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Old 01-19-2019, 05:06 PM   #1
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Solar charge controller help

HELP! We have a Mppt charge controller and we’re having problems with it. When our solar panels get completely charged we get an error that says over voltage disconnect voltage. And we have to take the positive of our solar panel off the charge controller. It’s like the charge controller isn’t stopping the charge from going to our batteries when their full. We just have the solar panels, inverter (usually always off), fuse box, charge controller, batteries. We put the system together ourselves. Are we missing anything?

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Old 01-20-2019, 07:38 AM   #2
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You should get some DC breakers before and after your charge controller. Sounds like your controller isn't properly sized for your panels.

Post the specs for your panels and specs for your controller. That will help people help you
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Old 01-20-2019, 01:36 PM   #3
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I have 4 100 watt solar panels 12 volt and 33.3 amps. Charge control is 40amp
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Old 01-20-2019, 03:30 PM   #4
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You didn't say how many amp controller. It should have a setting to control the over charge voltage. It should cut off. Check your settings.
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Old 01-20-2019, 05:13 PM   #5
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I have the mppt tracer4210A. I don’t know how to change the settings I couldn’t find it anywhere. I figured out how to tell it what size and type my batteries are but that was it
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Old 01-20-2019, 05:32 PM   #6
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Originally Posted by Jamie23 View Post
I have the mppt tracer4210A. I don’t know how to change the settings I couldn’t find it anywhere. I figured out how to tell it what size and type my batteries are but that was it
Charge and discharge current is 40a on that unit.
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Old 01-20-2019, 06:53 PM   #7
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Yes I said it was 40amp above
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Old 01-21-2019, 07:06 AM   #8
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HELP! We have a Mppt charge controller and we’re having problems with it. When our solar panels get completely charged we get an error that says over voltage disconnect voltage. And we have to take the positive of our solar panel off the charge controller. It’s like the charge controller isn’t stopping the charge from going to our batteries when their full. We just have the solar panels, inverter (usually always off), fuse box, charge controller, batteries. We put the system together ourselves. Are we missing anything?
Nothing obvious comes to mind.

You should have a fuse/circuit breaker between the array and charge controller (CC) and also between CC and battery bank. The distance between CC and battery should be as small as possible (few feet). Do you have a voltage sense line from battery bank & CC? If not and your CC supports it, it is worth adding.

Are your panels in series or parallel? (what is theoretical maximum voltage going into CC and can it take that voltage)? In other words, if your panels are in series and produce 15-ish volts maximum, then your CC may be seeing up to 60-ish volts.
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Old 01-21-2019, 10:31 AM   #9
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Max input voltage on the 4210a is 100vdc.

Even If you had 4 (12v) panels in series you should not have an overvoltage issue.

I would suspect that the charge controller may be defective. Have you contacted the manufacturers tech support?
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Old 01-21-2019, 10:50 AM   #10
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Nothing obvious comes to mind.

You should have a fuse/circuit breaker between the array and charge controller (CC) and also between CC and battery bank. The distance between CC and battery should be as small as possible (few feet). Do you have a voltage sense line from battery bank & CC? If not and your CC supports it, it is worth adding.

Are your panels in series or parallel? (what is theoretical maximum voltage going into CC and can it take that voltage)? In other words, if your panels are in series and produce 15-ish volts maximum, then your CC may be seeing up to 60-ish volts.
I have fuses on all my panel lines and a fuse from the CC to the batteries. My panels are in parallel, 4 100watt at 12volt 33.3amp
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Old 01-21-2019, 11:02 AM   #11
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My panels are in parallel, 4 100watt at 12volt 33.3amp
I'm reading between the lines a wee bit here but it might be useful for anyone reading this to know that a "12 volt" panel is fairly generic. It's similar to saying that we have a 12 volt battery. It really isn't 12 volt but we all know that. We also know that a 12 volt battery (which is more like a 12.6 volt battery) requires more than 12 volts to charge (more like 14 volts, depending on the battery type and state of charge). Since you have them connected in parallel and given the info that Steve provided (max voltage that CC can handle), my suggestion is not of any value - you are well under the 100 volt max. However; that 12 volt panels might be producing more like 18 volts (or anything in between). Apologies...
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Old 01-21-2019, 11:03 AM   #12
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When you parallel more than two panels you should have a fuse or breaker for each panel.

This is commonly done with a combiner box with a breaker for each leg.

Like this one: https://www.solar-electric.com/mnpv6...EaAvW8EALw_wcB
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Old 01-21-2019, 02:00 PM   #13
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When you parallel more than two panels you should have a fuse or breaker for each panel.

This is commonly done with a combiner box with a breaker for each leg.

Like this one: https://www.solar-electric.com/mnpv6...EaAvW8EALw_wcB
There are fuses on all my panels and I have a fuse box, here are some pictures of my setup
Attached Thumbnails
7BDCA3C7-2D67-4A6E-B67B-8AE0D95D8FBA.jpg   DD1CAA49-62F1-4EFF-98A3-E8B12370A525.jpg   CEFE80C4-8BDA-4AAA-A6C5-01E19CC913E2.jpg  
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Old 01-21-2019, 02:58 PM   #14
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This is what it looks like, sometimes it is up to 17 volts
Attached Thumbnails
59EEA4CA-0692-472A-9EFD-54CA50BDF49C.jpg   19028DA7-5716-4C41-9ED8-0FB42501F354.jpg  
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Old 01-21-2019, 04:07 PM   #15
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Looks like it reaches it's limit and shuts down the input. It says your are inputing 16.6 and that's also the cut off to save your batteries. Does it do anything other than give you the frowny face? Does it a affect your ability to use that charge?
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Old 01-21-2019, 07:04 PM   #16
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Looks like it reaches it's limit and shuts down the input. It says your are inputing 16.6 and that's also the cut off to save your batteries. Does it do anything other than give you the frowny face? Does it a affect your ability to use that charge?
No, we can still run stuff, but is it supposed to do that? We have to unplug the positive on our solar from the charge controller for it to go back to good
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Old 01-21-2019, 07:30 PM   #17
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The only thing i can think of then is that the shut off isn't kicking in. Shutting off is its last ditch to save your batteries. The controller is either bad or the over charge limit needs to be set lower. Strange. But You said something about not being able to set it?
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Old 01-22-2019, 10:09 AM   #18
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Yeah I was only able to set the settings for my batteries, also having the problem that it doesn’t show the arrows from the solar panel picture the batteries showing that it’s charging
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Old 01-22-2019, 11:02 AM   #19
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I looked at the instruction manual for the 4210a and found that the spec for max battery voltage is 16 volts. Exceeding that causes battery disconnect.


My question is: Why is it trying to feed your batteries 16.2 volts?

The troubleshooting section in the manual is pretty much useless.

If I were in your shoes, I would triple check the battery settings in the charge controller and if you don't find a problem with that then I would exchange the charge controller for a new one.
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