“SOLAR CHARGE CONTROLLER”

A
MINOR PROJECT REPORT
Submitted to
partial fulfillment of the requirement for the award of the degree of

BACHELOR OF
TECHNOLOGY IN
ELECTRICAL ENGINEERING

Submitted By

Hemant Rathore (0201EE191025)

Inaki A. Chishi (0201EE191026)
Khushboo (0201EE191027)
Jharbade
Mayank Meshram (0201EE191029)
Naveen Singh (0201EE191030)
Nehal Shrivastava (0201EE191031)
Nimish Kalbande (0201EE191032)

Under the Guidance

Dr.V.S.Pandey
(Asst. Professor)

DEPARTMENT OF ELECTRICAL ENGINEERING

 JABALPUR ENGINEERING COLLEGE, JABALPUR (M.P.)
(Established in 1947 as Government Engineering College, Jabalpur)
(Declared Autonomous by Government of Madhya Pradesh and RGPV, Bhopal)

SESSION: 2019-2023

DEPARTMENT OF ELECTRICAL ENGINEERING

CANDIDATE’S DECLARATION

We hereby declare that the work, which is being presented in this Minor Project
Report, entitled “Solar Charge Controller” in partial fulfillment for the award of
Bachelor of Technology degree in Electrical Engineering, submitted in the
Department of Electrical Engineering, Jabalpur Engineering College, Jabalpur, is
an authentic record of our own work carried out under the guidance of
Dr.V.S.Pandey, Asst. Professor,Department of Electrical Engineering, Jabalpur
Engineering College, Jabalpur.

We have not submitted the matter embodied in this report for award of any other
degree or diploma.

Hemant Rathore (0201EE191025)

Inaki A. Chishi (0201EE191026)
Khushboo Jharbade (0201EE191027)
 Mayank Meshram (0201EE191029)
Naveen Singh (0201EE191030)
Nehal Shrivastava (0201EE191031)
Nimish Kalbande (0201EE191032)

Date:

Place
:

DEPARTMENT OF ELECTRICAL ENGINEERING

CERTIFICATE

This is to certify that Minor Project Report entitled “Solar Charge Controller”
submitted by , Nimish Kalbande (0201EE191032) have been carried out under my
guidance and supervision. This report is forwarded for submission towards the
partial fulfillment for the award of Bachelor of Technology degree in Electrical
Engineering.

Forwarded to : Guided by :

Dr. A.K.Kori Prof. Dr.V.S.Pandey

(Professor & HOD) ( Professor )
 DEPARTMENT OF ELECTRICAL
ENGINEERING

CERTIFICATE OF APPROVAL
This is to certify that Minor Project Report entitled “Solar Charge
Controller” submitted by Nimish Kalbande (0201EE191032) is accepted
towards partial fulfillment for the award of Bachelor of Technology
degree in Electrical Engineering.
INTERNAL EXAMINER EXTERNAL EXAMINER
DATE: DATE:

ACKNOWLEDGEMENT

It is a matter of extreme honor and privilege for us to offer our grateful acknowledgement
to our respected guide Dr.V.S.Pandey, Asst. Professor, Electrical Engineering,
Jabalpur Engineering College, Jabalpur to give us a chance to work under his guidance
and supervision. We also grateful for all kinds of support and inspiration, constant
encouragement, sincere criticism and valuable guidance which were given by him
throughout the investigation and preparation of this thesis.

We would also like to take this opportunity to present my sincere regards to Dr. A. K.
Kori(HOD), Dr. S. Shukla, Dr. R. Singh and all faculty members of the Department of
Electrical Engineering, for their valuable advice and assistance during our studies at
Jabalpur Engineering College Jabalpur, and their support.

We want to express our sincere gratitude to Dr. A. K. Sharma, Principal, Jabalpur

Engineering College, Jabalpur, for his valuable support and facilities provided to us to
carry out this work at Jabalpur Engineering College, Jabalpur (M.P.).

