Solar Battery Charger Circuit

Submitted by
Najibullah Id: 153422
Farhad Id: 153423
Mahmoud Srhan Id: 153433

Supervised by
Prof. Dr. Kazi Khairul Islam

Department of Electrical and Electronics Engineering

Islamic University of Technology
Organization of Islamic Cooperation (OIC)
Gazipur-1704, Bangladesh
November, 2016
 Islamic University of Technology
Department of Electrical and Electronics Engineering (EEE)

Solar Battery Charger Circuit

Submitted by
Najibullah Id: 124454
Farhad Id: 124447
Mahmoud Srhan Id: 153433

Supervised by
Prof. Dr. Kazi Khairul Islam

Department of Electrical and Electronics Engineering

Islamic University of Technology
Organization of Islamic Cooperation (OIC)
Academic Year: 2015-16
November – 2016
 Declaration
This is to certify that the work presented in this thesis is the outcome of the analysis and

Experiments carried out by Najibullah, Farhad and Mahmoud Srhan under the supervision of
Prof. Dr. Kazi Khairul Islam Department of Electrical and Electronics Engineering

(EEE), Islamic University of Technology (IUT), Dhaka, Bangladesh. It is also declared that

neither of this thesis nor any part of this thesis has been submitted anywhere else for any
degree or diploma.

Submitted By:

-------------------------

Najibullah

Student ID - 153422

-------------------------

Farhad

Student ID – 153423

-------------------------

Mahmoud Srhan

Student ID – 153433
 Supervised By:

-------------------------
Prof. Dr. Kazi Khairul Islam
Department of Electrical and Electronics Engineering (EEE)
Islamic University of Technology (IUT)
Dedicated to our dear parents for the love and support
they have given us throughout our studies
 Acknowledgments

All praises is to Allah and to Him alone. First and above all, we praise Allah, the almighty
for providing us this opportunity to research on such a hot issue of these days. Every nerve
ending, joint, limb, organ, and faculty of ours are indebted to Allah (S.W.T.) for all the
bounties he bestowed on us to enable us to Alhamdulillah (praise be to him) successfully
finish this thesis. Words are insufficient to describe our gratefulness and appreciation to him
in the whole process of the preparation, compiling and writing of this thesis. In moments of
distress, he guided us, showed us what to do, removed all obstacles from and lighted our
path, inspired us, eased the tedious task of writing, and gave us surplus energy so that we
may stay up night after night, putting down words on paper. Without him we would not have
been able to undertake this daunting task. Peace and blessing be upon the holy prophet and
the final messenger Mohammad.

We revere the patronage and moral support extended with love, by our parents and
relatives whose financial support and passionate encouragement made it possible for us to
complete this thesis.

We would like to express our special appreciation and thanks to our supervisor Prof.
Dr. Kazi Khairul Islam, you have been a tremendous mentor for us. We would like to thank
you for encouraging our research. Your advice on our career have been invaluable.

We humbly extend our thanks to all concerned persons who co-operated with us in
this regard. Thank You.
 Abstract

Solar concept is not new for us. As non-renewable energy sources are decreasing,
usage of solar energy is increased. This solar energy is not only used on the Earth but also
used in space stations where no electrical power is available. Solar energy begins with the
sun. Solar panels, also known as photovoltaic, are used to convert light from the sun, which
is composed of particles of energy called "photons", into electricity that can be used to power
electrical loads. Light from the sun is a renewable energy resource that provides clean
energy, produced by solar panels. Many people are familiar with so-called photovoltaic cells,
or solar panels, found on things like spacecraft, rooftops, and handheld calculators. The cells
are made of semiconductor materials like those found in computer chips. When sunlight hits
the cells, it knocks electrons loose from their atoms. As the electrons flow through the cell,
they generate electricity.

Here is the simple circuit to charge 12V, 1.3Ah rechargeable Lead-acid battery from
the solar panel. This solar charger has current and voltage regulation and also has over
voltage cut off facilities. This circuit may also be used to charge any battery at constant
voltage because output voltage is adjustable.
Contents
Chapter 1 .................................................................................................................................................................. 10
1.1 Introduction .............................................................................................................................................................. 10

