Author Topic: Charging 48V Batteries from 24V Panel  (Read 3790 times)

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tsweeney

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Charging 48V Batteries from 24V Panel
« on: January 27, 2007, 11:32:15 PM »
Howdy All,

  I'm starting to put together a system based on an APC Matrix 5000 for emergency power.  The plan is to transition to solar but for the time being I have on a single BP/Solarex SX120U 24V panel.  The ups battery pack is 48V.  I've been looking for a cheap/small charge controller that can take charge a 48V pack from a 24V Panel but have come up empty handed.  It appears the outback MX60 would accomplish this but it really overkill for this system as well as being too much money.  Ditto on the blue sky controllers.  Are there any less expensive options?  I know the MMPT controllers are fancy DC-DC converters.  Anyone think it'd work to use a wide-input DC-DC converter to step up the 24 to 48 and then use a standard PWM controller?  It's not ideal but perhaps it would get the job done till I could get another panel.  Any thoughts suggestions ext are greatly appreciated.


Sincerely,

  Tim Sweeney

« Last Edit: January 27, 2007, 11:32:15 PM by (unknown) »

sk windpirate

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Re: Charging 48V Batteries from 24V Panel
« Reply #1 on: January 27, 2007, 05:26:17 PM »
It might be cheaper to get another 24 volt solar panel and hook then up in series

to give you 48 volts.


The pirate

« Last Edit: January 27, 2007, 05:26:17 PM by sk windpirate »

craig110

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Re: Charging 48V Batteries from 24V Panel
« Reply #2 on: January 27, 2007, 07:27:41 PM »
Since you are planning on eventually getting a second panel, I'd avoid paying more for a special controller that can step-up the lower-voltage input.  By the way, you mentioned the MX60.  My understanding is that while it handles a large range of input voltages, it can only step the voltage down to match the battery and can't step a voltage up.  The product spec, for example, states "Can charge a lower voltage battery from a higher voltage PV array" but doesn't say anything about stepping the voltage up.  (It has a very low end voltage it can take, but that is because it can be configured to charge 12v batteries.)


Something to look into is making a buck/boost converter.  This would sit between the panel and the charge controller and, in your case, double the DC voltage.  Be aware that it does this by cutting the amperage in half, so it doesn't provide any magical boost in overall power.  For example, if a 2:1 boost converter had 24v 10A input, it would have, not counting conversion inefficiency, a 48v 5A output.  The advantage of the boost converter is that you'd be able to get a normal 48v charge controller without having to buy a second panel.  The disadvantage (as there is no free lunch) is that there will be a conversion power loss.  Depending upon the converter, you might lose up to 10-15% of the power.  Some purists would object over losing that much expensive solar power, but in my view being able to use 85+% of the panel's output now beats not being able to use any of its output until a second, expensive, panel is purchased.


There is plenty of info on this site about building converters, so a search of the site might be a useful thing for you to do.

« Last Edit: January 27, 2007, 07:27:41 PM by craig110 »

TAH

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Re: Charging 48V Batteries from 24V Panel
« Reply #3 on: January 27, 2007, 08:52:16 PM »
You could get one of these http://cgi.ebay.com/CHARGE-BOOSTER-1500W-12-24VDC-Wind-Solar-32-48-Avail_W0QQitemZ270082468859QQihZ0
17QQcategoryZ41980QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
« Last Edit: January 27, 2007, 08:52:16 PM by TAH »

vawtsup

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« Last Edit: January 27, 2007, 09:48:05 PM by vawtsup »

tecker

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Re: Charging 48V Batteries from 24V Panel
« Reply #5 on: January 28, 2007, 08:30:53 AM »
At around 30 volts 3 amp you have some easy options .The apc has four 12 volt batts install a disconnect at a 24 volt common and add your charging circuit. Set the other side of the disconnect to keep the ups down during charging You'll have to brake into the unit to you can tap the maintenance circuit to give yourself some monitoring with the apc software package . Here's the maintainece manuel for the 5000.Nice unit .


http://sturgeon.apcc.com/techref.nsf/partnum/990-7503-A/$FILE/D7503A2.pdf    

« Last Edit: January 28, 2007, 08:30:53 AM by tecker »

craig110

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Re: Charging 48V Batteries from 24V Panel
« Reply #6 on: January 28, 2007, 11:07:15 AM »
That would work, but it has the downside that if there is a power outage on a nice sunny day, Tim will have to decide between using the APC to power items in the house (batteries wired as 48v) or charging the APC (batteries wired as 24v) with nothing being powered by it.  We had an extended power outage last week, and I would have hated to be in the position of not being able to capture the power from the panels (when we needed it most!) due to us using the batteries to power "minor" things like our furnace.  Which way to configure the batteries in an outage is a decision I'd want to avoid having to make.


(More specifically, I wouldn't want to hear things like "You spent how much on this solar stuff and we can't turn anything on even with the sun shining??"  No thanks.)


Craig

« Last Edit: January 28, 2007, 11:07:15 AM by craig110 »

tecker

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Re: Charging 48V Batteries from 24V Panel
« Reply #7 on: January 28, 2007, 11:22:39 AM »
At 3 amps you have to do either or and the ups electronics are going to be looking for a charge at 46.9 or so .Even if you have the 48 volts connected , the ups is looking for something more like 25 or 30 amps . Apcs are either chargeing or discharging controlwise. That being said unless you want to use it for backup with a set discharge rate you have to do some modifing to what appears to be a very expensive unit .
« Last Edit: January 28, 2007, 11:22:39 AM by tecker »

tecker

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Re: Charging 48V Batteries from 24V Panel
« Reply #8 on: January 28, 2007, 12:00:27 PM »
 This unit is a power hog big time but it's built ti last .
« Last Edit: January 28, 2007, 12:00:27 PM by tecker »

tsweeney

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Re: Charging 48V Batteries from 24V Panel
« Reply #9 on: January 28, 2007, 12:09:03 PM »
Thanks for all the info everyone.  I'll digest it all and let you know what I end up with and how it works out.


T

« Last Edit: January 28, 2007, 12:09:03 PM by tsweeney »

scottsAI

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Re: Charging 48V Batteries from 24V Panel
« Reply #10 on: January 28, 2007, 06:47:04 PM »
Hello tsweeney,


I have several APC smartUPS 3000 backup powering my house.

They each draw 47watts with NO load.

8 golf cart batteries should give me 2 days, Ref, lights, TV.


Power efficiency at light load is like 50% Tested on a smartUPS 1000w unit.

Both units seem to be made the same way.

Full load your unit claims 93% on line efficiency.


On to your question.

UPS charges the battery, so adding solar is not going to do much unless disconnected from the grid. Off grid a UPS is not your best choice for an inverter. Is CHEAP.


24 to 48 volt charging? I would consider charging half the battery at a time.

Balancing would be a problem...

Most solutions are near the cost of another 24v solar panels, a much better solution.

Have fun!

Scott.

« Last Edit: January 28, 2007, 06:47:04 PM by scottsAI »

Gordy

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Re: Charging 48V Batteries from 24V Panel
« Reply #11 on: January 29, 2007, 10:53:34 AM »
Tim,


Check out this site, they have a circuit to convert a 1.2 v solver cell out put to 5v (5 voltsolar power supply). And a simular circuit (12 volt fluorescent inverter). If you contact them they may design a circuit for your volt's and amps. (I you agree to buy the parts kit from them)


 http://www.talkingelectronics.com/te_interactive_index.html


Gordy

« Last Edit: January 29, 2007, 10:53:34 AM by Gordy »