We have a great pleasure in expressing our deep sense of gratitude to all the respected
faculty members of Electricaldepartment.
Above all my deepest love and gratitude is devoted to my parents. They are always a
source of love, support and encouragement.

Last but not least, we also thankful to Almighty God for giving us the patience and the
strength for guiding us make choices in life and helping us in such mysterious way that is
impossible for us to explain.

 Hemant Rathore

 Inaki A. Chisi

 Khushboo Jharbade

 Mayank Mesharam

 Naveen Singh

 Nehal Shrivastav

 Nimish Kalbande
7

ABSTRACT

The project allows for battery charging system from a solar panel.
With the help of the solar panel the solar energy is converted into
electrical energy through photo-voltaic cells. The system is
beneficial for storing the energy for night time use. The project
even controls the charging mechanism i.e. when the battery gets
overcharged or undercharged. It requires a set of op-amps that
constantly monitors the parameters like panel voltage, load
current etc. When the battery is fully charged a green LED is
switched on and when the battery is over charged or
undercharged a red LED glows.
MOSFET is used to cut off the load when it gets overcharged or is
undercharged whereas a transistor is used to switch the load to
another dummy one when it is fully charged thereby protecting it
from being damaged.

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INTRODUCTION
Brief Overview Of Solar Charge Controller

A solar charge controller is used to keep the battery from

overcharging by regulating the voltage and current coming from
the solar panel to the battery. It is programmed at 15-A/200-W
unit and uses MPPT (maximum power point tracking) to
accelerate solar charging of the battery up to 30% per day. MPPT
checks the output of the solar panel compares it to the battery
voltage and adjusts it to the best voltage in order to get
maximum current in to the battery. The solar charge controller
uses a 25-A circuit breaker to protect it against overcurrent and
has a baseline of continuous power consumption of 35 mA.
The continous 12-V DC power is accessible via a female connector
that is implanted on the PCB , and is protected against
overcurrent by the internal circuitry of the solar charge controller.
This DC power is supplied by using a 12-V power adapter.

SOLAR CHARGE CONTROLLER

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A solar charge controller is used to charge the battery by

regulating and controlling the output from the solar PV array; it
also protects the battery from being overcharged or
overdischarged. Overcharging of the battery creates release of
hydrogen and oxygen gases from the electrolyte, which could
cause explosion and failure. If the battery is allowed an excessive
discharge of current, the battery charge will be drained. So, the
life of the battery will be reduced and cause premature failure of
the battery.
Solar charge controllers redirect or switch off all or part of the
array to reduce the current flow to the battery when it is
becoming full. If the battery is discharged below a specified
voltage, which is a low voltage preset point, the disconnection of
some or all the loads takes place. To protect the battery from
overcharging, the charge controller will have a high voltage
disconnect (HVD) point. So, the controller will have set points
such as low voltage disconnect (LVD) and HVD. The controller
voltage must be compatible with the nominal system voltage and
it must be capable of handling the maximum current produced by
the PV array.
The solar charge controller protects the batteries from being
overcharged by solar PV array/modules during the day. During
night, when solar panels don't generate and have zero voltage,
there will be a current flow from the battery to the solar panels.
The charge controller provides controls by incorporating
a blocking diode or relay to prevent the reverse flow of the
current from the battery to the array to avoid draining the
batteries during low solar irradiance or night time. This means
that the batteries are not drained during the day and that the
electricity does not run overnight back to the solar panels and
drain the batteries. Some solar charge controllers, such as the
one used for streetlight applications, take care of lighting control
as an additional function. Additionally, a load control feature is
also available with some solar charge controllers.

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3. HARDWARE REQUIREMENTS

HARDWARE COMPONENTS:

 Solar panel
 Load
 Battery
 Indicator
 Comparator (op-amp)
 Resistors
 Capacitors
 Diodes

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BATTERY

An electrical battery is a combination of one or more

electrochemical cells, used to convert stored chemical energy into
electrical energy. The battery has become a common power
source for many household and industrial applications.