Chapter 2 .................................................................................................................................................................. 12
2.1 Solar Energy .............................................................................................................................................................. 12
2.1.1 Importance of Solar Energy: .................................................................................................................................. 12
2.1.2 Advantages and Uses of Solar Energy: ................................................................................................................... 13
2.1.3 Disadvantages of Solar Energy: .............................................................................................................................. 14
2.1.4 Applications of Solar Energy: ................................................................................................................................. 14
2.2 Solar Panel................................................................................................................................................................. 15
2.2.1 Types of solar panel ............................................................................................................................................... 15
2.3 Working principle of solar panel: .............................................................................................................................. 21
2.4 Solar Cell Overview ................................................................................................................................................... 22
2.5 Basic theory of solar cell ........................................................................................................................................... 23
2.6 Solar cell connections ............................................................................................................................................... 24
2.7 Solar Cell Technologies ............................................................................................................................................. 26
2.8 Solar Cell, Solar Module or Panel and Solar PV Array ............................................................................................... 26
2.8.1 PV Module.............................................................................................................................................................. 27
2.8.2 PV Array ................................................................................................................................................................. 27

Chapter 3 .................................................................................................................................................................. 28
3.1 LM 317 Adjustable Output, Positive Voltage Regulator ........................................................................................... 28
Features .......................................................................................................................................................................... 28
3.2 LM317 datasheet ...................................................................................................................................................... 28
3.2 Types of Batteries ..................................................................................................................................................... 30

Chapter 4 .................................................................................................................................................................. 32
4.1 Related works............................................................................................................................................................ 32
4.2 Solar Battery Charger Circuit Diagram: ..................................................................................................................... 33
4.3 Circuit Components .................................................................................................................................................. 34
4.4 Solar Battery Charger Circuit Design ......................................................................................................................... 35
4.4.1 for Charging 12V Battery........................................................................................................................................ 35
4.4.2 For 6V Application .................................................................................................................................................. 36
4.4.3 Power Dissipation .................................................................................................................................................. 37
4.4.4 Current Limiting ..................................................................................................................................................... 37
4.4.5 Solar Charger Protection ........................................................................................................................................ 38
4.4.6 Solar Charger Specifications................................................................................................................................... 38
4.4.7 How to Operate this Solar Battery Charger Circuit? .............................................................................................. 38
4.4.8 Solar Battery Charger Circuit Advantages .............................................................................................................. 38
4.4.9 Solar Battery Charger Circuit Applications ............................................................................................................. 39
4.4.10 Limitations of this Circuit: .................................................................................................................................... 39

Chapter 5 .................................................................................................................................................................. 40
Conclusions ..................................................................................................................................................................... 40
5.1 Summary ................................................................................................................................................................... 40
5.2 Limitations................................................................................................................................................................. 40
5.3 Future Work .............................................................................................................................................................. 40
Chapter 1

1.1 Introduction

Solar power is energy from the sun that is converted into thermal or electrical energy.

Solar energy is the cleanest and most abundant renewable energy source available, and the
U.S. has some of the richest solar resources in the world. Modern technology can harness
this energy for a variety of uses, including generating electricity, providing light or a
comfortable interior environment, and heating water for domestic, commercial, or industrial
use.

There are several ways to harness solar energy: photovoltaics (also called solar electric),
solar heating & cooling, concentrating solar power (typically built at utility-scale), and
passive solar.

The first three are active solar systems, which use mechanical or electrical devices that
convert the sun's heat or light to another form of usable energy. Passive solar buildings are
designed and oriented to collect, store, and distribute the heat energy from sunlight to
maintain the comfort of the occupants without the use of moving parts or electronics.

Solar energy is a flexible energy technology, solar power plants can be built as distributed
generation (located at or near the point of use) or as a central-station, utility-scale solar
power plant (similar to traditional power plants). Some utility-scale solar plants can store the
energy they produce for use after the sun sets.

Every hour the sun beams onto Earth more than enough energy to satisfy global energy
needs for an entire year. Solar energy is the technology used to harness the sun's energy and
make it useable. Today, the technology produces less than one tenth of one percent of global
energy demand.

Solar energy used in space stations (satellite communication system) where no electrical
power is available.

Solar energy doesn't work at night without a storage device such as a battery, and cloudy
weather can make the technology unreliable during the day. Solar technologies are also very

10
expensive and require a lot of land area to collect the sun's energy at rates useful to lots of
people.

In this project the simple circuit is used to charge 12V, 1.3Ah rechargeable Lead-acid battery
from the solar panel. This solar charger has current and voltage regulation and also has over
voltage cut off facilities. This circuit may also be used to charge any battery at constant
voltage because output voltage is adjustable.

