Step7: Sizing Charge controller

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To calculate the size of the charge controller required, we first need to determine the solar array's maximum current output and then ensure the charge controller can handle that current at the system's voltage.

Step 1: Calculate Solar Array's Maximum Current Output

The formula to calculate the current (in Amps) is:
Current = Total Solar Array Power/System Voltage

Given:
- Total Solar Array Power = 6.48 kW = 6480 W (Calculated Solar Array Value)
- System Voltage = 48V (Battery Bank Voltage)

Current = 6480W/48V = 135A

Step 2: Determine Charge Controller Size

The charge controller must be able to handle at least 135A. However, it's good practice to add a safety margin (about 25%) to accommodate for potential increases in current due to bright sunlight conditions or other factors.

Required Controller Current Capacity = 135A x 1.25 = 168.75A

Since charge controllers are not typically available in this exact capacity, you would choose the next higher available size. If, for example, charge controllers are available in increments of 10A, you would select a 170A charge controller.

 Step 3: Number of Charge Controllers Needed

If a single charge controller of the required size is not available or if using multiple controllers is more practical for your setup, you could divide the total required current by the capacity of available controllers.

For instance, if you opt to use 100A charge controllers:
Number of Controllers = 168.75A/100A = 1.6875 

Since you cannot have a fraction of a controller, you would round up to 2.

Conclusion

For a system with your specifications, you would require charge controllers that can collectively handle at least 168.75A at 48V. This could be one 170A controller (if available) or two 100A controllers to ensure adequate coverage and add a safety margin.

Parameters Recap 
1. Daily Energy Consumption: 20.75 kWh
2. Total Peak Power: 3430 W
3. Days of Autonomy: 2 days
4. Solar Hour: 4 hours
5. Calculated Solar Array Value: 6.48 kW
6. Number of Solar Modules: 22 pieces of 300W modules
7. Battery Bank Size: Approximately 960.65 Ah at 48V (with 90% DOD)
8. Inverter Sizing: 5KVA inverter is ideal for the system
9. Charge Controller Size: 170A (rounded up from 168.75A with a safety margin of 25%)
Number of Charge Controllers Needed: 2 (assuming 100A controllers are used)

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