Batteries may be used once and discarded, or recharged

for years as in standby power applications. Miniature cells are
used to power devices such as hearing aids and wristwatches;
larger batteries provide standby power for telephone exchanges
or computer data centers.

Lead-acid

Tried, tested, and trusted, lead-acid batteries have been with us

since the middle of the 19th century. With an overall rating of 12
volts, they have six separate cells, each producing 2 volts.
Crudely reduced to its basic components, each cell has a
"spongy" lead metal electrode (negative), a lead dioxide electrode
(positive), and a sulfuric acid electrolyte. As the battery
discharges, both electrodes become coated with lead sulfate and
the sulfuric acid is largely converted into water, while electrons
flow out around the external circuit to provide power.

Lead-acid batteries made it possible to start cars without the help

of a dangerous and dirty hand crank. Normally, you never have to
recharge them—because your car does that automatically. The
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battery discharges (gives up a little of its energy) to help the

car's gasoline engine start up, and recharges (gets energy back
again) when the engine begins generating electrical energy
through a device called an alternator. As for disadvantages, lead-
acid batteries are relatively big, surprisingly heavy (try lifting
one!), expensive, and can't be fully charged and discharged too
many times. Another problem is their use of toxic lead metal,
which can cause environmental problems when they're dumped in
landfills.

Battery used is amptek 12-V 1.3amh lead - acid rechargeable.

RESISTORS

A resistor is a two-terminal electronic component designed to

oppose an electric current by producing a voltage drop between
its terminals in proportion to the current, that is, in accordance
with Ohm's law:
V = IR
Resistors are used as part of electrical networks and electronic
circuits. They are extremely commonplace in most electronic

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equipment. Practical resistors can be made of various compounds

and films, as well as resistance wire (wire made of a high-
resistivity alloy, such as nickel/chrome).

The primary characteristics of resistors are their resistance

and the power they can dissipate. Other characteristics include
temperature coefficient, noise, and inductance. Less well-known is
critical resistance, the value below which power dissipation limits
the maximum permitted current flow, and above which the limit is
applied voltage. Critical resistance depends upon the materials
constituting the resistor as well as its physical dimensions; it's
determined by design.
Resistors can be integrated into hybrid and printed circuits,
as well as integrated circuits. Size, and position of leads (or
terminals) are relevant to equipment designers; resistors must be
physically large enough not to overheat when dissipating their
power.

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14

A resistor is a two-terminal passive electronic component

which implements electrical resistance as a circuit element. When
a voltage V is applied across the terminals of a resistor, a current
I will flow through the resistor in direct proportion to that voltage.
The reciprocal of the constant of proportionality is known as the
resistance R, since, with a given voltage V, a larger value of R
further "resists" the flow of current I as given by Ohm's law:

Resistors are common elements of electrical networks and

electronic circuits and are ubiquitous in most electronic
equipment. Practical resistors can be made of various compounds
and films, as well as resistance wire (wire made of a high-
resistivity alloy, such as nickel-chrome). Resistors are also
implemented within integrated circuits, particularly analog
devices, and can also be integrated into hybrid and printed
circuits.
The electrical functionality of a resistor is specified by its
resistance: common commercial resistors are manufactured over
a range of more than 9 orders of magnitude. When specifying that
resistance in an electronic design, the required precision of the
resistance may require attention to the manufacturing tolerance
of the chosen resistor, according to its specific application. The
temperature coefficient of the resistance may also be of concern
in some precision applications. Practical resistors are also
specified as having a maximum power rating which must exceed

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the anticipated power dissipation of that resistor in a particular

circuit: this is mainly of concern in power electronics applications.
Resistors with higher power ratings are physically larger and may
require heat sinking. In a high voltage circuit, attention must
sometimes be paid to the rated maximum working voltage of the
resistor.
The series inductance of a practical resistor causes its
behaviour to depart from ohms law; this specification can be
important in some high-frequency applications for smaller values
of resistance. In a low-noise amplifier or pre-amp the noise
characteristics of a resistor may be an issue. The unwanted
inductance, excess noise, and temperature coefficient are mainly
dependent on the technology used in manufacturing the resistor.
They are not normally specified individually for a particular family
of resistors manufactured using a particular technology. A family
of discrete resistors is also characterized according to its form
factor, that is, the size of the device and position of its leads (or
terminals) which is relevant in the practical manufacturing of
circuits using them.

