Global Journal of Researches in Engineering: F

Electrical and Electronics Engineering

Volume 16 Issue 8 Version 1.0 Year 2016
Type: Double Blind Peer Reviewed International Research Journal
Publisher: Global Journals Inc. (USA)
Online ISSN: 2249-4596 & Print ISSN: 0975-5861

Solar Power Charge Controller

By Tarang Thakur
Maharaja Agrasen Institute of Technology
Abstract- The demand of renewable energy (alternative energy sources) is increasing day by day
as our non renewable sources have started depleting. The other reason for increased demand is
that it has a cleaner, easy setup and has a very low cost of maintenance during its operation.
Due to which, solar powered equipments and appliances are making its way into various sectors
of our day to day life. This research paper deals with the scenario that a storage or battery is
needed in order to harness the solar energy when the sunlight is available and supply it in vice
versa conditions. For this, a cost effective system is built which charges a battery with the help of
solar panel and protection is given to the battery in case of overcharge, deep discharge and
under voltage condition. The block diagram, circuit diagram, hardware design are discussed in
the paper.
Keywords: solar panel, battery, transistors, lm-324, op-amps, load.
GJRE-F Classification: FOR Code: 850505

SolarPowerChargeController

Strictly as per the compliance and regulations of :

© 2016. Tarang Thakur. This is a research/review paper, distributed under the terms of the Creative Commons Attribution-
Noncommercial 3.0 Unported License http://creativecommons.org/licenses/by-nc/3.0/), permitting all non commercial use,
distribution, and reproduction in any medium, provided the original work is properly cited.
 Solar Power Charge Controller
Tarang Thakur

Abstract- The demand of renewable energy (alternative energy which in turn illuminates electrical appliances or helps in
sources) is increasing day by day as our non renewable pumping water from the ground [1]. Hence, it is needed
sources have started depleting. The other reason for to protect battery form overcharge, deep discharging
increased demand is that it has a cleaner, easy setup and has
mode while dc loads are used or in under voltage as it is
a very low cost of maintenance during its operation. Due to
which, solar powered equipments and appliances are making
the main component in a solar power charge controller.
its way into various sectors of our day to day life. This research [2]
In this project, indications are provided by a red

2016
paper deals with the scenario that a storage or battery is
needed in order to harness the solar energy when the sunlight LED for fully charged battery while a green LED

Year
is available and supply it in vice versa conditions. For this, a indicates that battery is charging. White LED is provided
cost effective system is built which charges a battery with the in order to indicate overcharge, deep discharge or
help of solar panel and protection is given to the battery in under voltage condition. Charge controller also uses 13
case of overcharge, deep discharge and under voltage MOSFET as power semiconductor switch to ensure cut
condition. The block diagram, circuit diagram, hardware
off the load in low battery or overload condition. When

Global Journal of Researches in Engineering ( F ) Volume XVI Issue VIII Version I

design are discussed in the paper.
the battery gets fully charged, a transistor is used in
Keywords: solar panel, battery, transistors, lm-324, op-
order to bypass the solar energy to a dummy load which
amps, load.
protects the battery from getting over charged.
I. Introduction A solar charge controller or regulator is a small

S
box placed between a solar panel and a battery
olar Power Charge Controller can be used in consisting of solid state circuits PCB. They are used to
various sectors. For instance, it can be used in regulate the amount of charge coming from the solar
solar home system, Hybrid systems, solar water panel in order to protect the battery from getting
pump system etc. In this, a solar panel converts sunlight overcharged. Adding to this, it can also be used to allow
energy into electrical energy through an electrochemical different dc loads and supply appropriate voltage. [2]
process also know as photovoltaic process. Energy is
stored in the battery with the help of solar panel through II. Block Diagram
a diode and a fuse. Energy stored in the battery can be
In figure 1, the basic arrangement of the
used when there is no sunlight as during discharge,
implemented project can be found.
chemical energy is converted into electrical energy

