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The use of batteries has its drawbacks. First, batteries can reduce the efficiency of the overall system because the operating voltage is dictated by the batteries and not the PV panels. Depending on their tempera- ture and how well the batteries are charged, the voltage supplied by the batteries can be one to four volts lower than the voltage produced by the panels during maximum sunlight conditions. This reduced efficiency can be minimized with the use of an appropriate pump controller that boosts the battery voltage supplied to the pump. System Components Pump Controller: The primary function of a pump controller in a battery-coupled pumping system is to boost the voltage of the battery bank to match the desired input voltage of the pump. Without a pump controller, the PV panels’ operating voltage is dictated by the battery bank and is reduced from levels which are achieved by operating the pump directly off the solar panels. For example, under load, two PV panels wired in series produce between 30 to 34 volts, while two fully charged batteries wired in series produce just over 26 volts. A pump with an optimum operating voltage of 30 volts would pump more water tied directly to the PV panels than if connected to the batteries. In the case of this particular pump, a pump controller with a 24-volt input would step the voltage up to 30 volts, which would increase the amount of water pumped by the system. Charge Control Regulators: Solar panels that are wired directly to a set of batteries can produce voltage levels sufficient enough to overcharge the batteries. A charge control regulator should be installed between the PV panels and the batteries to prevent excessive charging. Charge controllers allow the full current produced by the PV panels to flow into the batteries until they are nearly fully charged. The charge controller then lowers the current, which trickle charges the battery until fully charged. The regulator installed should be rated at the appropriate system voltage (i.e., 12-volt, 24-volt, etc.) and the maximum number of amperes the solar panels can produce. The regulator should be installed near the batteries, in accordance with the manufacturer’s instructions. This usually requires only four connections: the PV panel “POS” and “NEG” terminals and the battery “POS” and “NEG” terminals. In addition to overcharging protection, a low-voltage or battery state-of-charge control is required to prevent deep-discharge damage to batteries. The low-voltage relay acts as an automatic switch to disconnect the pump before the battery voltage gets too low. The relay is activated and switches when battery voltage drops to “low-voltage” threshold, and de-activates and switches back when the battery voltage rises to “recon- nect” threshold. Most suppliers of PV equipment offer a charge control regulator that combines both over- charge protection and low-voltage disconnect to protect the batteries. Batteries: The most common batteries used in stand-alone PV systems are lead-acid batteries. The familiar deep-cycle, marine-grade battery is a good example. They are rechargeable, easily maintained, relatively inexpensive, available in a variety of sizes and most will withstand daily discharges of up to 80 percent of their rated capacity. A new type of lead-acid battery “gel cell” uses an additive that turns the electolyte into a non-spillable gel. These batteries can be mounted sideways or even upside down if needed because they are sealed. Another type of battery using nickel cadmium (NiCd) plates can be used in PV systems. Their initial cost is much higher than lead-acid batteries, but for some applications the life-cycle cost may be lower. Some advantages of NiCd batteries include their long-life expectancy, low maintenance requirements and their ability to withstand extreme conditions. Also, the NiCd battery is more tolerant to complete discharge. It is important to choose a quality battery rated at a minimum of 100 amp-hour storage capacity. Shallow-cycle (car batteries) should not be used for PV applications. These batteries are lighter, less expensive and are designed to produce a high-current cold-cranking amps for a short period. The battery is then quickly recharged. Generally, shallow-cycle batteries should not be discharged more than 25 percent of the rated battery capacity. Battery banks are often used in PV systems. These banks are set up by connecting individual batteries in series or parallel to get the desired operating voltage or current. The voltage achieved in a series connection is the sum of the voltages of all the batteries, while the current (amps) achieved in series-connected batteries is equal to that of the smallest battery. For example, two 12-volt batteries connected in series produce the equivalent voltage of a 24-volt battery with the same amount of current (amps) output as a single battery. When wiring batteries in parallel, the current (amps) is the sum of the currents (amps) from all the batteries and the voltage remains the same as that of a single battery. 6 Solar-PoweredPDF Image | Solar-Powered Livestock Watering Systems
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