Furstrated- Unable to get rated solar Amperage

[bhvm]

I'm not too sure of what I am seeing, but ideally there would be one wire on each battery post (going to a bus bar). Since he is NOT using a bus bar, there should be either 1 or 3 wires per battery post... the post where you see wires to the inverter and controller should have a third wire to parallel the two 12 volt batteries.

--mapmaker

The Wires are exactly as you said , map maker. Just that they're in a staggered parallel for the good.
I'll post a close up pic later on.

Thanks.

[bhvm]

Wished I had some more time but you have some serious wiring issues. I should be seeing two sets of wires on the battery post, one from the controller and one going to the inverter. Undersized wire. Not a single breaker or fuse on the batteries.

Take your time sir,
1) The wires used are 10 SQMM for Inverter and Interconnection, and 6 SQmm for solar charge controller. They're neatly tucked behind battery so not visible. manufacturer recommendation was 4 SQMM but we went overkill.
2) The Fuse box is under the charger controller, Half visible in the picture (Ceramic fuese)
3) The Batteries are in Staggered (Diagonal) parallel to distribute the load, as mentioned by experts here.

http://www.smartgauge.co.uk/batt_con.html

[mapmaker]

Wished I had some more time but you have some serious wiring issues. I should be seeing two sets of wires on the battery post, one from the controller and one going to the inverter. Undersized wire. Not a single breaker or fuse on the batteries.

I'm not too sure of what I am seeing, but ideally there would be one wire on each battery post (going to a bus bar). Since he is NOT using a bus bar, there should be either 1 or 3 wires per battery post... the post where you see wires to the inverter and controller should have a third wire to parallel the two 12 volt batteries.

--mapmaker

[Sunking]

Wished I had some more time but you have some serious wiring issues. I should be seeing two sets of wires on the battery post, one from the controller and one going to the inverter. Undersized wire. Not a single breaker or fuse on the batteries.

[bhvm]

Here are the images I promised.

My battey bank and Inverter setup-




Getting 5.7 Amps from Panels


The MPPT making 12 Amps out of it!


Temperature compensated charging-


My sweet controller-


The DC 12V LED wiring and lights at my house-

[bhvm]

Why still using parallel panels in array. You can make them series to get lesser current but same power. You have to consider the Vmax input of charge controller. Till then you can make them parallel that will help you reduce wire size.

Max voltage support for controller is 70v. as in already using 44v panles for 12v Battery, I can't series them As they'll exceed 70v

for the cables we are using 5.sqmm for panels and 6 sqmm for Battery to controllers.

[tufail_74]

Why still using parallel panels in array. You can make them series to get lesser current but same power. You have to consider the Vmax input of charge controller. Till then you can make them parallel that will help you reduce wire size.

[bhvm]

Hello everyone and Thanks for Concerns and sincere help.

I have recieved my Charge controller, and in one fell swoop- ITs WORTH THE WEIGHT IN GOLD.

The controller is very advanced and has all the functions as the seller promised. A few advanced ones are-
1) Boost charging with equalizing function
2) Temperature compensated charging with Ambient sensor and battery temperature probe
3) FULL MPPT function
4) Ability to set Charging Current, Float Voltage, Boost Voltage, Float timing, Equalizing voltage.
5) Full Load control with user settings. Load ampere measurement. Low voltage disconnect, Overload protection
6) Power saving relay that shifts load to inverter (Battery) when the solar energy is ample.

I must say this is a godsend controller priced at just 200$.

I have currently hooked it up to my house on a small system as follows-
2x 150AH 12v batteries in Parallel
2x 200W solar panels in parallell (VOC 44v, VMP 37v, IMP 5.4A, ISC 5.8A)
20A Above said MPPT controller.

In current weather with slight clouds i am Seeing the MPPT make upto 16 Amps from 7A Incoming current. I am expecting full 20A in full Sun.

I will post the images of setup soon.
thanks.

P.s. My larger 1000W (250w x 4 ) setup is still pending as the 24v 40A MPPT controller is yet to arrive.