Theory of operation
Ohm's law
The behaviour of an ideal resistor is dictated by the relationship
specified in Ohm's law:

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Ohm's law states that the voltage (V) across a resistor is

proportional to the current (I) passing through it, where the
constant of proportionality is the resistance (R).
Equivalently, Ohm's law can be stated:

Resistor marking
Electronic color code
Four-band resistors
Four-band identification is the most commonly used colour-
coding scheme on resistors. It consists of four coloured bands that
are painted around the body of the resistor. The first two bands
encode the first two significant digits of the resistance value, the
third is a power-of-ten multiplier or number-of-zeroes, and the
fourth is the tolerance accuracy, or acceptable error, of the value.
The first three bands are equally spaced along the resistor; the
spacing to the fourth band is wider. Sometimes a fifth band
identifies the thermal coefficient, but this must be distinguished
from the true 5-color system, with 3 significant digits.
For example, green-blue-yellow-red is 56×104 Ω =
560 kΩ ± 2%. An easier description can be as followed: the first
band, green, has a value of 5 and the second band, blue, has a
value of 6, and is counted as 56. The third band, yellow, has a
value of 104, which adds four 0's to the end, creating 560,000 Ω at
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±2% tolerance accuracy. 560,000 Ω changes to 560 kΩ ±2% (as a

kilo- is 103).
Each colour corresponds to a certain digit, progressing from
darker to lighter colours, as shown in the chart below.
1st 2nd 3rd band 4th band Temp.
Color
band band (multiplier) (tolerance) Coefficient
Black 0 0 ×100
Brown 1 1 ×101 ±1% (F) 100 ppm
Red 2 2 ×102 ±2% (G) 50 ppm
Orange 3 3 ×103 15 ppm
Yellow 4 4 ×104 25 ppm
Green 5 5 ×105 ±0.5% (D)
Blue 6 6 ×106 ±0.25% (C)
Violet 7 7 ×107 ±0.1% (B)
Gray 8 8 ×108 ±0.05% (A)
White 9 9 ×109
Gold ×10−1 ±5% (J)
Silver ×10−2 ±10% (K)

±20% (M)
None
There are many mnemonics for remembering these colours.

CAPACITORS

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A capacitor or condenser is a passive electronic

component consisting of a pair of conductors separated by a
dielectric. When a voltage potential difference exists between the
conductors, an electric field is present in the dielectric. This field
stores energy and produces a mechanical force between the
plates. The effect is greatest between wide, flat, parallel, narrowly
separated conductors.

An ideal capacitor is characterized by a single constant

value, capacitance, which is measured in farads. This is the ratio
of the electric charge on each conductor to the potential
difference between them. In practice, the dielectric between the
plates passes a small amount of leakage current. The conductors
and leads introduce an equivalent series resistance and the
dielectric has an electric field strength limit resulting in a
breakdown voltage.
The properties of capacitors in a circuit may determine the
resonant frequency and quality factor of a resonant circuit, power
dissipation and operating frequency in a digital logic circuit,
energy capacity in a high-power system, and many other
important aspects.
A capacitor (formerly known as condenser) is a device for
storing electric charge. The forms of practical capacitors vary
widely, but all contain at least two conductors separated by a
non-conductor. Capacitors used as parts of electrical systems, for

