The Solar Charge Controller

Charge controller is a device located between photovoltaic modules and batteries as an element of an isolated solar system.

Modules output voltage is set some volts higher than voltage battery needs to charge. The reason is to ensure that modules will always be able to charge the battery, even when cell temperature is high and generated voltage decreases.

This causes the drawback that once battery reaches its full charge state, module continues to try to inject energy producing an overload that, if not avoided, can destroy battery.

Charge controller is responsible for extending batteries life protecting them from overload situations, controlling load phases depending on their status and even reaching the cut depending on load needs of them.

Charge controllers may be working in one of the following situations:

Equalization status: equalization of batteries charge, after a period of low charge.

Deep charging state: regulation system allows charging until reaching final load voltage point.

Float state: battery has reached a charge level close to 90% of its capacity.

State of final charge and flotation: regulation system zone of action within Dynamic Flotation Band (range between final load voltage and nominal voltage + 10%).

To know which regulator to incorporate into a photovoltaic system it is necessary to know some elementary parameters.

First, one is isolated solar system nominal voltage. Batteries voltage and photovoltaic solar field define this voltage. Typical values are 12, 24, 48 and up to 60 volts.

The other parameter is photovoltaic modules system load current. It is recommended to multiply short circuit current Isc under standard conditions by 1.25 so that charge controller is always able to withstand current produced by modules.

Known system voltage and determined current value, we can choose the right charge controller. If there are still doubts, we can consult with provider technical department.

The simplest design is one that involves a single stage of control. Charge controller constantly monitors battery voltage but controls charge or discharge, never both. They are the cheapest and the simplest.

This can be achieved by opening the circuit between photovoltaic modules and battery (serial control) or by short-circuiting photovoltaic modules (shunt control).

Resultado de imagen de regulador de carga solar una etapa

In case of controllers that operate in two control stages, the two functions are controlled, both charge and discharge of battery. They are more expensive, but they are the most used.

Current charge controllers introduce microcontrollers and control 3 and up to 4 control stages.

Resultado de imagen de regulador de carga solar

During last years a new generation of charge controllers has been developed, whose main characteristics are to make photovoltaic field work at maximum working point and to always render it optimally.

These charge controllers are known as power maximizers or MPPT.

Another advantage of these devices compared to conventional controllers is the possibility of working with a different voltage in the generator field (solar panels) and batteries.

This directly influences in being able to put several modules in series, elevating system tension.

Working with lower currents we can reduce considerably voltage drop losses and use smaller cable sections and therefore of lower price.

For the choice of a conventional controller or an MPPT, we have to assess cost overruns that these systems have compared to benefits that it gives us due to system performance increase. In some cases, annual power increase can reach up to 30% compared to conventional controller.

Resultado de imagen de regulador de carga solar MPPT

Charge controller may not be essential in installations where the ratio between modules power and battery capacity is very small (eg: oversized batteries for safety reasons) so that charging current can hardly damage battery.

If modules field power in W is less than 1/100 battery capacity in W / h, charge controller may not be incorporated.

It can also be dispensed with a charge controller if system has self-regulated solar modules (not recommended for extreme climates).

This is an extract of contents included in Technical-Commercial Photovoltaic Solar Energy Manual and Sopelia e-learning training.

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Free Solar Tools (III)

On Internet we can find free tools for basic or low complexity solar systems dimensioning and for certain components or accessories estimation.

Sopelia research team has carried out an exhaustive search and testing from which a new corporate website section called Free Solar Tools has been created.

Selected tools were classified into 4 categories.

Today we will analyze the third of them: Solar Thermal.

In first category we have already analyzed tools to obtain data about solar resource and other variables to be considered in energy estimation solar system will provide in our location.

In the second category we have analyzed tools to calculate the “load”, ie the energy demand to be met.

Now we are going to analyze tools to solar thermal system dimensioning and others to estimate individual components of a system.

The order of the tools is not random. We have prioritized the most intuitive, the most universal and those that can be used online without download.

For this third category our selection is as follows:

1) Solar Thermal Calculator

Approximate calculation tool from which budget, production data and system performance study is automatically obtained.

A Navigation Guide and Manuals can be found at page bottom.

Resultado de imagen de calculadora solar térmica

2) Simulation for Solar Thermal System Pre-design

Online application based on the TSOL software that allows solar energy system simulating to ACS and ACS + heating contribute.

Available in German, English, Spanish and French.

Resultado de imagen de simulación solar térmica

3) Solar Fraction Calculation

Free download program developed by IDAE (Institute for Energy Diversification and Saving) and ASIT (Solar Thermal Industry Association) that allows to define a wide variety of solar systems introducing a minimum of project parameters, associated to each system configuration; and in this way, obtain solar system coverage on ACS and pool conditioning energy demand.

Resultado de imagen de fracción solar térmica

4) Solar Expansion Vessel Calculation

Tool developed to calculate solar expansion vessel volume.

Volume values (total circuit, solar collectors, pipes), Maximum system temperature (ºC), Glycol concentration (%), Height between expansion vessel and system highest point (minimum value 1 Bar) and safety valve Pressure setting must be introduced.

Resultado de imagen de cálculo vaso expansión solar

5) Thickness Insulation Pipes Calculation

Calculator that allows to estimate minimum and more economical water pipes insulation thickness.

Pipe Grade and Size, Insulation Material, Humidity and Temperature (Internal and Ambient) must be entered.

Resultado de imagen de aislamiento tubería solar

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Other Thermal Collectors

We have already talked about flat solar collectors and vacuum tube collectors.

Air collectors are also found in collectors without concentration category.

They are flat and their main characteristic is to have air as heat transfer fluid.

