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The shunt controller regulates the charging of a When a battery is deeply discharged, the
battery from the PV array internal to the charge reaction in the battery occurs close to the grids
controller. All shunt controllers must have a and weakens the bond between the active
blocking diode in series between the battery and materials and the grids. When we deep discharge
the shunt element to prevent the battery from a battery repeatedly, loss of capacity and
short-circuiting when the array is regulating lifespan eventually occurs. To protect the battery
[Marufa, 2012]. The regulation element in shunt form deep discharge, most charge controllers
controllers is typically a power transistor or include an optional feature to disconnect the
MOSFET, depending on the specific design. 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
Advantages of Series Type of Charge minimum period of 20sec, then the charge
Controller controller will be switched off for a minimum
A series Type of Charge Controller has the 30 seconds. The delay of 30 seconds is
following advantages over a Shunt Type integrated to protect the system against a
swinging situation [Marufa, 2012].
i. Lesser switching noise: during charging.
ii. Less susceptible to high voltage transient 2.7 Component Selection for Controller
disturbances. Design
iii. The voltage applied across the Series
MOSFET switch is lesser and so In light of the foregoing appraisal of design
experiences lesser stress styles, the following components will form an
and is, therefore, more reliable. integral part of the design and hence, their
iv. A Shunt Type requires a schottky diode in importance and working principles are
series with the battery to prevent short discussed. A list of necessary components
circuiting of the battery during the time the required to carry out the design on this project
MOSFET switch shunts the PV Array. In a are as follows
Series Type, this schottky diode is not
(i) Diodes
required and hence lower voltage drop, less
heating and consequent lower losses. These are simply blocking diodes which ensure
Reverse leakage through the schottky is that the current flows only one way, so that the
also eliminated. [Samlex, 2014] battery doesn’t discharge when the output from
the solar panel is low.
2.5 Overcharge Protection (ii) Zener Diodes
In a 12V battery system, the voltage varies This part of the circuit ensures that once the
between 10.5 to 14.4volts, (depending on the charging cut off voltage is reached by the
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JOURNAL OF ELECTRICAL AND ELECTRONIC ENGINEERING VOL 12, NO 2, ISSN 1118 – 5058
NOVEMBER 2015
battery, the charging stops. The zener diode is
rated at 6.8V as breakdown voltage. 3.0 DESIGN OF SOLAR CHARGE
CONTROLLER
(iii) MOSFET
Based on the block diagram of Figure. 5, the
The metal-oxide-semiconductor field effect design is as follows:
transistor is used for amplification or switching
electronic signals. It ensures cut off of the load
in low battery or overload conditions.
(iv) Transistor
It is used to bypass the solar energy to a dummy
load while the battery gets fully charged. Once
the battery is fully charged, it draws all the
current thus protecting the battery.
(v) Indicators
Figure 5: The block diagram of a solar
Indicators are provided by a green LED for fully controller.
charged battery, while a set of red LEDs are
3.1 Current Booster
used to indicate under charged, overcharged and
deep discharge conditions. The current booster allows the maximum value
of current from the solar panel to flow through
Voltage Regulators to battery. The main component of the current
(vi) LM317 booster is the LM317, transistor and blocking
diodes.
It is a 3-terminal adjustable voltage regulator
which can supply an output voltage adjustable
from 1.2V to 37V. It can supply more than 1.5A
of load current to a load. We can modify the
voltage by changing the value of the resistor
connected to a pin of the voltage regulator.
These resistors determine the voltage that the
voltage regulator adjusts to and outputs.
(vii) LM7812
It is a fixed linear voltage regulator integrated
circuit. It is commonly used in electronic Figure 6: The current booster
circuits requiring a regulated power supply due
to their ease of use and low cost. They produce a The LM317 keeps the voltage constant and can
voltage that is positive relative to a common handle a maximum of 1A; so if the panel
ground. This IC has three terminals. produces a current of less than 1A, the transistor
Other components used to realize these circuits does not conduct and the current flows through
are op-amp, filter capacitor and relay. the LM317 to charge the battery.
If current is above 1A, the transistor conducts
because there is a voltage drop across that is
large enough to be the base voltage of the
transistor to be turned on.
To ensure that the transistor does not conduct
when the current is still less than or equal to
1amp, we calculate the value of .
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JOURNAL OF ELECTRICAL AND ELECTRONIC ENGINEERING VOL 12, NO 2, ISSN 1118 – 5058
NOVEMBER 2015
The drop should be less than 0.7V for the that it is fully charged and it needs to stop
transistor not to conduct so; hence charging and it is cut off with the help of the
charge controller circuit. The diode near is
reversed biased and doesn’t conduct.
V=I (1) From the voltage divider rule; to get ,
equation (3)
V=0.7V; I=1A, the value of is 0.7Ω
At above 1amps, the voltage drops exceeds 0.7V ( )
and the transistor conducts and the excess
current flows through to the battery via the pass
transistor.
= =12V=voltage from the battery
To get the resistor value , we use voltage
divider rule; Assuming =10V (reference voltage) i.e. at
12V, the inverting terminal should be 10V
( )
( )
=1.25V (LM317 rating), (which is
required) = 14.2V, Assume =220Ω ∴ Let =10kΩ, hence =2kΩ
=2288Ω (as a practical value)
The values of and can also be calculated
Diode and are blocking diodes. using equation (4)
The diodes used here should be able to
withstand a fault current of more than 10A. The ( )
diode 6A1D is used in this circuit with forward
current =15A and peak inverse voltage and are current limiting resistors
PIV=100V.
3.2 Battery Level Indicator
Where = =12v, =2v, =20mA,
This circuit monitors the level of charge of
the battery. The circuit diagram is shown in = = =500Ω
Figureure 7;
3.3 Battery Charge Controller
The circuit diagram as shown in Figure.8
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JOURNAL OF ELECTRICAL AND ELECTRONIC ENGINEERING VOL 12, NO 2, ISSN 1118 – 5058
NOVEMBER 2015
3.5 Mode of Operation: The complete circuit diagram of the charge controller is shown in Figure 10.
5.0 TESTING/RESULTS
The functionality of the charge controller [2] Cook G. F. “Solar Charge Controller for
depends on the fixed voltage output of 14.2V Medium Power Applications” February / March
from the current booster block of the solar 1998, pg 42.
charge controller; hence the test data includes
reading from a 200Ah, 12V battery charged for [3] Ashiquzzaman M. , Afroze N., Hossain J. M.
approximately 12hrs under varying weather , Zobayer U., and Hossain M.M. “Cost Effective
conditions. Solar Charge Controller Using Microcontroller”
Canadian Journal on Electrical and Electronics
i. Initial battery voltage level was 9.83V. Engineering Vol. 2, No.12, Dec. 2011. Pg 2.
ii. Battery voltage level after first 6hrs under [4] Ishtiak A. K., Abid A. S., Navid A. M. , Irin
exposure of panel to intense sunlight was P. S. Saha S. “Design of A Solar Charge
11.3V. Controller for a 100WP Solar PV System”
International Journal of Engineering Research &
iii. Battery voltage level after approximately
Technology (IJERT) Vol. 2 Issue 11, November
12hrs under exposure of panel to reduced
– 2013, pg 1.
sunlight intensity was 12.2V.
[16]www.solar-electric.com/solar-charge-
controller-basicshtml accessed 21/10/2015.
Solarelectric.com article, viewed June, 2015.
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