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example, consist of metal foils separated by a layer of insulating

film.
Capacitors are widely used in electronic circuits for blocking
direct current while allowing alternating current to pass, in filter
networks, for smoothing the output of power supplies, in the
resonant circuits that tune radios to particular frequencies and for
many other purposes.
A capacitor is a passive electronic component consisting of a
pair of conductors separated by a dielectric (insulator). When
there is a potential difference (voltage) across the conductors, a
static electric field develops in the dielectric that stores energy
and produces a mechanical force between the conductors. An
ideal capacitor is characterized by a single constant value,
capacitance, measured in farads. This is the ratio of the electric
charge on each conductor to the potential difference between
them.
The capacitance is greatest when there is a narrow
separation between large areas of conductor, hence capacitor
conductors are often called "plates", referring to an early means
of construction. In practice the dielectric between the plates
passes a small amount of leakage current and also has an electric
field strength limit, resulting in a breakdown voltage, while the
conductors and leads introduce an undesired inductance and
resistance.

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Capacitor markings
Most capacitors have numbers printed on their bodies to
indicate their electrical characteristics. Larger capacitors like
electrolytics usually display the actual capacitance together with
the unit (for example, 220 μF). Smaller capacitors like ceramics,
however, use a shorthand consisting of three numbers and a
letter, where the numbers show the capacitance in pF (calculated
as XY x 10Z for the numbers XYZ) and the letter indicates the
tolerance (J, K or M for ±5%, ±10% and ±20% respectively).
Additionally, the capacitor may show its working voltage,
temperature and other relevant characteristics.
Example
A capacitor with the text 473K 330V on its body has a capacitance
of 47 x 103 pF = 47 nF (±10%) with a working voltage of 330 V.

LED

LEDs are semiconductor devices. Like transistors, and other

diodes, LEDs are made out of silicon. What makes an LED give off
light are the small amounts of chemical impurities that are added
to the silicon, such as gallium, arsenide, indium, and nitride.

When current passes through the LED, it emits photons as a

byproduct. Normal light bulbs produce light by heating a metal
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filament until it is white hot. LEDs produce photons directly and

not via heat, they are far more efficient than incandescent bulbs.

Fig 3.1(a): circuit symbol

Not long ago LEDs were only bright enough to be used as

indicators on dashboards or electronic equipment. But recent
advances have made LEDs bright enough to rival traditional
lighting technologies. Modern LEDs can replace incandescent
bulbs in almost any application.
Advantages of using LEDs

 Size:
LEDs can be very small (smaller than 2 mm2) and are
easily populated onto printed circuit boards.

 On/Off time:
LEDs light up very quickly. A typical red indicator LED
will achieve full brightness in microseconds. LEDs used
in communications devices can have even faster
response times.

 Lifetime:

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LEDs can have a relatively long useful life. One report

estimates 35,000 to 50,000 hours of useful life, though
time to complete failure may be longer.

Disadvantage of using LEDs

 Voltage sensitivity:
LEDs must be supplied with the voltage above the
threshold and a current below the rating. This can
involve series resistors or current-regulated power
supplies.

DC REGULATED POWER SUPPLY

Regulated DC power supplies provide accurate DC voltage,

which are derived from AC mains. Such supplies provide constant
voltage irrespective of load variations for which they are
designed. DC power supplies are used extensively in various
electronics laboratories, industries and communication
departments to feed DC voltage to the electronic modules, R and
D sections, institutions and colleges to impart practical training
etc. Present range of electronic equipment produced in the
country makes use of transistors and integrated circuits. These
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IC’s are designed to work on fixed regulated DC voltages.

Therefore, such supplies have become the part and parcel of such
equipment and are:
1. Preset Power supplies (single or dual supply type)
2. Variable power supplies Preset Power Supplies (Single or Dual
supply type)
These power supplies are generally customs made and preset for
fixed voltages like 5V/10V/15 Volts etc. These supply units are
normally mounted on/ integrated into the electronic equipment.
As such these power supplies are not fitted with any cabinets.
These power supplies are used in computers. Variable Power
Supplies Variable power supplies are supplies in which the
voltage can be varied continuously with the knob as per
requirement. They are generally available in the range of 5 to 30
volts in 0.5 to 10 amps capacities. These supplies are generally
used in research institutions, colleges, practical training centers
and electronic industries, etc.