The rest of the thesis book is organized as:

Chapter 2

Solar Energy, Importance of Solar Energy, Advantages and disadvantages of Solar Energy,
Applications of Solar Energy, Solar Panel, Types of solar panel, working principle of solar
panel, Solar Cell Overview, Basic theory of solar cell, Solar cell connection, Solar Cell
Technologies, Solar Cell, Solar Module or Panel and Solar PV Array, PV Module, PV Array.

Chapter 3

LM 317 Adjustable Output, Positive Voltage Regulator, LM317 datasheet, Types of

Batteries. And

Chapter 4

Related works

11
Chapter 2

2.1 Solar Energy

Solar energy is defined as energy obtained from the sun's radiation. The two main
forms of solar energy include active solar energy and passive solar energy .
Active solar energy involves equipment or an action to convert solar energy into a useful
form. One example of active solar energy is the use of solar cells to convert energy from the
sun into electrical energy that can be used in the home.
Passive solar energy does not require any specific action or equipment. An example of
passive solar energy is strategically placing windows in a home to allow sunlight to enter and
provide heat. In this project we discuss about Active solar energy which involves solar panel.

2.1.1 Importance of Solar Energy:

As mentioned before solar energy is required and is important for survival of life on
earth. Not only human beings, plants, animals everyone requires solar energy every day.
Plants require solar energy to produce oxygen, prepare food i.e. photosynthesis. Solar energy
is required to produce both pure and saltwater in oceans as it is the only source of melting the
frozen ice formed on the mountain caps. Apart from that the electricity which we get to run
various machines is all gained from the solar energy, thus its importance and existence is
very important on a planet where there is life.
Solar energy is a clean and renewable energy. Also it’s versatile and can help in
producing power for watches and calculators that do not run on batteries. It’s a clean energy
because it is received directly from the sun. The fossil fuels and other gas and oil that are
extracted from the mines are nonrenewable energy. Also they are costly and cause lot of
pollution. But solar energy is something that is renewable and can be used for lots of
activities. Also it is available free of cost. As fossil fuels and other oils are soon going to
disappear solar energy which is available in abundant should be utilized well and hence is
important.

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 2.1.2 Advantages and Uses of Solar Energy:
As we know solar energy is one such energy that is abundantly available and is free of cost,
let’s have a look at some of its advantages.

 An energy that is totally free of cost and saves your money as the Sun is always going
to be there.
 It is an environment friendly energy and hence does not create pollution.
 Provides electricity that is helps in producing electricity with the help of solar panels.
 A silent energy provider as the solar cells do not create sounds while extracting heat
from the sun and producing electricity.
 Solar energy helps in reducing the electricity bill.
 The solar energy system can work independently without any connection and can be
utilized and installed in remote areas too where there is no sign of electricity.
 Solar energy helps in decreasing the harmful gasses and does not contribute to acid
rains, global warming, forest destruction and other natural disasters.
 No maintenance is required for solar energy and also it does not have any specific life
span
 Solar energy is used for ventilating homes i.e. ceiling fans need electricity which is
gained from solar energy
 Solar energy can be used to boil water instead of suing water heaters you can make
use of the solar energy. Though you need to spend initially you will gain good benefits
out of it in future.
 Solar energy can help in heating your homes and charging batteries.
 It can also be used for cooking purposes by using solar oven
 It can be used to heat swimming pools. Suppose you have a swimming pool outside
you house you can make use of solar blanket to heat water during extreme cold
seasons.
 You can use solar energy for indoor and outdoor lighting at night as it will help you
see the entry door and walkway clearly.

Apart from these, solar energy can be used for commercial and industrial purposes too.

13
 2.1.3 Disadvantages of Solar Energy:

 Solar energy can be used only during the daytime i.e. when the sun is shining bright
 The solar collectors, panels and cells that are used to absorb heat from the sun are very
expensive
 In case of cloudy climate, there would be no signs of sun and solar energy which is
difficult.
 The solar batteries that are charged or needs to be charged are very heavy and require
large storage space. Replacing it is also difficult.
 Its low in efficiency and requires lots of land area
 There is no consistency because the devices that require energy of the sun will only
work if the delivery of photons is consistent.
 Replacing the solar energy panels is also a very difficult job.
 Installation of solar energy requires large area so that the system can provide good
amount of electricity. This is a great disadvantage in places where the area is small
 Pollution can be a hindrance to solar panels as pollution can degrade the efficiency of
the photovoltaic cells. Clouds can also affect solar energy.
 The technology that is used to create solar energy is changing from time to time and
we hope it makes lives better and more cost effective.