They do not have a maximum limit temperature (convective processes have less influence on the air) and work better in normal circulation conditions, but in contrast they have a low heat capacity and heat transfer process between plate and fluid is not good.

Its main application is heating.

Externally it is not possible to distinguish an air collector from a water collector. It is in the absorber where greatest differences are found. It has a rough shape and lacks the classic pipe of water collector ducts. The air circulates freely on absorber surface collecting the heat that it transforms.

Being a technology that has not been widely disseminated until now, there is no standardized solar collector model and each manufacturer makes its own model.

Resultado de imagen de colector solar de aire

There are also conical or spherical thermal solar collectors.

Their main characteristic is that they simultaneously constitute collection and storage unit.

Its catchment surface is conical or spherical with a same geometry glass cover. With this form it is achieved that illuminated surface throughout the day, in shade absence, is constant.

Their installation is simple, but they present water stratification problems and useful catchment surface is small.

Its main application is sanitary hot water in single-family homes production and in very benign climates, since large storage surface, weather exposed, causes great energy losses.

Resultado de imagen de colector solar cónico o esférico

Finally, in collectors without concentration category, we find outdoor swimming pools solar collectors.

They are made of rubber, polypropylene or polyethylene; and incorporate in their manufacturing process substances that protect them from plastics natural tendency to degrade under ultraviolet rays action.

They also carry other additives to protect them from chemical agents used in pool water purification. They have an acceptable night frosts resistance.

They are used mainly to heat pools water and thus be able to prolong its use for several more months.

These collectors do not have cover, neither with housing nor with insulating material. They are constituted by naked plate collector. This is because working temperature will not exceed 30ºC in any case and at this low temperature, radiation and conduction losses are very small, making it possible to dispense with covers and insulation.

It is not necessary to use any type of heat exchanger or accumulator, because pool water flows directly through collectors.

They need a frame because they are usually not rigid, but they can also be placed directly on a roof, or even on the ground. By being flexible, absorb surface irregularities on which they rest.

These equipment enjoy an approximate 10 years lifespan. They need little maintenance and there is little risk of corrosion, as they are synthetic.

Resultado de imagen de colector solar piscinas

The second major group is that of solar collectors with concentration.

Its most common use is not at domestic level but in thermoelectric plants and facilities that work at medium and high temperature.

These collectors concentrate the solar radiation received in a very small surface receiving element (a point, a line).

Being smallest receiver and concentrated radiation, it allows a better solar energy absorption.

They are capable of providing temperatures above 300 ° C with good yields.

Concentration collector plants generate high temperature steam for industrial processes and to produce electricity.

There are concentration collectors of various types (tower, cylindrical-parabolic, Stirling engine).

Nevertheless, all of them have in common that they demand to be equipped, to be efficient, with a tracking system that allows them to remain constantly located in best position to receive the Sun’s rays throughout the day.

One of the drawbacks of most concentration collectors (and especially the cylindrical-parabolic) is that they only take advantage of Sun direct radiation, that is, they only take advantage of solar rays that actually hit their surface. They are not able, on contrary, to capture diffuse solar radiation.

Therefore, they are not convenient in climatic zones that, although they receive an acceptable solar radiation amount, are relatively cloudy. They are only effective in authentically sunny áreas.

Resultado de imagen de colectores solares con concentración

This content was extracted from the Solar Thermal Energy Technical-Commercial Manual and is part of Solar e-learning.

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Honduras Solar PV

Honduras is a country where news about massacres, multiple forms of violence, corruption, instability and political intrigues usually comes out and in which two thirds of its 8 million inhabitants live in poverty while the 10% who receive higher salaries, accounting for 42% of national income and poorest 10% only receives 0.17%.

However, there is a sector in which Honduras stands out at regional level: renewable energies and, especially, solar energy.

Honduran government introduced fiscal incentives for photovoltaic installations in 2013.

A tariff supplement for first 300 PV MW that entered into operation before August 1, 2015 was also approved.

In 2015, Honduras and Chile were the largest PV markets in Latin America.

At the end of 2017, total private capital investment for PV plants construction exceeded US$ 1,600 million.

Investment has been divided into 12 solar plants that are already operational and add up to 405 MW; 39% of country’s private sector renewable capacity, amounting to 1,047.07 MW.

In general calculation, 61% of country’s energy comes from renewables, and in 2017 it became the first country in the world with 10% solar energy in its electric mix.

Resultado de imagen de parque solar nacaome

Most emblematic project is Nacaome-Valle Solar Park, which generates the energy consumed by some 150,000 Honduran families every day.

It has 480,480 modules with capacity to produce up to 125 MW of alternating current (AC) peak power.

It took more than 1,000 material containers, US$ 240 million in investment and the help of more than 1,200 employees who changed shifts without stopping, to build and start operating the plant in less than 2 years.

Photovoltaic modules receive the radiation to generate between 600 and 850 V, in CC form. With use of inverters, this energy is converted into AC, which passes through transformers to raise its Voltage to 34.5 kV and distribute it around the park.

Finally, this current is transmitted to plant electrical substation, where voltage rises to 230 kV to be transmitted throughout the country by Central American Electric Network, which arrives from El Salvador, passes through Honduras and goes to Nicaragua. .

The Nacaome solar plant has been an engine of economic, scientific and academic development for Honduras people and a monumental engineering work that has put Central American nation on sustainable energy industry international map.

Imagen relacionada

Construction of Los Prados solar park, which would have 53 MW and should have started operations at end of 2016, is being halted by local residents protests who fear possible damage to their people caused by the park.

A solution is currently being sought between authorities and settlers, since everything is ready for work execution, but news is not encouraging.

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