Figure 1: Block Diagram Arrangement of the Project

Author: B.Tech Student, Department of Electrical Engineering, Maharaja Agrasen Institute of Technology, New Delhi, India.
e-mail: [email protected]
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 Solar Power Charge Controller

metal contacts on top and bottom of the cell, from which

a) Components Used
we can draw current externally.
The main components used in order to
Solar panel is a panel designed to absorb sun’s
establish the project are Photovoltaic Cells and Solar
rays in order to generate electricity or heat. A PV module
panel, battery, LM 324 and Transistors.
is a packaged consisting of solar cells. Solar panels
i. Photovoltaic Cells and Solar panel constitute the solar array of a PV system that helps in
Photovoltaic (PV) cells are the one which are generating and supplying electricity to commercial and
made from special materials called semiconductors like residential sectors. Following are the advantages of
Silicon. They are used for conversion of light into solar panels-
electricity using semiconductor materials that exhibit the − These are the equipments that can covert solar
photovoltaic effect. When the light strikes the cell, energy into electrical energy directly, easily and
certain amount of light gets absorbed into the efficiently.
semiconductor material which triggers the flow of − They can easily last for 25 years and does not
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electrons that causes current to flow. We can place require much operational maintenance. [4]
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Global Journal of Researches in Engineering ( F ) Volume XVI Issue VIII Version I

Figure 2: Solar Panel

ii. Battery hearing aids, wristwatches etc. whereas as large

In this project a Sealed Rechargeable Battery batteries can be used telephone exchanges, computer
(6V4.5AH/20HR) is used in order to store energy. An data centres, power substations etc. A 12V, lead-acid
Electrical battery converts chemical energy directly into battery has 6 cells. The range is 0.1C rate, where C is
electrical energy comprising of one or more electro the battery capacity in Ah in order to charge lead acid
chemical cells. The battery comes in all shapes and batteries safely. The major disadvantage of
sizes and can be used for household, robotics, overcharging a battery is that it can cause reduction in
industrial applications etc. For example, miniature its life span. [3][9]
(small) cells can be used to power devices such as

Figure 3: Sealed Rechargeable Battery (6V4.5AH)

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 Solar Power Charge Controller

iii. LM 324 range of applications such as in transducer amplifiers,

It is a general purpose op-amp consisting of DC gain Blocks and Conventional op-amp circuits. Op-
four independent, high-gain, internally compensated amps in LM 324 are used as comparators in this project.
operational amplifiers designed to operate from a single [6]
power supply over wide range of voltages. It has a wide

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Figure 4: Pin Diagram

Figure 5: Schematic Diagram

iv. Transistors used for switching applications. Biasing is done in such

There are three types of transistors used in this a way that it will remain fully on if there is a signal at its
project. base otherwise not. The emitter can be recognized as it
− SL 100 will be projecting out. The base is nearest to emitter
It is a general purpose, medium power NPN while collector is far away in the casing. [5]
transistor and is commonly used as a switch in common
emitter configuration. The transistor terminal requires a
fixed DC voltage in order to operate in a desired region
of its characteristic curves. It is known as biasing and is

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 Solar Power Charge Controller
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Figure 6: SL 100
Global Journal of Researches in Engineering ( F ) Volume XVI Issue VIII Version I

In Figure 6 (b): C, B and E indicates collector, base and emitter.

− BC 547 amplify current. In BC547, its base having small current
It is an NPN bi-polar junction transistor. A controls larger current at emitter and collector terminals.
transistor means transfer of resistance which is used to [7]

Figure 7: BC 547

− IRF 630 (UPS), DC-DC converters for telecom, industrial and

It is an N-type power MOSFET. It can be used in lighting equipment etc. [8]
high current switching, uninterruptible power supply

(a) (b)
Figure 8: IRF 630
In Figure 8 (b): D, G and S represents Drain, Gate and Source.
© 2016 Global Journals Inc. (US)
 Solar Power Charge Controller

b) Quantities of components used

Table 1
Major Components Used Quantity
Solar Panel 1
Battery (6V4.5AH/20HR) 1
LM 324 1
Transistors 3
LEDs 3
Slide Switch 2
PCB Connector 2-PIN 2
Diodes- IN 4007 3

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Diodes- IN 4148 6
DC Fan (12V) 1

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c) Voltage at IC Pins
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Table 2
Integrated Chip Voltages at Pin Without Voltages at Pin With IC

Global Journal of Researches in Engineering ( F ) Volume XVI Issue VIII Version I

(IC) Pin (No.) IC (Voltage) (Voltage)
LM 324 1 0 3.2
(Operational 2 2 1.9
Amplifier) 5 2 1.9
8 0 3.2
14 0 5

Figure 9: Voltages at IC Pins without IC (PCB)

Source: - http://www.edgefxkits.com/

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Figure 10: Voltages at IC Pin with IC (PCB)

