Connected Hardware & Firmware for E-commerce Optimization

Customer Background & Requirements

The customer required a high-capacity PWM-based solar charge controller capable of managing two independent solar arrays and dual battery banks in a 24 V system. The system had to handle up to 60 A charging current, support dual load outputs (24 V, 25 A each), and include data logging for long-term performance monitoring. Additionally, the controller needed to operate in both common positive and common negative configurations, providing flexibility for integration into diverse solar installations. The solution also had to include multiple charging modes (bulk, absorption, float, equalization) for optimal battery performance and protection.

Solution Provided by Electrobit Technology:

Electrobit Technology designed and developed a robust PWM Solar Charge Controller supporting dual solar input arrays, dual battery management, and dual load control. The controller features advanced charging algorithms, real-time data monitoring, and event- based data logging for comprehensive performance tracking. It supports both common positive and common negative topologies, allowing universal compatibility across different solar system wiring schemes.

Services Provided:

The project included complete hardware and firmware development, power-stage design, and integration of a data-logging system.

Firmware Development

Implemented PWM charging algorithm with multi-stage charging (Bulk, Absorption,
Float, Equalization).
Developed logic for independent dual-array input management (up to 60 A combined).
Implemented dual battery control with 24 V, 30 A capacity each, including charging
priority selection.
Designed a dual load management system supporting 24 V, 25 A outputs with load
protection.
Added data logging for solar, battery, and load parameters with timestamped event
storage.
Integrated temperature compensation for charging voltage control.
Included LCD display/UI and RS485 communication for configuration and monitoring.

Hardware Design & Improvement

Designed a high-efficiency PWM power stage with thermal and short-circuit protection.
Implemented independent current and voltage sensing for arrays, batteries, and loads.
Added galvanic isolation and surge protection for field reliability.
Supported both common positive and common negative configurations through hardware jumpers.
Integrated real-time clock and data storage for accurate logkeeping.