2.1.4 Applications of Solar Energy:

The applications of solar energy can be bifurcated into three types i.e. Power,
Domestic and Agriculture. Few popular applications that can be listed under these are
as follows:
 Solar Water heater
 Tank collector
 Portable solar still
 Solar Cooker
 Solar steam cooker
 Portable solar dryer
 Solar PV street light

14
 These are some applications apart from these are many and are used on daily basis for
different purposes. Let’s have a look in architecture applications. Under these
applications we have the heating systems, cooling systems and the ventilation systems.

2.2 Solar Panel

Solar panel refers to a panel designed to absorb the sun's rays as a source of energy for
generating electricity or heating. A photovoltaic (PV) module is a packaged, connect
assembly of typically 6×10 solar cells. Solar Photovoltaic panels constitute the solar array of
a photovoltaic system that generates and supplies solar electricity in commercial and
residential applications. Each module is rated by its DC output power under standard test
conditions, and typically ranges from 100 to 365 watts. Fig 2.1 show different size of solar
panel.

Fig 2.1 Solar panel

2.2.1 Types of solar panel

There are three types of solar panels

I. Monocrystalline
II. Polycrystalline
III. Thin film

15
I. Monocrystalline:-

Solar cells made of monocrystalline silicon (mono-Si), also called single-crystalline

silicon (single-crystal-Si), are quite easily recognizable by an external even coloring and
uniform look, indicating high-purity silicon, as we can see on the picture below [Fig 2.2]

Fig 2.2 Monocrystalline silicon solar cells

Monocrystalline solar cells are made out of silicon ingots, which are cylindrical in
shape. To optimize performance and lower costs of a single monocrystalline solar cell,
four sides are cut out of the cylindrical ingots to make silicon wafers, which is what gives
monocrystalline solar panels their characteristic look.

A good way to separate mono- and polycrystalline solar panels is that polycrystalline
solar cells look perfectly rectangular with no rounded edges.

Advantages:-
 Monocrystalline solar panels have the highest efficiency rates since they are made out
of the highest-grade silicon. The efficiency rates of monocrystalline solar panels are
typically 15-20%. Sun Power produces the highest efficiency solar panels on the U.S.
market today. Their E20 series provide panel conversion efficiencies of up to

16
 20.1%.Update (April, 2013): Sun Power has now released the X-series at a record-
breaking efficiency of 21.5%.
 Monocrystalline silicon solar panels are space-efficient. Since these solar panels yield
the highest power outputs, they also require the least amount of space compared to any
other types. Monocrystalline solar panels produce up to four times the amount of
electricity as thin-film solar panels.
 Monocrystalline solar panels live the longest. Most solar panel manufacturers put a
25-year warranty on their monocrystalline solar panels.
 Tend to perform better than similarly rated polycrystalline solar panels at low-light
conditions.
 Monocrystalline panels are generally constructed from high-quality silicon, giving
them the highest performance rates in the industry, usually up to 21 percent. By
comparison, monocrystalline panels outperform thin film by four to one. They also
make wise use of space, so they offer a high power yield per square foot. Warranties
often last for 25 years, and these panels perform better in low-light conditions than
their poly-counterparts.

Disadvantages:-
 Monocrystalline solar panels are the most expensive. From a financial standpoint, a
solar panel that is made of polycrystalline silicon (and in some cases thin-film) can be
a better choice for some homeowners.
 If the solar panel is partially covered with shade, dirt or snow, the entire circuit can
break down. Consider getting micro-inverters instead of central string inverters if you
think coverage will be a problem. Micro-inverters will make sure that not the entire
solar array is affected by shading issues with only one of the solar panels.
 The Czochralski process is used to produce monocrystalline silicon. It results in large
cylindrical ingots. Four sides are cut out of the ingots to make silicon wafers. A
significant amount of the original silicon ends up as waste.
 Monocrystalline solar panels tend to be more efficient in warm weather. Performance
suffers as temperature goes up, but less so than polycrystalline solar panels. For most
homeowners temperature is not a concern.
 The disadvantages of this panel type are significant.
Because they are high-quality, these panels are also costly. Circuit break down is
common when the panel is obstructed or shaded. The manufacturing process produces
significant waste. The panels perform best in warm weather, with performance
decreasing as temperatures increase.

