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PV charge controllers: Absorption algorithm

W

William P.N. Smith

Jan 1, 1970
0
Scott Willing said:
So far I've only found one series of controller, manufacturered mostly
for installers by a small Canadian company called Solar Converters
Inc. (happens to be MPPT as well) that finishes the charge based on
acceptance current, not some arbitrary time period. In effect, the
battery tells the controller when it's fully charged instead of the
other way around.

The Accumate (as seen at
http://www.mayberrys.com/honda/generator/html/accumate.htm ) does the
'terminate high voltage on current less than some value' thing, but
it's not really what you want...

Note that these charge controllers are called three-stage, but they
are really two stage:

1) Charge to "equalization" voltage with a current limited supply.

2) When current drops, switch to the lower "float" voltage.

[When current increases, goto 1) above]

They try to make 1) above sound like "Charge at a constant current to
some voltage and then switch to equalization mode", but it's a single
voltage setpoint with a current limit... Not a big deal, but the
pendant in me wants to ding them for false advertising. 8*)
 
S

Scott Willing

Jan 1, 1970
0
Hey group,

After three years with a Trace C-40 charge controller between my solar
panels and batteries (Trojan L16-HC's), I've developed the impression
the common absorption-stage algorithm for multi-stage charge
controllers -- i.e. after the battery has reached the set-point for
absorption voltage, you hold it there for some fixed time period -- is
really kinda dumb.

I kept track of numbers for a couple of years and I get the impression
that, overall, it tends to over-charge in summer (e.g. a few passing
clouds can reset the timer and initiate an unneeded cycle) and
under-charge in winter. BTW, I do have temp compensation.

I may be more sensitive to this problem since at present we don't have
a good seasonal match-up between available power and requirement (such
as electric refrigeration). Consequently we have bags of power
available in summer and things are touch-n-go in the doldrums of
winter, with a generator picking up the slack a half-dozen days in a
season.

So far I've only found one series of controller, manufacturered mostly
for installers by a small Canadian company called Solar Converters
Inc. (happens to be MPPT as well) that finishes the charge based on
acceptance current, not some arbitrary time period. In effect, the
battery tells the controller when it's fully charged instead of the
other way around.

This sounds to me like a far superior idea, and I'm surprised that it
isn't more common. Even the super-duper gee-whiz all-singing
all-dancing MX-60 from Outback appears to use the fixed-time
absorption cycle approach. But then aren't they a bunch of renegades
from Trace? (Not sure about that.)

Learned opinions, off-the-cuff flames?

-=s
 
S

Scott Willing

Jan 1, 1970
0
The Accumate (as seen at
http://www.mayberrys.com/honda/generator/html/accumate.htm ) does the
'terminate high voltage on current less than some value' thing, but
it's not really what you want...

Nope. Interesting though.
Note that these charge controllers are called three-stage, but they
are really two stage:

1) Charge to "equalization" voltage with a current limited supply.

I haven't read every word on the page, but I think I would call
"absorption voltage" what you're calling "equalization voltage."

In fact they say the unit is suitable for gell cells etc., and you
wouldn't want to equalize one of those.
2) When current drops, switch to the lower "float" voltage.

[When current increases, goto 1) above]

They try to make 1) above sound like "Charge at a constant current to
some voltage and then switch to equalization mode", but it's a single
voltage setpoint with a current limit... Not a big deal, but the
pendant in me wants to ding them for false advertising. 8*)

The description of the basic charging approach is muddied by all the
stuff about the additional testing behaviors. I'm frankly not sure
whether it has a legitimate absorption phase or not.

Incidently, the additional automated testing they describe sounds
quite useful (if it works) 'specially for folks who don't know much
about batteries -- or do, but don't have time to futz around.

-=s
 
S

Scott Willing

Jan 1, 1970
0
On Fri, 12 Dec 2003 10:56:09 -0700, Scott Willing

...

This sounds good in theory, but the situation may be even more complex. A
couple of years ago I replaced some Trojan L-16s with Rolls/Surrette "Solar
1" batteries. The Trojans under constant current had a relatively gradual
increase in voltage as they got near fully charged. The Rolls batteries
will accept my full available charge current for much longer, and then
quite suddenly their voltage shoots up way above what I ever saw from the
Trojans even when intentionally "equalizing" them. But the Rolls batteries
are not fully charged at that point - to reach the "full" hydrometer
reading one must provide a much lower "absorption" current than the Trojans
wanted, for a longer time.

