Work on the diversion charge controller

[Clément Gangneux]

Here is the topic to work on the open source charge controller that has been designed during the last kickstarter project. For more informations, consult the page of the regulator on the website.

You want to participate ? Here are different approach on how to improve the existing regulator :

• Further testing of the existing prototype : It would be nice to test the existing prototype in a large setting of different installations and particularly to measure the ability of the prototype to dissipate heat. If you installed a prototype and had a problem with it, please report it on the forum.
• Equalization : The existing prototype doesn't take into account the equalization of the batteries. The equalization consists into forcing the battery voltage to a high level during a few hours once every months. This concerns the open lead acid batteries and helps to expand their lifetime. It could be interesting to add this feature to the existing regulator.
• Temperature correction : For installations where the temperature varies a lot, it is interesting to be able to change the setting of the topping voltage
• Translation of the manual : You want to translate the manual into your language ? Please feel free to do it and post the translated text on the forum.
• Numeric design : The creation of a numeric design for a new charge controller could be interesting to add more features to it, although it might be less robust. If you are interesting into designing such a controller, you can download a first attempt at designing one here

If you have any question, remarks about the design, if you want to report a malfunction or share your improvements on the device, please contact me.

[Hugh]

hi Clement,

Are you looking for people to test this controller?  I can put a post on my blog and maybe find somebody or I might be able to test one here at Scoraig.  Of course it's dangerous to test a controller if it does not work because the battery could be damaged but if the owner lives with the system then it should be OK.

I wonder if you have any plans to introduce a "float charging" stage in the design?  Modern charge controllers have many stages:

bulk when you start (no control)

absorption at a suitable set point voltage

float at a lower voltage after a few hours

equalize at a higher voltage every few weeks or months

Temperature compensation is also a good idea.  If the battery gets hot it can start to gas vigorously and get hotter in runaway.

You need to consider what this is for.  If it has to be lowest cost then maybe you don't need any fancy extra features like this.  But then the user must be vigilant and take care of the battery.

Let me know what you would like me to do with helping to test it.

cheers

Hugh

[Clément Gangneux]

Hi Hugh,

Thank you for your answer, I would like indeed some help for testing it. Of course it is still a prototype so I would strongly advice to use it on installations with another regulator from the market as a security. The regulator is at its first version and is now quite simple, only achieving bulk and absorption phase. Although, due to the intermittent nature of the production of a wind turbine we assumed that float charge is not that necessary ( the absorption phase can last 48 hours without damaging the battery ) but this has to be taken in account for installation with a strong constant wind and/or not much electricity consumption. A second version of a regulator is on its way.
If you would like to test it in Scoraig, I can send you a kit with the PCB and the components needed for installation. That way, you can build it yourself and also give me a feedback on the fabrication and calibration. All the informations needed for building one are compiled in the installation manual.

Thank you for offering help, cheers
Clem