II. Polycrystalline:-
The first solar panels based on polycrystalline silicon, which also is known as polysilicon
(p-Si) and multi-crystalline silicon (mc-Si), were introduced to the market in 1981. Unlike
monocrystalline-based solar panels, polycrystalline solar panels do not require the
17
Czochralski process. Raw silicon is melted and poured into a square mold, which is cooled
and cut into perfectly square wafers as we can see on the [Fig 2.3]

Fig 2.3 Polystalline silicon solar cells

Advantages:-
 The process used to make polycrystalline silicon is simpler and cost less. The amount
of waste silicon is less compared to monocrystalline.
 Polycrystalline solar panels tend to have slightly lower heat tolerance than
monocrystalline solar panels. This technically means that they perform slightly worse
than monocrystalline solar panels in high temperatures. Heat can affect the
performance of solar panels and shorten their lifespans. However, this effect is minor,
and most homeowners do not need to take it into account .
 High temperature ratings are slightly lower than those for monocrystalline panels;
however, the difference is minor, making these types of panels a good option for many
homeowners. The manufacturing process produces little waste, and the technology
allows for a cost-effective panel.

Disadvantages:-
 The efficiency of polycrystalline-based solar panels is typically 13-16%. Because of
lower silicon purity, polycrystalline solar panels are not quite as efficient as
monocrystalline solar panels.
 Lower space-efficiency. You generally need to cover a larger surface to output the
same electrical power as you would with a solar panel made of monocrystalline

18
 silicon. However, this does not mean every monocrystalline solar panel perform better
than those based on polycrystalline silicon.
 Monocrystalline and thin-film solar panels tend to be more aesthetically pleasing since
they have a more uniform look compared to the speckled blue color of polycrystalline
silicon.
 Efficiency is lower, typically between 13 and 16 percent, which is not nearly as high
as the ratings for monocrystalline panels. The panels require more space when
installed to produce the same electrical output as a panel constructed from
monocrystalline.

III. Thin film:-

Depositing one or several thin layers of photovoltaic material onto a substrate is the basic
gist of how thin-film solar cells are manufactured. They are also known as thin-film
photovoltaic cells (TFPV). The different types of thin-film solar cells can be categorized by
which photovoltaic material is deposited onto the substrate:

 Amorphous silicon (a-Si)

 Cadmium telluride (CdTe)
 Copper indium gallium selenide (CIS/CIGS)
 Organic photovoltaic cells (OPC)

Depending on the technology, thin-film module prototypes have reached efficiencies

between 7–13% and production modules operate at about 9%. Future module efficiencies are
expected to climb close to the about 10–16%.

The market for thin-film PV grew at a 60% annual rate from 2002 to 2007. In 2011, close to
5% of U.S. photovoltaic module shipments to the residential sector were based on thin-film.

Fig [2.4] shows the picture of thin film solar cell.

19
 Fig 2.4 Thin-film solar cells (TFSC)

Advantages:-
 Mass-production is simple. This makes them and potentially cheaper to manufacture
than crystalline-based solar cells.
 Their homogenous appearance makes them look more appealing.
 Can be made flexible, which opens up many new potential applications.
 High temperatures and shading have less impact on solar panel performance.
 In situations where space is not an issue, thin-film solar panels can make sense.

Disadvantages:-
 Thin-film solar panels are in general not very useful for in most residential situations.
They are cheap, but they also require a lot of space. Sun Power’s monocrystalline
solar panels produce up to four times the amount of electricity as thin-film solar panels
for the same amount of space.
 Low space-efficiency also means that the costs of PV-equipment (e.g. support
structures and cables) will increase.
 Thin-film solar panels tend to degrade faster than mono- and polycrystalline solar
panels, which is why they typically come with a shorter warranty.

Note: - The specifications of the solar panel used in this project will be discussed in the
next chapter.

20
2.3 Working principle of solar panel:

2.3.1 How does a solar panel works?

The process starts when the sun shines on solar PV panels that have been installed on the
roof. [Fig 2.5]

Solar panels are made up of smaller units called solar cells. The most common solar
cells are made from Silicon. There are a number of silicon cells within each PV panels
these reacts with photons, or units of light, from the sun to produce direct current (DC) or
electricity. DC electricity then travels to an inverter which converts this energy to
electricity known as Alternating current (AC) that can be used in our home or office.

AC electricity then travels to the distribution network in your home powering your
domestic or office appliances.

21
 Fig 2.5 Solar panels converting sunlight to DC current.

2.4 Solar Cell Overview

A solar cell is an electronic device that converts the light energy directly into electric
energy without any form of moving parts by using photovoltaic effect.