So whichever method one uses to adjust charging current, it needs to be
able to be fine tuned to match the particular batteries it is charging. On
the other hand, my own system uses only intelligent diversion, in
relatively large steps, to control charging, and my Trojans lasted 12
years. My big 2V industrial cells are still going at over 16 years, so the
perfect charging curve may not be all that critical.

Loren

Interesting post Loren, thanks for taking the time. I especially like
the happy ending. :)

-=s
 
B

boB

Jan 1, 1970
0
Hey group,
So far I've only found one series of controller, manufacturered mostly
for installers by a small Canadian company called Solar Converters
Inc. (happens to be MPPT as well) that finishes the charge based on
acceptance current, not some arbitrary time period. In effect, the
battery tells the controller when it's fully charged instead of the
other way around.

This sounds to me like a far superior idea, and I'm surprised that it
isn't more common. Even the super-duper gee-whiz all-singing
all-dancing MX-60 from Outback appears to use the fixed-time
absorption cycle approach. But then aren't they a bunch of renegades
from Trace? (Not sure about that.)

Learned opinions, off-the-cuff flames?

-=s



No flames coming from here, but the MX60 does have an adjustable
Absorb Ending Amps setting which is initially factory set for 0 amps
so it is disabled when the unit is shipped. If the charging current,
after the Absorb cycle has started, goes below that setpoint, it will
go to float at that time.

Otherwise, the MX60 Absorb cycle time is based on how long it took to
get to that voltage, with a settable maximum time. If the battery
voltage cannot be kept, then the MX60 will go back to MPPTing and keep
racking up the time.

I think the C-40/C-60 etc. just Absorbed for a preset amount of time.

There are some batteries, like the Absolyte VRLA batteries that can
reach the Absorb voltage (Bulk ending V or whatever you want to call
it), in a very short time, so adding a MINIMUM Absorb time will be
added soon. The other way out of this might be to lower the current
limit.

We take quite a few requests now, so this is a good thread...

boB Gudgel
OutBack Power Systems
 
S

Scott Willing

Jan 1, 1970
0
No flames coming from here, but the MX60 does have an adjustable
Absorb Ending Amps setting which is initially factory set for 0 amps
so it is disabled when the unit is shipped. If the charging current,
after the Absorb cycle has started, goes below that setpoint, it will
go to float at that time.
Ah...

Otherwise, the MX60 Absorb cycle time is based on how long it took to
get to that voltage, with a settable maximum time. If the battery
voltage cannot be kept, then the MX60 will go back to MPPTing and keep
racking up the time.
Ah^2.

I think the C-40/C-60 etc. just Absorbed for a preset amount of time.

Yep, one hour.
There are some batteries, like the Absolyte VRLA batteries that can
reach the Absorb voltage (Bulk ending V or whatever you want to call
it), in a very short time, so adding a MINIMUM Absorb time will be
added soon. The other way out of this might be to lower the current
limit.

We take quite a few requests now, so this is a good thread...

boB Gudgel
OutBack Power Systems

Well thanks BG, it's nice to see someone from Outback taking an
interest here. I suspect nobody in the Xantrex empire is allowed to do
this sort of thing.

Thanks for setting me straight on the MX60. It had a 50% chance of
being my next charge controller; that just went to 60%. :)

Care to take it to 70%? OK then: is the firmware field-upgradeable?

I'm tempted to add a question about the (V)FX inverters, but I should
pop it into a separate thread.

Cheers,
-=s
 
B

boB

Jan 1, 1970
0
Well thanks BG, it's nice to see someone from Outback taking an
interest here. I suspect nobody in the Xantrex empire is allowed to do
this sort of thing.

I posted some while I was at Trace. They may not know what usenet is
up there. Bob Wilson, who came from Statpower used to post but I
haven't seen or heard from him in quite a while. He hasn't been with
Xantrex since the buyout of Trace and Heart though.
Thanks for setting me straight on the MX60. It had a 50% chance of
being my next charge controller; that just went to 60%. :)

Care to take it to 70%? OK then: is the firmware field-upgradeable?

Darn! Got me on that one ! No, it is not, (at present), field
upgradeable, however, the hardware is (we think) there to be able to
do that through the Mate's RS232 port while connected to the network.
The necessary software has not been done though. Quite a few things
we gotta finish first. That should be a fun project. I hope there is
enough code space left in the MX for that.

