Battery overcharging

[Fishmagnet]

We have a 2021 R27OB that has an overcharging situation on the batteries which is shutting down the Abso battery charger due to high voltage. There is also an error light on the solar controller. I think I've isolated the issue to the solar charger by disconnecting the batteries from the solar controller and measuring the output of the controller to battery 1. The output voltage measures 19.96 volts which I'm guessing is way out of spec. Does this sound right?

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[Submariner]

We have a 2021 R27OB that has an overcharging situation on the batteries which is shutting down the Abso battery charger due to high voltage. There is also an error light on the solar controller. I think I've isolated the issue to the solar charger by disconnecting the batteries from the solar controller and measuring the output of the controller to battery 1. The output voltage measures 19.96 volts which I'm guessing is way out of spec. Does this sound right?

Sent from my SM-T510 using Tapatalk

19.96 volts sound high to me. Have you contacted the factory about this? Sounds like a potentially defective solar charger controller.

The spec's on the Duo Solar controller are as follows:
Specifications - Controller:
Max solar current 10 A for smaller panels or 20 A for larger panels (greater than 150 watts)
Absorption voltage 14.2V (sealed battery), 14.4V (flooded battery), 14.6V (industrial battery) or
Boost voltage 30 min 14.4V (sealed battery), 14.6V (flooded battery), 14.8V (industrial battery)
Float voltage 13.7V (all battery types)
Temperature range for use : from -35°C to +55°C
Temperature compensation -30 mV/°C
4 mm2 (10-12 AWG) max wire size terminals to solar panel and batteries
1.5 mm2 (16 AWG) terminals for optional remote temperature sensor

https://www.custommarineproducts.com/pwm-duo-dual-output-controller.html

 

[Cutwater28GG]

i had issues with the morningstar producing an overvolt situation. usually when on shore power and then the morningstar not reacting quickly enough when also producing solar power to the batteries. I discovered this with a balmar smartguage that flagged the historical incident.

this has been resolved moving to a Victron MPPT controller.

its not clear if I had a failed morningstar or its just the design of the unit. my voltage spike was transitory and not sustained - which might be different to your situation.

 

[Kevin Lamont]

We have a 2021 R27OB that has an overcharging situation on the batteries which is shutting down the Abso battery charger due to high voltage. There is also an error light on the solar controller. I think I've isolated the issue to the solar charger by disconnecting the batteries from the solar controller and measuring the output of the controller to battery 1. The output voltage measures 19.96 volts which I'm guessing is way out of spec. Does this sound right?

Sent from my SM-T510 using Tapatalk

Hello,

Please get in contact with your dealer so we can get this resolved. I believe the issue is with the solar controller and we can send them a new/correct one in order to fix your issue. If you have questions you can email me direct at kevinlamont@rangertugs.com.

Thanks,

 

[Red Raven]

...it’s not clear if I had a failed morningstar or its just the design of the unit. my voltage spike was transitory and not sustained ...

This is normal for a Pulse Width Modulation (PWM) controller like the Sunsaver Duo. A PWM controller does not convert the voltage from the panel. Whatever the panel is putting out is what you get. The controller opens and closes the circuit to approximate the voltage desired (thus the Pulse Width Modulation [PWM] name). The battery “kind of” helps to smooth it out to an average but you will still see voltage variation. An MPPT controller includes a voltage converter (thus the higher price!) to give the optimum desired voltage.

The OP’s controller appears to have a continuous high voltage with an error light on, which likely means the controller is not modulating (switching) properly.

Curt