Fig 2.6 Solar cell

22
  A Solar cell is also known as Photovoltaic (PV) cell.
 It is a static device, no moving part.
 “Photo” means Light and “voltaic” means producing electricity.
 It is a solid state electronic device made of semiconductor materials like silicon.
 Solar cell converts energy of light directly into Direct current (DC).
 Solar cell does not use heat of light to produce electrical energy.
 In 1839 the photovoltaic effect was discovered, in 1883 first thin film solar cells
fabricated and the first practical photovoltaic cell was developed in 1954.
 Efficiency of solar cell depends on many factors like shading on cells, irradiance,
temperature etc.
 In 2014 the highest 44.7% efficiency has achieved by using the multiple junction cells.

2.5 Basic theory of solar cell

Solar cells are made by two types of semiconductor materials one is n-type
semiconductor and other is P-type semiconductor material for generation of electricity.

 When light strikes on semiconductor, it generates electrons (-) and holes (+) pairs.
 when electron and hole pair reaches between two different type of semiconductor's
joint surface then electron and hole are separated, electron is attached by N-type
semiconductor and hole is attached by P-type semiconductor after that they are not
rejoin due to joint surface do not allow both way traffic.

Fig 2.7 P-N junction illustration of PV cell

23
  Now electrons are contained by N-type semiconductor and holes are contained by P-
type semiconductor, an electro motive force (emf) is generated in electrodes.
 When these electrodes are connected together by a conductor electrons run toward O-
type semiconductor and holes run toward N-type semiconductor.

Fig 2.8 Flow of current

2.6 Solar cell connections

Solar cell connection is just like battery connection. When positive terminal of one
solar cell is connected to negative terminal of another solar cell then they form series
connection. In series connection current is same for all cells and voltage is added by each
cell shown in figure 5.

And when all positive terminals of solar cells connected to one terminal and all
negative positive terminals of solar cells connected to another one terminal then forms
parallel connection. As shown in figure 6 here current is added and voltage is same for all
cells.

24
 Fig 2.9 Series connection of solar cell

Fig 2.10 Parallel connection of solar cell

25
2.7 Solar Cell Technologies

Solar cell is manufacturing by different materials. The two major technologies are
wafer-based silicon and thin-film [3].

Crystalline silicon solar cell is more efficient than thin-film solar cell but that is more
expensive to produce. They are most commonly uses in large to medium electric applications
like grid connected PV power generation.

Mono-crystalline solar cell is manufactured by pure semi-conducting materials so it

has higher efficiency (above 17% in industrial production and 24% in research laboratories
[4]. Poly-crystalline solar cell is slightly less efficient than Mono-crystalline but less in cost.

In thin-film solar cell very thin layers of semiconducting materials are uses so they can
be produces in large quantity at lower cost but it efficiency is less. This technology is uses in
calculators, watches and toys etc.

There are too many other PV technologies available like Organic cells, Hybrid PV
cells combination of both mono crystalline and thin film silicon etc.

2.8 Solar Cell, Solar Module or Panel and Solar PV Array

In solar power generation system number of solar cells is required to produce high
power so they are connected in form of Solar Module or Solar panel and for higher capability
form Array as shown in figure 2.6

Fig 2.11 Formation of solar Module and solar PV Array

26
 2.8.1 PV Module
A solar panel or module is a group of connected solar photovoltaic cells electrically
and mounted on a sustaining structure. A photovoltaic module is a systematical arranged
series connection of solar cells.

2.8.2 PV Array
A solar array is a group of solar photovoltaic panels or modules connected electrically
together and mounted on a sustainable structure to produce higher amount of power. For this
project the main task is to design a stand-alone power generation system for a small load like
a house situated on hilly area or for any small load that is not connected to grid network.

For this kind of loads design such a system that uses the power generated from PV
Array and convert it into AC for AC loads or stores it in storage element with efficiently and
paralleling supplies the load. In this project Vikram solar panel is used so not need to bother
about solar PV Array implementation.

27
Chapter 3

3.1 LM 317 Adjustable Output, Positive Voltage Regulator

The LM317 is an adjustable 3−terminal positive voltage regulator capable of
supplying in excess of 1.5A over an output voltage range of 1.25 V to 37 V. This voltage
regulator is exceptionally easy to use and requires only two external resistors to set the
output voltage. Further, it employs internal current limiting, thermal shutdown and safe area
compensation, making it essentially blow−out proof. The LM317 serves a wide variety of
applications including local, on card regulation.

This device can also be used to make a programmable output regulator, or by

connecting a fixed resistor between the adjustment and output, the LM317 can be used as a
precision current regulator.