One thing I like about the MX60 is that it does well with partial
shading situations, compared to some other MPPT chargers out there
that guess at the MPPV, as well as some other neat features. All you
have to do is set the battery system voltage, connect up solar panels,
(140 Voc max), and a charging we will go ! The, you can play with
other settings.
A lot of people are using the MX60 with their PMG micro-hydro systems
as well, which works pretty good so far. The only thing to watch out
for is the free-running voltage of the generator and to make sure it
doesn't go over 140 or so volts. We will (are) working on a voltage
"clipper" to make sure that Voc doesn't go over a pre-set voltage. A
failsafe circuit is what I call it. Could also be handy for PV
situations where it gets real cold and the Voc goes very high.

Lots of folks also want to use it for wind (WX60 ?) (some already
are I understand) but the gusty nature of wind means that we have to
optimize the software (or make it adjustable) so that works better.
Again, we have a few things to get done before going full bore on that
one.

I'm tempted to add a question about the (V)FX inverters, but I should
pop it into a separate thread.

Got it ! Thanks. (PF = .98 @ full power)
Cheers,
-=s

Have a day and 1/2 !

boB
K7IQ
 
W

William P.N. Smith

Jan 1, 1970
0
Down the road we will be adding a SMART
SHUNT system to monitor the actual battery current which will then be
communicated to the other parts of the system via the OutBack MATE/HUB
network.

I've seen several mentions of Smart Shunt on your WWWebsite, is that
an existing product or a future one?

Thanks!
 
S

Scott Willing

Jan 1, 1970
0
Greetings from the OutBack (power that is...)

The problem with only using an "end amps" level to terminate the
absorption charge phase is that DC loads can cause the current from
the PV array to stay high even though the current going into the
battery is very low. You really need to watch the net current into
the battery and not just the DC charging source.

Holy crap, that obvious (in retrospect) catch hadn't occured to me.
This is the reason the OutBack MX60 offers both a timed absorption and
a "end amps" setting as well. Down the road we will be adding a SMART
SHUNT system to monitor the actual battery current which will then be
communicated to the other parts of the system via the OutBack MATE/HUB
network.

<drool> Oh yeah, I like the sound of this. Hmm, that raises some other
questions... but I'll go find out if the answers are already in the
literature first.
And yes - we are a bunch of renegades from the old (non-existant)
Trace...

Thanks for the confirmation, I can't even remember where I heard that
rumour.

The more I learn, the more I love the gear.

Cheers,
-=s
 
S

Scott Willing

Jan 1, 1970
0
I posted some while I was at Trace. They may not know what usenet is
up there.

Dunno. Seems like it's basically a commercial power supply company
that decided (and why not) to corner the market on related RE
hardware. Probably don't have a long history of being chummy with "the
little people" however.
Bob Wilson, who came from Statpower used to post but I
haven't seen or heard from him in quite a while. He hasn't been with
Xantrex since the buyout of Trace and Heart though.


Darn! Got me on that one ! No, it is not, (at present), field
upgradeable, however, the hardware is (we think) there to be able to
do that through the Mate's RS232 port while connected to the network.
The necessary software has not been done though. Quite a few things
we gotta finish first. That should be a fun project. I hope there is
enough code space left in the MX for that.

I know the feeling. One of my employer's products is an all-singing,
all-dancing audio software engine for embedded applications like cell
phones. Can you say "resource constraints?"

If you need to generate polyphonic alarm tones in 3D surround sound,
let me know. :)
One thing I like about the MX60 is that it does well with partial
shading situations, compared to some other MPPT chargers out there
that guess at the MPPV, as well as some other neat features. All you
have to do is set the battery system voltage, connect up solar panels,
(140 Voc max), and a charging we will go ! The, you can play with
other settings.

Neat.

My little hippie-built array is a mish-mash of different stuff
guaranteed to have a mix of MPP's. I'm assuming the controller will
still manage to find the overall optimal operating point without
suffering some kind of algorithmic mental breakdown, yes?

It gets freakin' cold up here, so I figure I'm a good candidate for
MPPT, but in the short term I'm mainly looking forward to rewiring for
higher array voltage. I'll be stuck with 12V primary until I feel
wealthy enough to justify a VFX. (Poor tech writer is not worthy, not
worthy.)

