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Solar Charge Controller Sizing Help Please

theHouserHouse

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Sep 5, 2020
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I've read so much my head is spinning and I'm still not completely sure what size solar charge controller to buy. We have 8- 100 watt panels, each panel has VMP (volts) of 20.6 & IMP (amps) of 4.85. We are wiring them in sets of 2, in series, which brings the VMP to 41.2 and the IMP to 4.85 per set. Then putting the 4 sets in parallel which brings the totals to VMP to 41.2 and total IMP of 19.4. Whew!

I've read several ways of calculating for the solar charge controller. What's not clear is if the wiring configuration affects the calculation or not.

-If I use the # of panels (8) X panel watts (100) = watts of array (800), then divide the watts of array (800) by the battery volts (12) , and add 25%; I get 83.333 amps and would need a 100 amp controller.
-If I use the watts of the array (800) divided by the volts of the battery (12); I get 66.666 amps and would need a 80 amp controller.
-If I use the amps the panels are rated at from the sticker on the back (4.85) X the number of panels (8); I get 38.3 and would need a 40 amp controller.
-Or do I some how use the total amps after wiring up the panels in series and parallel, which is 19.4?
Good Golly I'm totally confused.

We have 10 gauge wire for the connection of solar panels and 8 gauge wire for the run down to the solar charge controller. We have purchased a 3000 watt pure sine wave inverter.
As batteries go we are still on the fence. We have 2- Group 24 deep-cycle sealed lead acid batteries on the tongue of the travel trailer. They are one year old 70 amp/hr, 12 volt batteries. Pretty much generic RV dealer batteries. We'd like to use these for awhile if we can. Not sure yet if they are big enough though. We plan to buy used lithium batteries, but are finding that selecting them is just a complicated as buying a charge controller. So any affordable battery suggestions is greatly appreciated. A new updated picture of our rooftop wiring diagram is included. Hopefully I don't have panels wired up wrong this time.
 

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Putting aside the specific array configuration, pay attention to the array wattage. If you have a 12V battery (bank) and 800W of panels peak current to the battery is 67A. Actual current varies with battery voltage. 800W at 11V is 73A while at 14V is 57A. An 80A SCC would be advisable minimum. If you put in a lower rated controller, typically, nothing bad will happen the controller will just current limit at its rating, say 60A. If you could find one you could use a 70A controller with the understanding that if the planets aligned correctly you would be dropping 3A of production during the peak of the day. If you want more info on this search the forum for over panelling, lots of discussion about it.

If your array can supply more current than the SCC is rated to accept on it's PV input, typically the amp rating applies to both the solar and battery charger terminals, you should have an appropraite fuse between the array and the SCC.

Make sure your battery is happy with being charged at what ever current your system can theoretically provide.

A paper 800W array may never actually produce 800W too. Attention to array voltage WRT the controller's abilities etc needs to be given, but that's another story.
 
We found two options I think might work. Any thoughts on these?
Victron SmartSolar MPPT 150/60-MC4 Solar Charge Controller 150V 60A with Bluetooth
Or the Outback Flexmax 80 FM80 MPPT 80 AMP Solar Charge Controller
I'm leaning toward the Victron. I like the ability to monitor it with the bluetooth.
 
Amazon sells the EPEVER 60amp MPPT Charge Controller 48V/36V/24V/12V Negative Ground Max 150V which is a lesser $ option
 
Amazon sells the EPEVER 60amp MPPT Charge Controller 48V/36V/24V/12V Negative Ground Max 150V which is a lesser $ option
Thanks for the suggestion. We decided to go ahead with the 80amp. It's quite large, but has excellent reviews.
 
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