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III. Schematic Diagram

Figure 9: Circuit diagram

a) Connections connected to GND through R2 of resistance 82K. The
A solar panel is used in a solar charging circuit. base of BC 547 is connected to the Pin no. 1 of LM 324
In this project, the base of SL 100 (power transistor) is through R3 of resistance 100K. Pin no. 4 is connected to
connected to the emitter of the transistor (BC 547), +VE terminal and 11th is connected to GND for all four
collector is connected to the +VE terminal and emitter is
op-amps U1: A and U1: B. 2nd Pin of U1: A is connected
connected to GND. Transistor (SL 100), battery (6V) and
to Pin 1 of op-amp through two resistors R4 of 330K and
a transistor (BC 547) are connected parallel to each
other. The collector of BC 547 is connected to +VE R5 of 330k. Pin 3 of U1: A and Pin 5 of U1: B are shorted
terminal through R1 of resistance 18K and the emitter is and connected to POT of 5K. 6th Pin of U1: B is

© 2016 Global Journals Inc. (US)

 Solar Power Charge Controller

connected to GND through resistor R10 of 120K. 7th Pin pin 6 of U1:B via R9 and pin 10 of U1:C via 5K variable
of U1: B is an O/P pin connected to Led Green and Red resistor. Solar panel being a current source is used to
through R7 of 1K and R15 of 2K respectively. . VI: C is charge the battery B1 via D10. While the battery is fully
also an op-amp whose 10th Pin is connected to POT of charged, the voltage at cathode point of D10 goes up
5K of which one of the terminal is connected to 2nd Pin resulting in the set point voltage at pin 3 of U1: A to go
of U1:A whereas 9th Pin is connected to GND. 8th Pin of up above the reference voltage because of the potential
U1: C is an O/P Pin which is connected to Gate of divider formed by R12 of 22K, 5K variable resistor, R13
MOSFET Q2 through Diode IN4148. Along with this, 9th of 15K goes up.
Pin of U1: C is also connected to drain of MOSFET This results in pin no 1 of U1: A to go high to
whose gate is also connected to POT of RV1 which will switch ‘ON’ the transistor Q1 that places drive voltage to
also get O/P of U1: D known as Pin 14. 12th Pin and 13th the transistor SL 100 such that the current from solar
Pin of U1: D is connected to RV5 (22K PRESET) and to panel is bypassed via D11 and the transistor’s collector

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4 diodes in series known as D5, D6, D7, D8 respectively. and emitter. Simultaneously pin 7 of U1: B also goes

Year
The Source of U1: D is connected to GND. high to drive a led D1 indicating battery is being fully
charged. While the load is used by the switch operation
b) Working
Q2 usually provides a path to the (-ve) while the (+ve) is 19
Solar panel section connected to the DC (+ve) via the switch in the event of
In this, battery B1 is charged via d10 and fuse. over charge, the reference voltage at Pin 10 results in

Global Journal of Researches in Engineering ( F ) Volume XVI Issue VIII Version I

After battery getting fully charged, Q1 conducts from pin 8 of U1: C going low to remove the drive to the gate
output of the comparator ie Pin 1, resulting in Q2 to through the D4 of the MOSFET Q2 which in turn
conduct and divert the solar power through D11 and Q2. disconnects the load. In the event of over charge, Q2
In this way battery is not over charged. voltage across drain and source goes up which results
The project uses one IC LM 324 having four op- in Pin no 9 going above pin no 10 via R22. In the event
amps used as comparators that is U1: A, B, C, D. U1: A of battery voltage falling below minimum voltage is duly
is used for sensing over charging of the battery to be sensed by the combination of D3, R6, RV5 and R16 in
indicated by action of U1: B output fed D1 (Red) and Pin 12 resulting in Pin 14 going zero to remove the drive
D12 (Green) for indicating battery status. Diodes D5 to to Q2 gate via R20 and RV1. The correct operation of
D8 all are connected in series and forward biased the load in normal condition is indicated by D9 when the
through R14 and D3. This provides a fixed reference MOSFET Q2 conducts.
voltage of 0.65*4= 2.6v at anode (+) point of D8 which
is fed to pin 2 (-) of U1: A through R11, pin 13 of U1: D,

IV. Hardware Implementation

Step 1
First, the circuit is implemented on the Printed Circuit board (PCB).

Figure 10: PCB.

Then, all the connections should be done on PCB as discussed above.

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Figure 11: Components fitted on the PCB

After this, a solar panel, battery and the load i.e. a fan (12V DC/0.15A) is attached to the PCB.