Ultimately the odd panels will be sold off or reassigned in favor of
standardizing on one make/model so that the MPPT can truly shine.
A lot of people are using the MX60 with their PMG micro-hydro systems
as well, which works pretty good so far. The only thing to watch out
for is the free-running voltage of the generator and to make sure it
doesn't go over 140 or so volts. We will (are) working on a voltage
"clipper" to make sure that Voc doesn't go over a pre-set voltage. A
failsafe circuit is what I call it. Could also be handy for PV
situations where it gets real cold and the Voc goes very high.

....like here.
Lots of folks also want to use it for wind (WX60 ?) (some already
are I understand) but the gusty nature of wind means that we have to
optimize the software (or make it adjustable) so that works better.
Again, we have a few things to get done before going full bore on that
one.

If there isn't a long list, you're probably forgetting something.
Got it ! Thanks. (PF = .98 @ full power)

Close enough! :)

-=s
Have a day and 1/2 !

And boy, did I. Not quite what you probably had in mind though.
 
B

Brent Geery

Jan 1, 1970
0
Darn! Got me on that one ! No, it is not, (at present), field
upgradeable, however, the hardware is (we think) there to be able to
do that through the Mate's RS232 port while connected to the network.
The necessary software has not been done though. Quite a few things
we gotta finish first. That should be a fun project. I hope there is
enough code space left in the MX for that.

Some insurance against it becoming obsolete, as you guys tinker with
improvements, really makes it a much more attractive product!
 
B

boB

Jan 1, 1970
0
In the systems I'm familiar with, the shunt is in the negative lead of
the battery and so you are always measuring power in or out of the
battery. I don't understand how the load current would effect this
measurement. You may be drawing 10 amps from the array, with 9 amps
going to the loads, but only the remaining 1 amp should be what shows
up going through the shunt, no?

Bob


Yes, that's right, assuming the shunt is at the battery. The MX60
does not have an external shunt or external shunt input. It does
however have a (OutBack) network connection.
The Smart Shunt add on in the (near, hopefuly) future will take care
of all that.

boB
 
B

boB

Jan 1, 1970
0
My mistake. I would have thought a high end charger would have an
external shunt input, considering the parts cost would only be $10-20
given all the expensive stuff is already in the package.

Yes, it wouldn't be extrememely expensive to do that, but more
expensive nonetheless. Also, our shunt is in the positive leg, not
the negative leg like the other units so it is a bit more complicated
than that.

The price of the MX60 is already higher than some other MPPTs out
there and adding this feature would have made it quite a bit higher.
10$ in Bill of Material parts cost unfortunately reflects more than
10$ in the retail/list price.

We felt that it was better to make the external shunt a one time
extra system wide enhancement product, and not burden everybody with
that extra cost of adding that in every unit.

Some people use multiple MX60s and they would have to unnecessarily
add that extra cost with every charge controller added to their
system.

boB
 
S

Scott Willing

Jan 1, 1970
0
Yes, it wouldn't be extrememely expensive to do that, but more
expensive nonetheless. Also, our shunt is in the positive leg, not
the negative leg like the other units so it is a bit more complicated
than that.

The price of the MX60 is already higher than some other MPPTs out
there and adding this feature would have made it quite a bit higher.
10$ in Bill of Material parts cost unfortunately reflects more than
10$ in the retail/list price.

We felt that it was better to make the external shunt a one time
extra system wide enhancement product, and not burden everybody with
that extra cost of adding that in every unit.

Some people use multiple MX60s and they would have to unnecessarily
add that extra cost with every charge controller added to their
system.

boB

It's frustrating to have to add external programmer/controllers and
other options if you're only buying one piece, but clearly it makes
sense from an integrated system standpoint to amortize the cost of
these bits over the various components they work with rather than
making people pay for redundant features.

That aside, I wonder if Mr. Reimiller can point out another controller
with inputs for an external shunt. My C-40 certainly has nothing of
the kind.

Since one of my frustrations with my current system is that none of
the bits talk to each other, I'm strongly in favor of your overall
approach.

As much as I like my Trimetric meter, for example, it doesn't talk to
my C-40. Try as I might to set up "charged" test conditions on the
Trimetric so that it resets the AHr "clock" around the same time that
the C-40 considers the batteries charged, there are always ambiguous
sets of conditions that result in a false resetting of the Trimetric
before the batts are charged, or a failure to reset when they are.

Consequently I gave up on the automatic Trimetric AHr reset feature.
It's better to let it drift and manually reset it once in a while to
get back in sync.

