Re: [pvusers] Fried controller...

["Robert Warren" <robertwarren@mail.com>]

Dear William,
 It helps that you were doing the startup on a rainy day as it tells me, even without a schematic, that it looks like you had the right starting voltages n your PV modules. I am writing this from home, so I don't have my normal reference materials and am not familiar with the specs on the Solarex Millenia 42w modules. I will take a look at this later on.
 However, I used to be PV product manager at Heliotrope some years ago,and I can tell you that we had a huge number of failures with the CC120-48V. When I worked there, in 95 or '96, they hadn't had an engineer on staff for a year or two: just a really Vietnamese good circuit board troubleshooter, who didn't always get the finer details like the right size heat sink on something he was building, as he never did the calcs for the power these things would have to handle once they were out in the field. We had a lot of upset folks in Australia, I can tell you that. Heliotrope used to be a really great company, but they lost their edge somewhere along the way. I heard that the whole building where I used to work near San Diego burned down about a year ago, and that the owner was going to retire and not re-build it. So I am a bit surprised to hear of this product still being sold. Perhaps you got some old inventory from someone? The CC120 48V is toxic waste now, sad to say. Not much you can do with it. It may only be a burned FET, but typically these burns avalanche and they are toast. However, your dealer made a ton of money selling you  this complete setup, so he should get you another controller. You couldn't know that Heliotrope was bad news, but he should guarantee what he sells. 
 My advise is keep the Solpan as your main DC junction and fusing box, as all that stuff will be good, and it is a lot beefier than the Powercenters that Trace puts out. Then, by all means do buy and use the Trace C-60, as there aren't a lot of 48 volt controllers with the track record & reliability that Trace will give you. If only they would put them in a bigger box.... Perhaps you could stick them on the outside front panel of the Solpan and hide the hole left by the fried CC-60?  
 On a 48 volt system, you will normally see around 58 volts when you are starting out with new batteries and the sun comes out. Your open circuit voltage will likely be somewhere around 86 to 90 volts. Follow your battery settings in the Trace instructions manuals pretty closely. Sealed batteries need to be set just a tad lower than flooded cells. 
 A question for you? do you mean Concorde PVX-180T batteries or Concorde PVX-1080T. 180 amp hours would be way too light for the 2100 watts of panels. You need to have at least 800 amp hrs of storage, but if you have the 1080 amp hour set, then this is about right. 
 About MPPT (power point tracking) vs. PWM. PWM is great, and that is what Trace does now, finally after all these years of listening to the annoying clicking relays of the old C-30's. But MPPT is the new kid on the block and while still a bit on the expensive side, well worth it as it can get around 10-20% more power into your batteries--the solar racing cars prove this. The one I know of from experience is the Maximiser from Australia. With the money you've got invested now, go ahead and optimise it with the best controller you can get.. It is like adding another dozen PV modules.
 You didn't say where-abouts you live, but if you live in the States, I can't help you on buying any of this stuff as I work in London now for Solar Century. We have a good web site but don't sell on the other side of the pond.
Regards,
robertwarren@solarcentury.co.uk

-----Original Message-----
From: william stewart <v_stewart@earthlink.net>
Date: Wed, 08 Feb 2040 15:15:58 -0500
To: pvusers@crest.org
Subject: [pvusers] Fried controller... 


> I could use some experienced insight on two questions below.
> 
> I bought components for a grid-interactive (net metering), battery backup 
> PV system with the primary components;
>  - 50 Solarex Millenia 42w 
>  - Trace SW4048
>  - Heliotrope Solpan 110 Power Fuse Center with CC120 48V
>  - Concorde PVX-180T, qty 12
> 
> After installation and array checkout, we engaged the arrays at the 
> Solpan, which showed 85v, no load (a rainy day, too).   Then we engaged 
> the battery to controller CB, and the readings added were battery 
> voltage 52.4 and charging amps 0.1.
> 
> We then turned on the inverter, with the technician starting to go 
> through the menus.  After approximately a minute, the bulk light came 
> on.  At the same time, the Solpan readout changed quickly, a CHARGED 
> indicator came on, and then it stopped functioning, with a acrid smell 
> of burned electronics in the air.  We opened the breaker from the 
> battery to the controller and rechecked the wiring diagram and 
> polarities; everything checked out.
> 
> QUESTION 1: What is the problem?  Are the components mismatched?  I 
> realize a schematic would help fault isolate, but attachments are 
> difficult here.
> 
> Now there appears to be two options going forward.
> 
> 1. Install a "compatible" charge controller, such as a Trace C60, or
> 2. Let the inverter control battery charging, with a mercury 
> displacement relay to protect the batteries if the grid goes out (as 
> shown in manual).
> 
> QUESTION 2: Any pros and cons associated with these selections?  Do I 
> really need PWM?  Can I take advantage of power tracking if I have 
> batteries?
> 
> Thanks,
> 
> Will Stewart
> 
> 
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