Figure: Dc Regulated Power Supply

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Diode 1N4007
1N4007 is a rectifier diode, designed specifically for circuits that
need to convert alternating current to direct current. It can pass
currents of up to 1 A, and have peak inverse voltage (PIV) rating
of 1,000 V.

1N4007 rectifier diode has in total 2 pins. However, you need to

know functions of every pins before it can work better for you.

1N4007 owns a cathode (-) and anode (+). In the schematic

symbol, the tip of the triangle with the line on top of it is the
cathode. The cathode is marked on the body of a diode by a
band. It allows current flow through only one direction that
means current can flow from the anode to the cathode only and
never from the cathode to the anode – it likes a one way valve.

The 1N4007 pinout diagram is as shown in the picture below:

1N4007
Features
and

Specifications
 Peak Reverse Voltage: 1000 Volts
 Average Forward Current: 1A
 Non-Repetitive Peak Forward Current: 30A
 Operating Junction Temperature : -550C – 1750C
 Power Dissipation : 3 Watts
 Forward Voltage: 1.1 Volts
 Reverse Current: 5 uA
 Package Type: DO-41

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Some of the other features are mentioned below :

1. Low forward voltage drop
2. High current carrying capability
3. Almost negligible reverse current

Applications
 Rectifiers
 Freewheeling diode applications
 Embedded systems for switching
 Power supplies
 Protection Circuits

103 AND 104 Variable resistor

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A variable resistor 10K(103) is a device that is used to change

the resistance according to our needs in an electronic
circuit. It can be used as a three-terminal as well as a two
terminal device. Mostly they are used as a three terminal device.
Variable resistors are mostly used for device calibration.

LM358 (IC)
LM358 is a Dual, 30-V, 700-kHz operational amplifier.The LM358
contain two independent high gain operational
amplifier,low power,dual channel op-amp,high with
internal frequency compensation.single power supply will required
to operate both op-amp in LM358.we can also use a split power
supply .The device has low power supply .

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KEY FEATURES OF LM358 DUAL OP-AMP:

 Low power operation of 0.7mA

 Operates from a single positive power supply of 3 to 32V
 Can also operate from a split supply of ± 1.5 to ±16V like
typical Op-Amp

 700kHz unity gain bandwidth

 Open loop gain of 100x

 The LM358 is a low-power dual Op-Amp with two independent

high-gain and frequency compensated operational amplifiers. It
is designed to operate from a single power supply over a wide
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range of voltages from 3 to 32V. This makes it a popular

general purpose Op-Amp that is used in many projects since a
negative power supply is not required as with most Op-Amps.
This gives it a place in every hobbyists parts bin.
 Besides single supply operation, they can also be operated
from dual power supplies ranging from ± 1.5V to ± 16V if
needed for a particular application.
 Outputs have good drive capability and can source up to 30mA
per channel and sink 20mA.
 These Op-Amps are frequently used to buffer or amplify
signals. They can be utilized in a wide range of circuits such as
voltage comparators, active filters and voltage controlled
oscillators (VCOs).
 They have a gain of up to 100x and can handle frequencies of
up to 700KHz.

LM358 AS COMPARATOR

IC LM358– LM358 consists of two independent, high gain

operational amplifiers in one package. Important feature of this
IC is that we do not require independent power supply for
working of each comparator for wide range of power
supply. LM358 can be used as transducer amplifier, DC gain
block etc.

JQC-3FC/T73

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JQC 3FC(T73) Sugar Cube Relay

 Product Name – 5V PCB Mount Sugar Cube SPDT Relay

JQC-3FC(T73)
 Model – JQC-3FC(T73) 5V
 Coil Voltage – 5VDC
 Contact Rating – 10A @ 220V AC/ 28V DC
 Coil Resistance – 70 Ohm
 Dimensions – 20x15x15 mm
 Product Weight – 10 Grams

No of Poles – 2
Life Expectency - Mechanical 10,000,000 operations at no load ,
Electrical 100,000 at rated resistive load

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TRANSISTOR

BC547 is a bipolar junction transistor (BJT). It is kind of an NPN

transistor. It has three terminals: Emitter, Collector and Base.
The maximum current gain of BC547 is 800A. The
Collector−Emitter Voltage is 65V.