I've often thought that a simple signal from the C-40 telling the
Trimetric that its charge cycle had completed would at least keep them
in sync. In effect, this would also enable the Trimetric to benefit
from the battery temperature sensor on the C-40 -- seasonal
temperature variations being one of the issues preventing me from
setting reliable "charged" conditions on the Trimetric.

Now, this brings me to an obvious question: With all this data flying
around your little network, once remote shunt sensing is added, surely
you could replace the functions of my Trimetric meter with new Mate
capabilities - far more convenient, coordinated, consistent, and
available to a PC for long-term datalogging.

This assumes that sufficient sensing accuracy will be built into the
remote shunt unit (and if not, why bother?) and a bit of memory is
available to store some running data.

I'm tempted to quote earlier posts musing about the potential benefit
of an open standard for control and data interchange between power
devices, using MIDI as an example of an interface that permitted an
explosion of new applications in electronic music. But I won't.

For now, just tell me that one day I will be able to reassign my
Trimetric to other purposes and get all the system information I need
from my future Mate. (Hope my wife doesn't read this...)

-=s
 
B

boB

Jan 1, 1970
0
It's frustrating to have to add external programmer/controllers and
other options if you're only buying one piece, but clearly it makes
sense from an integrated system standpoint to amortize the cost of
these bits over the various components they work with rather than
making people pay for redundant features.

That aside, I wonder if Mr. Reimiller can point out another controller
with inputs for an external shunt. My C-40 certainly has nothing of
the kind.

The RVPP I believe has that feature.

I'm tempted to quote earlier posts musing about the potential benefit
of an open standard for control and data interchange between power
devices, using MIDI as an example of an interface that permitted an
explosion of new applications in electronic music. But I won't.

Being a musician myself, I proposed trying the midi opto-isolated
connected early on in the design... It would have been good for
isolated grounds, etc. There aren't enough data paths for our use
though... We use at least 3 data paths, and even if one was enough,
you'd need a transmit and receive cable, and so on...
For now, just tell me that one day I will be able to reassign my
Trimetric to other purposes and get all the system information I need
from my future Mate. (Hope my wife doesn't read this...)

Yes, I think you will be able to do that, but I think you should
probably sort that out with your wife...

Merry Christmas !

boB
 
S

Scott Willing

Jan 1, 1970
0
I lookd at the Solar Boost 3048 (I need a charge controller to handle
25 amps at 24V) and it has an input for external shunt. It can use
that input to switch between absorption and float based on battery
current. I don't know if this feature is unique to this model or not.
Gotcha.

I've rejected the 3048 because of it's questionable (from an
engineering philosophy standpoint) way it determines
the power point. It is a fairly brain dead method of open circuiting
the solar array every 10 seconds to measure the voltage, and then
setting the desired array voltage when loaded at a fixed voltage
less than open circuit.

Interesting... um... concept.
That's too bad, because one of the things
I liked about it was that the remote panel output was simple analog
that I could feed into my house/barn internal network without having
to reverse engineer someone's protocols.

Hard to get everything one would like to have in one product, without
the time and resources to build it from scratch AND be satisfied with
the outcome.
That's been one of my pet peeves about this type of equipment as well,
poor integration.


It's sort of the same situation as you have with communication between
home entertainment equipment, each manufacturer has it's own protocols.
I remember building a circuit using one of those 8 pin PIC processors
that would receive the remote control signals from my JVC receiver and
translate them into the codes required by my Pioneer CD changer.

Oh gawd. I frequently contemplate this sort of project (which can be
fun and rewarding even though it's a response to a silly situation)
but I simply do not have the time to make it that far down the
priority list. I keep dreaming though, which is why I bought a bunch
of PIC stuff about a year ago (so far untouched).

Thanks for the info on the Solar Boost controller.

-=s
 
S

Scott Willing

Jan 1, 1970
0
The RVPP I believe has that feature.

BZZT. OK, that's it. You've already received enough Brownie points for
volunteering information about competitive products, so you can just
cut it out now. ;-)
Being a musician myself, I proposed trying the midi opto-isolated
connected early on in the design... It would have been good for
isolated grounds, etc. There aren't enough data paths for our use
though... We use at least 3 data paths, and even if one was enough,
you'd need a transmit and receive cable, and so on...

Interesting that you actually considered the MIDI interface
specifically.
Yes, I think you will be able to do that, but I think you should
probably sort that out with your wife...

Merry Christmas !

boB

And all de best in '04. Thanks sincerely for your time and interest.