Features
 Output Current in Excess of 1.5 A
 Output Adjustable between 1.2 V and 37 V
 Internal Thermal Overload Protection
 Internal Short Circuit Current Limiting Constant with Temperature
 Output Transistor Safe−Area Compensation
 Floating Operation for High Voltage Applications
 Eliminates Stocking many Fixed Voltage
 Available in Surface Mount D2PAK−3, and Standard 3−Lead Transistor Package
 NCV Prefix for Automotive and Other Applications Requiring Unique Site and
Control Change Requirements; AEC−Q100 Qualified and PPAP Capable
 These are Pb−Free Devices

3.2 LM317 datasheet

The LM317 is versatile in its applications, including uses in programmable output
regulation and local on-card regulation. Or, by connecting a fixed resistor between the
ADJUST and OUTPUT terminals, the LM317 can function as a precision current regulator.
An optional output capacitor can be added to improve transient response. The ADJUST

28
terminal can be bypassed to achieve very high ripple-rejection ratios, which are difficult to
achieve with standard three-terminal regulators.

Fig 3.1 LM 317 front view

Fig 3.2 LM 317 top view

29
3.2 Types of Batteries

Rechargeable batteries play an important role in our lives and many daily chores
would be unthinkable without the ability to recharge. The most common rechargeable
batteries are lead acid, NiCd, NiMH and Li-ion. Here is a brief summary of their
characteristics.

 Lead Acid – This is the oldest rechargeable battery system. Lead acid is rugged,
forgiving if abused and is economically priced, but it has a low specific energy and
limited cycle count. Lead acid is used for wheelchairs, golf cars, personnel carriers,
emergency lighting and uninterruptible power supply (UPS). Lead is toxic and cannot
be disposed in landfills.

 Nickel-cadmium – Mature and well understood, NiCd is used where long service life,
high discharge current and extreme temperatures are required. NiCd is one of the most
rugged and enduring batteries; it is the only chemistry that allows ultra-fast charging
with minimal stress. Main applications are power tools, medical devices, aviation and
UPS. Due to environmental concerns, NiCd is being replaced with other chemistries,
but it retains its status in aircraft due to its good safety record.

 Nickel-metal-hydride – Serves as a replacement for NiCd as it has only mild toxic

metals and provides higher specific energy. NiMH is used for medical instruments,
hybrid cars and industrial applications. NiMH is also available in AA and AAA cells
for consumer use.

 Lithium-ion – Li-ion is replacing many applications that were previously served by

lead and nickel-based batteries. Due to safety concerns, Li-ion needs a protection
circuit. It is more expensive than most other batteries, but high cycle count and low
maintenance reduce the cost per cycle over many other chemistries.

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 Here in this project we used a 12v, 1.3A rechargeable battery as shown in
picture below [Fig 3.3]

Fig 3.3 A 12V-1.3Ah rechargeable battery

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Chapter 4

4.1 Related works

4.1.1 Specifications of the Charging Circuit

 Solar panel rating – 5W /17V
 Output Voltage –Variable (5V – 14V)
 Maximum output current – 0.29 Amps
 Drop out voltage- 2- 2.75V
 Voltage regulation: +/- 100mV

4.1.2 Solar Battery Charger Circuit Principle:

Solar battery charger operated on the principle that the charge control circuit will
produce the constant voltage. The charging current passes to LM317 voltage regulator
through the diode D1. The output voltage and current are regulated by adjusting the adjust
pin of LM317 voltage regulator. Battery is charged using the same current.

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4.2 Solar Battery Charger Circuit Diagram:

Fig 4.1 Solar Battery Charger Circuit diagram

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4.3 Circuit Components

 Solar panel – 17V

 LM317 voltage regulator

 DC battery

 Diode – 1n4007

 Capacitor – 0.1uF

 Schottky diode – 3A, 50V

 Resistors – 220, 680 ohms

 Pot – 2K

 Connecting wires

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4.4 Solar Battery Charger Circuit Design

Circuit must have adjustable voltage regulator, so Variable voltage regulator LM317 is
selected. Here LM317 can produce a voltage from 1.25 to 37 volts maximum and maximum
current of 1.5 Amps.

Adjustable Voltage regulator has typical voltage drop of 2 V-2.5V .So Solar panel is
selected such that it has more voltage than the load. Here I am selecting 17v/5w solar panel.

Lead acid battery which is used here has specification of 12v/1.3Ah. In order to charge
this battery following are required.