[paulcheung]

Sorry to tell you the MPPT charge controller you listed won't work with your system. The maximum input voltage is 70volts and one of your panel VOC is 36volt which will be 72 volt when you put them in series. So that is no no. hope you didn't buy them yet.

[bhvm]

1) I tried shufling the battery to troubleshoot any issue with chargers or Location, But the battery stays hot even after shuffling. As a result i have marked it as bad battery

2)My batteries are Flooded lead acid, tall Tublar ones. AGMs do not suceed in India due to Heavy heat and poor power conditions.

3) I have placed order for amaron 150AH x 2 Tall tublar units. As a result I won't be mixing new and old battery.

[mapmaker]

As an upgrade, I am thinking to Parallel 2x 150AH batteries for total 300AH.

So that would be four 12 volt batteries in a 24 volt system. How many did you have before you removed the hot one?

Previously you wrote:

My Clamp meter says that battery is continuously eating about 6 amps from neighboring batteries or charger.

That implies that you already had at least 4 batteries.

How many batteries can be charged using a 20A MPPT charge controller? One? two?
Some people say single battery should not be charged more than 10A? How true is that?

You should be able to charge at 10% (in amps) of the capacity in amphours. For a 300 ah battery bank you can put in 30 amps. I forget... are those AGM batteries? If so, you can double or triple that charge rate without harm.

I am thinking to get 2 Charge controllers, and Hooking each one to its own battery system. The batteries will be finally paralleled before sending to the inverter.

If the batteries are in parallel then so are the charge controllers. That's not a problem... you can parallel as many chargers as you wish. Generally you should NOT parallel batteries. If you parallel new batteries with old batteries, the new batteries will last no longer than the old batteries. It is difficult with parallel batteries to get the charging current to divide evenly among the parallel pathways... especially so with AGM batteries.

--mapmaker

[bhvm]

Thanks for the blazing fast reply. I have removed the battery promptly. It appears to be around 50.C. even after removal.

As an upgrade, I am thinking to Parallel 2x 150AH batteries for total 300AH.

How many batteries can be charged using a 20A MPPT charge controller? One? two?
Some people say single battery should not be charged more than 10A? How true is that?

Reason is, The new MPPT charge controller is only rated at 20A. I am thinking to get 2 Charge controllers, and Hooking each one to its own battery system. The batteries will be finally paralleled before sending to the inverter.
-------------------------------------------------------------------------------------------
I have 2 batteries in my 24v system 150AH
and Single battery in a separate 12v system 165AH

Both the Systems are in the que for MPPT charge controller upgrade. The MPPT in question is auto select 12 or 24v, with 4 stage temperature compensated charging but rated at only 20A.

[mapmaker]

Batteries- 12v Lead acid 150 AH in series for 24 system

I bring in a Bit of bad news folks,
One of the Battery in the system seems to be giving up.

Battery-
Flood Lead Acid Tubular Deep cycle (exide branded)
12v Nominal
165 AH

Of late the battery feels hot to touch. Assuming ambient near 35.C, be battery temperature stays around 42~43.C Irrespective of Charge or Floating voltage or Discharging load. Similar battries in other units do no exhibit such behaviour.

What could be the issue? Why is Battery heating up?

P.s- My Clamp meter says that battery is continuously eating about 6 amps from neighboring batteries or charger.

That hot battery is ruined, probably has a shorted cell. Remove it immediately... it is going to ruin the rest of your batteries. How many batteries are in your battery bank?

--mapmaker

[bhvm]

bad news

I bring in a Bit of bad news folks,
One of the Battery in the system seems to be giving up.

Battery-
Flood Lead Acid Tubular Deep cycle (exide branded)
12v Nominal
165 AH

Of late the battery feels hot to touch. Assuming ambient near 35.C, be battery temperature stays around 42~43.C Irrespective of Charge or Floating voltage or Discharging load. Similar battries in other units do no exhibit such behaviour.

What could be the issue? Why is Battery heating up?

P.s- My Clamp meter says that battery is continuously eating about 6 amps from neighboring batteries or charger.

[inetdog]

At the very best a PWM is 66% efficient. MPPT up around 95%.

When used with the standard V_MP to nominal battery voltage ratio anyway.... (e.g. 18V panel for 12V battery system.)