The features of the BC547 transistor include the following.

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The gain of DC current (hFE) = 800 A

Continuous Ic (collector current) = 100mA

VBE (emitter-base voltage) = 6V

IB (base current) = 5mA

The polarity of the transistor is NPN

The transition frequency is 300MHz

It is obtainable in semiconductor package like-92

Power dissipation is 625mW

CONSTRUCTION AND WORKING ;

charge Controller Designs

There are two basic methods for controlling or

regulating the charging of a battery; they are
shunt and series regulation
While both of these methods are effectively
used, each method may incorporate a number of
variations that alter their basic performance and
applicability.
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When the MOSFET switch is connected in

series with the PV Array and the battery,
the Controller is called Series Type. When it is
connected in parallel across the PV Array
/ the Battery, it is called Shunt Type. In Series
Type, the MOSFET Switch is kept open
when the battery is fully charged. The PV Array
stops supplying current during this
period. In the Shunt Type, when the battery is
fully charged, the MOSFET switch is
kept closed to shunt (divert) the full short circuit
current of the PV Array away from
the battery.

Series Controller Design

A series charge controller disables further

current flow into batteries when they are full.
Figure 3: Solar Home System with a series
charge controller

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This type of controller in Figure. works in

series with the array and the battery. There are several
variations to the series
type controller, all of which use some type of
control or regulation element in series. Relay or
solid-state switch either opens the circuit
between the array and the battery to
discontinuing charging, or limits the current in a
series-linear manner to hold the voltage of the
battery at a high value.

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Overcharge Protection ;

In a 12V battery system, the voltage varies

between 10.5 to 14.4volts, (depending on the
actual state of charge of the battery, charge
current, discharge current, type and age of the
battery).
For a normal full loaded battery with no
charging or discharging current, the battery
voltage is about 12.4volts to 12.7volts. When
charging current is flowing, the voltage jumps to
a higher level e.g. 13.7V (depending on the
current), and when loads are switched on, the
voltage drops down to a lower level e.g. 12volts
or 11.8volts (also depending on the current).

Deep Discharge Protection

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When a battery is deeply discharged, the

reaction in the battery occurs close to the grids
and weakens the bond between the active
materials and the grids. When we deep discharge
a battery repeatedly, loss of capacity and
lifespan eventually occurs. To protect the battery
form deep discharge, most charge controllers
include an optional feature to disconnect the
system loads once the battery reaches a low
voltage or low state of charge condition. If the
voltage of the system falls below 11.5volts for a
minimum period of 20sec, then the charge
controller will be switched off for a minimum
30 seconds. The delay of 30 seconds is
integrated to protect the system against a
swinging situation

Battery Level Indicator ;

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This circuit monitors the level of charge of

the battery.
Battery level indicator
The circuit used an Op amp, LM358 as
comparator. If the voltage that appears across
the inverting terminal is higher than the
reference voltage, the output of the comparator
is low, which will be forward biased with the
diode close to , making it come on, indicating
that it is fully charged and it needs to stop
charging and it is cut off with the help of the
charge controller circuit. The diode near is
reversed biased and doesn’t conduct.

Battery Charge Controller

The circuit makes use of a comparator IC

(LM358) and a relay with a contact of 10A

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When the IC is positively saturated, it means the

battery needs to charge; the transistor conducts,
collector current flows, the relay is energized
and the contact closes, current then flows to the
battery to charge it.
When negatively saturated (when full), the
transistor doesn’t conduct, the relay is de
energized and the contact opens and current
seizes to flow to the battery and it doesn’t
charge.

The transistor used is BC547 and to ensure that

it operates at cut off or saturation
This circuit acts as a stable power supply to the
battery level indicator.