Schottky diode is used to protect the LM317 and panel from reverse voltage generated
by the battery when it is not charging. Any 3 A diode can be used here.

4.4.1 for Charging 12V Battery

Output voltage
 Set the output voltage to 14.5 volts (This voltage is specified on the battery as cycle
use.)

Charging current
 Charging current = Solar panel wattage/Solar Panel Voltage = 5 / 17 = 0.29A.

 Here LM317 can provide current upto 1.5A .So it is recommended to use high wattage
panels if more current is required for your application.(But here my battery requires
initial current less than 0.39Amps. This initial current is also mentioned on the
battery).

 If the battery requires initial current more than 1.5A,it is not recommended to use
LM317.

Time taken for charging

Time taken for charging = 1.3Ah/0.29A = 4.44hours.

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Power dissipation
Here solar panel has 5Watts

 Power going into battery = 14.5*0.29 =4 watts

 Thus 1 watt of power going into regulator.

 All the above mentioned parameters have to be taken into account before charging a
battery.

4.4.2 For 6V Application

Output voltage
 Set the output voltage to 7.5-8 volts (This voltage is specified on the battery as cycle
use.)

Charging current
 Charging current = Solar panel wattage/Solar Panel Voltage = 5 / 17 = 0.29A.

 Here LM317 can provide current upto 1.5A .So it is recommended to use high wattage
panels if more current is required for your application.(But here my battery requires
initial current less than 0.39Amps. This initial current is also mentioned on the
battery).

 If the battery requires initial current more than 1.5A, it is not recommended to use
LM317.

Time taken for charging

 Time taken for charging = 1.3Ah/0.29A = 4.44hours.

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Power dissipation for 6V battery
Here solar panel has 5Watts

 Power going into battery = 7.5*0.29 =2.175watts

 Thus 2.825 watt of power going into regulator.

 All the above mentioned parameters have to be taken into account before charging a
battery.

4.4.3 Power Dissipation

In this project, power is limited because of the thermal resistance of LM317 voltage
regulator and the heat sink. To keep the temperature below 125 degree Celsius, the power
must be limited to 10W. LM317 voltage regulator internally has temperature limiting circuit
so that if it gets too hot, it shuts down automatically.

When battery is charging, heat sink becomes warm. When completing the charging at
maximum voltage, heat sink runs hot. This heat is because of excess power that not needed
in the process of charging a battery.

4.4.4 Current Limiting

As the solar panel provides constant current, it acts as a current limiter. Therefore the
circuit does not need any current limiting.

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4.4.5 Solar Charger Protection
In this circuit, capacitor C1 protects from the static discharge. Diode D1 protects from
the reverse polarity. And voltage regulator IC provides voltage and current regulation.

4.4.6 Solar Charger Specifications

 Solar panel rating: 20W (12V) or 10W (6V)

 Vout range: 5 to 14V

 Maximum power dissipation: 10W (includes power dissipation of schottky diode)

 Typical drop out value: 2 to 2.75V (depends on load current)

 Max current: 1.5A (internally it limited to 2.2A)

 Voltage regulation: +/- 100mV

4.4.7 How to Operate this Solar Battery Charger Circuit?

1. Give the connections according to the circuit diagram.
2. Place the solar panel in sunlight.
3. Now set the output voltage by adjusting pot RV1
4. Check the battery voltage using digital multi meter.

4.4.8 Solar Battery Charger Circuit Advantages

 Adjustable output voltage

 Circuit is simple and inexpensive.

 Circuit uses commonly available components.

 Zero battery discharge when no sunlight on the solar panel.

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4.4.9 Solar Battery Charger Circuit Applications
This circuit is used to charge Lead-Acid or Ni-Cd batteries using solar energy.

4.4.10 Limitations of this Circuit:

1. In this project current is limited to 1.5A.
2. The circuit requires high drop-out voltage

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Chapter 5

Conclusions

5.1 Summary
In this paper we present a solar battery charger circuit to charge 12V, 1.3Ah
rechargeable Lead-acid battery from the solar panel. This solar charger has current and
voltage regulation and also has over voltage cut off facilities. This circuit may also be used
to charge any battery at constant voltage because output voltage is adjustable.

We bought the components and done the project practically.

5.2 Limitations
1. In this project current is limited to 1.5A.
2. The circuit requires high drop-out voltage.

5.3 Future Work

The current circuit is to charge 12V, 1.3Ah rechargeable Lead-acid battery from the solar
panel. We chose the circuit in such way so that can be used to charge any battery at constant
voltage because output voltage is adjustable.

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