-=s

 
B

boB

Jan 1, 1970
0
BZZT. OK, that's it. You've already received enough Brownie points for
volunteering information about competitive products, so you can just
cut it out now. ;-)

OK... I was told (by one of my betters) that for every couple bad
things to say, I had to say something nice too... It's hard
sometimes.

Bob (Reimiller) is correct about their algorithm not being optimum.

The constant voltage offset from Voc doesn't take into account partial
shading of panels and aging etc....
In one of my MX60 test installs here at the factory, I have 2 strings
of 3 Sharp 185 panels in parallel. Every morning there is partial
shading (it's a great example of this very common real-life problem.)

When nothing is shaded, the MPP is about 75% of Voc (about 90 volts),
(not constant offset, but constant percentage of Voc which is about
the same thing), but when partial shading occurs, that MPP voltage
drops to about 68 volts. It works its way back to about 75% Voc
during the course of the morning.

Last summer, when I got about 10 Amps out, (24 Volt battery), at 90V
MPP, the MX60 would find the MPP at 68 Volts and I was getting about
13 Amps out. Significant increase in my book. This is one area where
that other method, patented or not, just doesn't cut it.

BTW, the constant ~percentage~ of Voc method was documented in a paper
in 1982 and has been used by AERL (and other MPPTs) since. It's
essentially the same thing as constant offset from Voc but still
doesn't take into account the partial shading (etc...) issues.

Also, the MX60 has a mode (U-Pick) where you can run the MPP at a
percentage of Voc and samples it at a user picked interval, if you
want to.

And midi ?? It's all so much fun don't you think ? I spend quite a
bit of time (not nearly enough) in my little basement studio..

OK, Now, back to our regularly scheduled Christmas !

boB (Yes, that's "Bob" spelled backwards to avoid confusion)


Interesting that you actually considered the MIDI interface
specifically.


And all de best in '04. Thanks sincerely for your time and interest.

-=s


That aside, I wonder if Mr. Reimiller can point out another controller
with inputs for an external shunt. My C-40 certainly has nothing of
the kind.

I lookd at the Solar Boost 3048 (I need a charge controller to handle
25 amps at 24V) and it has an input for external shunt. It can use
that input to switch between absorption and float based on battery
current. I don't know if this feature is unique to this model or not.

I've rejected the 3048 because of it's questionable (from an
engineering philosophy standpoint) way it determines
the power point. It is a fairly brain dead method of open circuiting
the solar array every 10 seconds to measure the voltage, and then
setting the desired array voltage when loaded at a fixed voltage
less than open circuit. That's too bad, because one of the things
I liked about it was that the remote panel output was simple analog
that I could feed into my house/barn internal network without having
to reverse engineer someone's protocols.
As much as I like my Trimetric meter, for example, it doesn't talk to
my C-40.

That's been one of my pet peeves about this type of equipment as well,
poor integration.
I'm tempted to quote earlier posts musing about the potential benefit
of an open standard for control and data interchange between power
devices, using MIDI as an example of an interface that permitted an
explosion of new applications in electronic music. But I won't.

It's sort of the same situation as you have with communication between
home entertainment equipment, each manufacturer has it's own
protocols.
I remember building a circuit using one of those 8 pin PIC processors
that would receive the remote control signals from my JVC receiver and
translate them into the codes required by my Pioneer CD changer.

Bob
 
B

boB

Jan 1, 1970
0
Okay, who's picture did you use for your entry at QRZ.COM? It doesn't
seem to match your picture in the latest EORenew newsletter :)

That's a very old picture... I take on many forms I guess.
Happy New Year !
boB
 
E

Ecnerwal

Jan 1, 1970
0
I would like to know if anyone
has ideas on a Charge Controller that would handle ~80 Amps! ....
Any ideas would be appreciated.

From what I can trell, as somone still in a "shopping around" rather
than "using" mode:

Buy another C60, or an MX60, or some other 60 amp controller and put 40
amps worth of panel on each one, running in parallel.

If you don't plan any more expansion, get a 20 or 30 amp controller, and
run them in parallel, with the appropriate split in the input from the
panels.

I don't know about the C60, but I assume they parallel adequately well,
as large systems have been built using them - I've read up on the MX60
and know that they can actively communicate with each other. Given that
they all would be looking at the same battery bank voltage, I don't know
how much communication is needed, but presumably a little would help
keep them from fighting over small differences in behavior associated
with component tolerances.
 
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