The battery level indicator monitors the charge

of the battery through the use of a comparator

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which compares a reference voltage, to the

voltage of the battery and indicates through
LEDs if the battery is fully charged or
undercharged.
The power supply unit supplies a constant
output voltage of 12V to the comparator circuits
in the design to ensure that unstable power
output is avoided and this is used as the
reference voltage which is compared to the
battery’s voltage.

The battery charge controller cuts off the battery

from charging when fully charged through the
use of a comparator IC and a relay. When the
battery is not full, the IC is positively saturated,
the transistor conducts, the relay is energized and the
contact closes ensuring that the current
flows through to charge the battery. When the
battery is charged full, the IC is negatively
saturated, the transistor doesn’t conduct, the

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relay is de-energized and the contact opens and

current seizes to flow to the battery.

BLOCK DIAGRAM
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SCHEMATIC DIAGRAM

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RESULT AND CONCLUSION

i. After proper connection of the solar panel

and battery leads to their respective
terminals on the solar charge controller,
the power and undercharging LEDs turn
ON to indicate battery charging.
ii. After 12 hours and 20 minutes of charge,
the optimum charge LED turns ON
indicating full charge and undercharge
LED turns OFF indicating that no more
current is getting to the battery. Generally
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the circuit performed satisfactorily

HARDWARE TESTING

CONTINUITY TEST:
In electronics, a continuity test is the checking of an electric
circuit to see if current flows (that it is in fact a complete circuit).
A continuity test is performed by placing a small voltage (wired in
series with an LED or noise-producing component such as a
piezoelectric speaker) across the chosen path. If electron flow is
inhibited by broken conductors, damaged components, or
excessive resistance, the circuit is "open".

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Devices that can be used to perform continuity tests include

multi meters which measure current and specialized continuity
testers which are cheaper, more basic devices, generally with a
simple light bulb that lights up when current flows.
An important application is the continuity test of a bundle of wires
so as to find the two ends belonging to a particular one of these
wires; there will be a negligible resistance between the "right"
ends, and only between the "right" ends.

This test is the performed just after the hardware soldering

and configuration has been completed. This test aims at finding
any electrical open paths in the circuit after the soldering. Many a
times, the electrical continuity in the circuit is lost due to
improper soldering, wrong and rough handling of the PCB,
improper usage of the soldering iron, component failures and
presence of bugs in the circuit diagram. We use a multi meter to
perform this test. We keep the multi meter in buzzer mode and
connect the ground terminal of the multi meter to the ground. We
connect both the terminals across the path that needs to be
checked. If there is continuation then you will hear the beep
sound.

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POWER ON TEST:
This test is performed to check whether the voltage at
different terminals is according to the requirement or not. We
take a multi meter and put it in voltage mode. Remember that
this test is performed without ICs. Firstly, if we are using a
transformer we check the output of the transformer; whether we
get the required 12V AC voltage (depends on the transformer
used in for the circuit). If we use a battery then we check if the
battery is fully charged or not according to the specified voltage
of the battery by using multimeter.

Then we apply this voltage to the power supply circuit. Note

that we do this test without ICs because if there is any excessive
voltage, this may lead to damaging the ICs. If a circuit consists of
voltage regulator then we check for the input to the voltage
regulator (like 7805, 7809, 7815, 7915 etc) i.e., are we getting an
input of 12V and a required output depending on the regulator
used in the circuit.
EX: if we are using 7805 we get output of 5V and if using 7809 we
get 9V at output pin and so on.

This output from the voltage regulator is given to the power

supply pin of specific ICs. Hence we check for the voltage level at
those pins whether we are getting required voltage. Similarly, we
check for the other terminals for the required voltage. In this way

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we can assure that the voltage at all the terminals is as per the
requirement.

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10.BIBLIOGRAPHY

WEBSITES

 www.beyondlogic.org

 www.wikipedia.org

 www.howstuffworks.com

 www.alldatasheets.com

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