Electric Code for PWM controllers (maximum rated output current times 0.8)
Model | Max output current | Nominal PV array size |
Item code | ||
12 VDC | 24 VDC | 48 VDC | |||
SmartHarvest SCCP10-050 | 10 A | 120 W | 240 W | — | 020-02039 |
SmartHarvest SCCP05-050 | 5 A | 60 W | 120 W | — | 020-02038 |
MidNite MNBRAT | 20 A charger w/10 A load control or 30 A charger | 360 W | 720 W | — | 020-02435 |
Schneider C-35 | 35 A | 420 W | 840 W | — | 020-08004 |
Schneider C-40 | 40 A | 480 W | 960 W | 1,920 W | 020-08005 |
Schneider C60 | 60 A | 720 W | 1,440 W | — | 020-08040 |
Schneider C-12 | 12 A | 144 W | — | — | 020-08048 |
Morningstar TS-45 | 45 A | 540 W | 1,080 W | 2,160 W | 020-01105 |
Morningstar TS-60 | 60 A | 720 W | 1,440 W | 2,880 W | 020–01108 |
Morningstar PS-15
Morningstar PS-15M
| 15 A | 180 W | 360 W | — | 020-01120
020-01123 |
Morningstar PS-15M-48
Morningstar PS-15M-48-PG | 15 A | — | — | 720 W | 020–01126
020-01129 |
Morningstar PS-30
Morningstar PS-30M Morningstar PS-30M-PG
| 30 A | 360 W | 720 W | 3,448 W | 020–01132
020-01135 020-01138 |
Morningstar SS-6-12V
Morningstar SS-6L-12V | 6 A | 72 W | — | — | 020-01245
020-01248 |
Morningstar SS-10-12V
Morningstar SS-10L-12V | 10 A | 120 W | — | — | 020-01230
020-01233 |
Morningstar SS-10L-24V | 10 A | — | 240 W | — | 020–01236 |
Morningstar SS-20L-12V | 20 A | 240 W | — | — | 020-01239 |
Morningstar SS-20L-24V | 20 A | — | 480 W | — | 020-01242 |
Morningstar SL-10-12V | 10 A | 120 W | — | 020-01218 | |
Morningstar SL-10-24V | 10 A | — | 240 W | 020-01221 | |
Morningstar SL-20-12V | 20 A | 240 W | — | 020-01224 | |
Morningstar SL-20-24V | 20 A | — | 480 W | 020-01227 | |
Morningstar SG-4 | 4.5 A | 75 W | — | — | 020-01215 |
Morningstar SK-6 | 6 A | 72 W | — | — | 020-01252 |
Morningstar SK-12 | 12 A | 144 W | — | — | 020-01253 |
Morningstar SSD-25RM | 25 A | 300 W | — | — | 020-01250 |
Blue Sky SB2000E | 25 A | 300 W | — | — | 020-03122 |
Blue Sky SC30
Blue Sky SC30-LVD | 30 A | 360 W | — | — | 020-03180
020-03181 |
Atkinson PVLC-15
Atkinson PVLC-15MD | 15 A | 180 W | 360 W | — | 020-05425
020-05432
|
Atkinson PVLC-40
Atkinson PVLC-40MD | 40 A | 480 W | 960 W | — | 020-05427
020-05435 |
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