Direct DC Coupling

Morningstar has released a 600V MPPT Solar Controller that allows for direct battery charging in DC rather than going via the  inverter charge controller in a typical grid-tie solution. The intent is to eliminate the double conversion from solar panels being DC power through the inverter to mains then back through a charge controller into the batteries.

This isn't really something new its more of a variable option, it allows you to use your house's power via your distribution power board in the event of the grid going down.

Many people won't know that when the power provider or mains power line is not working if power is cut, that stops your solar panel system from functioning. If power is purposely disconnected because of rolling blackouts or accidental line failure or like in California U.S.A power has been cut to prevent fires from failures in the national grid in dry summer environments.

The Direct DC Coupling allows you to be more efficient and charge your storage batteries directly and keep your grid-tie system live. Other manufacturers call this an "island", an island is where you can operate independantly of the grid and distribute and manage your own resources.

Charging efficiencies

In this article, we will discuss so of the losses when power is converted or transformed or used. Our niche is the conversion of energy and with that there are losses. For example, a light bulb was designed to provide light. It does this by making a small filament of wire glow. The glowing generates the light that's wanted but also heat and that is a wasteful by-product of a light bulb.

With battery charging which is a chemical reaction, there are losses through the chemical conversions of electrons moving between plates and acids. These losses are minimalised with improvements in the technology with over 100 years in development. Losses in charging lead-acid vary from 12% for AGM batteries to about 20-25% for wet cell batteries. That means a 100Ah battery requires 112-125 Amps to recharge and store 100Ah of usable energy.

When you convert DC power from a battery into AC mains power using an inverter the equipment inside the inverter uses power and that accounts for a 5% loss in available power. The same happen when converting AC power into DC power, these devices are called power supplies, or chargers, or power rectifiers. Switch-mode supplies are typically used in all modern-day equipment to help reduce these inefficiencies but they need to be calculated and allowed for.

An example of this might be an off-grid solar system with a small inverter for charging a cellphone.

Solar panels generate DC power 18-20% efficient, that's run through a solar controller 95% into a battery for storage 85% efficient. The mains power inverter converts DC power into AC mains 95% and you connect your phone charger in here. The charger is only 90-95% efficient which then connects to your phone's Lithium battery. Let's just say here it's 99% efficient at charging. All in all, you have four pieces of equipment all with up to 10% losses so your generation of the panels needs to be almost twice the power you want to consume.

When using mains power or grid-tie to power your home but have batteries for backup energy there are losses. You also lose more power in converting them back from DC stored energy in the battery back into usable mains power. This highlights an issue with grid-tie and battery backup. Multiple conversions, the storage, use and generation all have efficiencies and losses.

In future articles, we'll discuss DC versions much like our DC to DC chargers. Direct DC Coupling in a renewable energy system and more.

Hardware differences for Grid Tie and Off Grid

With a grid-tie connection, the property uses mains power provided from the nationwide power grid as a secondary power source. It generates DC power from solar panels, sends that power through an inverter which converts it into mains power which is used within the home or passed back to the national grid. This is passed back power is referred to as selling back.

With an off grid setup other than your solar panels you'd use some other source of secondary power for times when the sun's not shining. Options include a generator, wind turbine, hydro-power or battery backup each of these systems has its own pro's and con's but each situation for their use and or cost, duration, return on investment will differ. The main schematic difference between a grid and off-grid though is an off-grid generates DC power which it stores in batteries using a charger (the name of the charger will change depending on what your charging source is. A solar array uses a solar controller, wind and hydro both use controllers (in fact all 3 use the same model controller in different ways so if you have multiple sources of generation you will require multiple controllers) All these controllers essentially charge your batteries, one might say solar/charge controller or wind/charge controller. These batteries are used to provide power and flatten out the curves of either low power generation times or high power usage from multiple appliances all being used at the same time. The second part of an off-grid system is the generation of mains power onsite, rather than coming from the grid it is converted from DC power (the batteries power). This is just like the inverter used in a grid-tie setup to convert the solar DC power to mains AC power.