Figure 12: Solar Power charge Controller Hardware Module

Step 2 Powering the Circuit
The “slide switch on the side of solar panel and battery” is switched “On” due to which, Red LED glows
indicating that battery is fully charged.

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 Solar Power Charge Controller

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Figure 13: Powering the circuit
Now, switch “ON” the “second slide switch The “Preset 1 nearer to red and green led” is
nearer to the load”. After switching both, load will also adjusted in this project in order to set the battery charge.
switch on and the fan will start rotating. A battery while charging is indicated by a glowing
“Green” LED.

Figure 14: After switching “On” both switches

− First Test of Protection given to the battery
In order to test overcharge protection, rotate
Preset 2 one which is close to white LED and is
subjected to deep discharge/overcharge. So, when the
preset is rotated, the white LED starts glowing and the
fan will stop rotating.

© 2016 Global Journals Inc. (US)

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.
Figure 15: Overcharge/Deep Discharge Protection Test
− Second Protection fan will stop rotating. This will conclude our under
Secondly, in order to test under voltage voltage test.
protection, rotate Preset 3 which is second to white LED.
After preset is rotated, the white LED will glow and the

Figure 16: Under voltage Protection Test

Finally rotate a Preset 4 closer to the load’s PCB battery is used to store energy with the help of solar
Connector 2 PIN. After rotating the preset we will see energy through a solar panel and how it can be used in
that the rotating speed of the fan will increase and vice order to supply power when there is no sun. It also
versa will happen when done in opposite direction. includes protection methods for the battery in order to
curb problems like overcharging, deep discharge or
V. Conclusion under voltage which harm the life of a battery. The
In this paper, a solar power charge controller proposed system used solar PV module as an input and
has been discussed effectively i.e. how rechargeable DC load (fan) as an output. Further the project can be

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 Solar Power Charge Controller

enhanced by using microcontroller and GSM modem to

communicate the status of the system to a control room
via SMS. This system can also be upgraded to control
normal UPS, when connected with the solar charger will
convert to SOLAR INVERTER/UPS with solar charge as
priority. [2]

References Références Referencias

1. Thin Film Solar Charge Controller: A Research
Paper for Commercialization of Thin Film Solar Cell;
Mohammad Shariful Islam, Dhanmondi R/A,
Bangladesh, Advances in Energy and Power 3(2):

2016
29-60, 2015 DOI: 10.13189/aep.2015.030203.

Year
2. Design and Development of Microcontroller Based
Solar Charge Controller; Wallies Thounaojam1, V
Ebenezer2, Avinash Balekundri3 1M.Tech Student, 23
2Associate Professor, Department of
Instrumentation Technology, Dayananda Sagar

Global Journal of Researches in Engineering ( F ) Volume XVI Issue VIII Version I

College of Engineering, Bangalore, India 3Assistant
General Manager, Research and Development, BPL
Techno Vision Private Limited, Bangalore, India;
IJEATE; International Journal of Emerging
Technology and Advanced Engineering; ISSN 2250-
2459, ISO 9001:2008 Certified Journal, Volume 4,
Issue 5, May 2014.
3. Design and Construction of Microcontroller Based
Solar Battery Charger; Zar Ni Tun, Aye Thin Naing,
Hla Myo Tun; IJSTR; INTERNATIONAL JOURNAL
OF SCIENTIFIC & TECHNOLOGY; ISSN 2277-
8616; RESEARCH VOLUME 5, ISSUE 06, JUNE
2016.
4. Photovoltaic Charge Controller Using Mppt
Algorithm; Rakshit Shetty, Aniket Upadhyay,
Mahesh Shinde, Chirag Rajput, Prof. Martand Jha,
Department of Electronics and Telecommunication,
K. J. Somaiya Institute of Engineering & Info.
Technology, Mumbai 400022, India; IJETR;
International Journal of Engineering and Technical
Research; ISSN: 2321-0869, Volume-2, Issue-12,
December 2014
5. http://www.engineersgarage.com/sites/default/files/
SL100_0.pdf
6. http://www.ti.com/lit/ds/symlink/lm2902-n.pdf
7. https://www.sparkfun.com/datasheets/Components/
BC546.pdf
8. http://www.st.com/content/ccc/resource/technical/d
ocument/datasheet/bf/f6/23/6a/d8/7f/4a/e0/CD0000
0701.pdf/files/CD00000701.pdf/jcr:content/translatio
ns/en.CD00000701.pdf
9. http://www.micropik.com/PDF/CP645.pdf

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