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Solar System with 96VDC charge Controller

12/14/2022 7:39 AM

Hello everyone

In some photovoltaic installations that should deliver 24 V DC, they used a charge controller of 96 V DC to charge batteries then and a converter 96VDC/24VDC in order to get 24 VDC to feed the loads, when I asked why they didn't use a charge controller 24VDC directly and in this case, we don't need to use the converter 96VDC/24VDC, they said this configuration with 96 V helps to reduce the current. In addition:

1. with 96 V DC we need two strings in parallel in each string there are 36 batteries.

2. with 24V DC we need four strings in parallel in each string18 batteries.

As more batteries are paralleled together, the risk of one faulty battery affecting the entire battery bank increases.

For example in 24VDC there are 4 four strings in parallel, If the voltage of the first string is less than the voltage of the second string, then the first string becomes a load and will not output power so there will be a circulatory current flow between the first and the second string. The result can be overheating, leaking, or bulging in the lower voltage battery string and/or overheating in the higher voltage battery string as it drains rapidly.

Are there technical books or guides that explain this in detail, especially the use of 96VDC/24VDC converter augment the risk of breakdowns, I mean the more equipment we use, the more the rate of breakdowns increases

Best regards

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#1

Re: Solar System with 96VDC charge Controller

12/14/2022 7:56 AM

Here is a good source of battery information.

Battery University Homepage

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#2

Re: Solar System with 96VDC charge Controller

12/16/2022 3:55 PM

It is more common to have a 96 volt input inverter that converts everything to ac such as 230V or 120V. rather than direct usage of dc. A 96 volt dc to 24 volt dc converter seems like an expensive item to have rated for the full output, unless there is a special or unusual load. The un-paralleling of the batteries in this case may not pay for the operation cost and initial investment for the extra power supply, but there may be a special case in the details that we can not see from here.

Good old electrical engineering should win out as a guide, but there will be many rather young opinions out there as to the actual cost effective path to take. The technology available at the consumer level is an order of magnitude more sophisticated than what we could buy over the counter even 5 years ago.

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#3

Re: Solar System with 96VDC charge Controller

01/12/2023 10:47 AM

Higher voltage soon becomes more efficient. Right back in the dawn of electric supply, Mr Edison's incandescent lamps dimmed noticeably for 2% drop. Building supply regulations used to dictate 2% regulation for lighting circuits. A 2% drop at 6 Volts compared 12 volt is half the voltage at double the current - 4 times the copper. Copper is expensive & twice the insulation material is needed @ 6V.

I have had 6V battery car, the lights dimmed under load & windscreen wipers would not start with headlamps on!! No trouble with 12v battery.

The standard solar panel is ~ 10 amps at 24V. It is much easier to loop panels in series with a standard cable/plug than parallel where current & cable/plug size must go up along the run.

Devices like diodes/thyristors drop 1 volt regardless of their voltage rating, so watts loss can be cut by higher voltage and lower current for same power.

Solar panels are silicon diodes, they do not reverse conduct, so parallel is not a problem. At 96V a diode to avoid feedback is not much loss. There is a problem if some panels are sun-shaded - different voltage - but output is better with series. It is always best to have diodes from each charge source to avoid back-feed - one charger can continue to work.

So much equipment works at 24V that converters from higher voltage are common & efficient. Compact fluorescent & LED lights have had built-in converters for over 20 years by the million [billion?].They are not complicated compared to a light switch, which now works on Wi--Fi, and do not add much to overall failures.

Wiring Regulations for buildings are now specifying voltage surge protection because of the vulnerable electronic LED lighting [lighting is a safety concern in large buildings due to number of people & fire risk/panic if mains fails] & proliferation of electronics.

It is not even possible to 500V megger-test circuits because lighting & timers etc are electronic & could be damaged.

If reliability is primary, then simplicity is good, but all faults must be considered and often duplication is needed.

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