Mini solar charge controller

Fathima jahana Shrimayi Santhana lakshmi ECE-B

MINI SOLAR CHARGE CONTROLLER

Why a Charge Controller is necessary Since the brighter the sunlight, the more voltage the solar cells produce, the excessive voltage could damage the batteries. A charge controller is used to maintain the proper charging voltage on the batteries. As the input voltage from the solar array rises, the charge controller regulates the charge to the batteries preventing any over charging.

Modern multi-stage charge controllers Most quality charge controller units have what is known as a 3 stage charge cycle that goes like this : 1) BULK: During the Bulk phase of the charge cycle, the voltage gradually rises to the Bulk level (usually 14.4 to 14.6 volts) while the batteries draw maximum current. When Bulk level voltage is reached the absorption stage begins. 2)ABSORPTION: During this phase the voltage is maintained at Bulk voltage level for a specified time (usually an hour) while the current gradually tapers off as the batteries charge up. 3)FLOAT: After the absorption time passes the voltage is lowered to float level (usually 13.4 to 13.7 volts) and the batteries draw a small maintenance current until the next cycle. The relationship between the current and the voltage during the 3 phases of the charge cycle can be shown visually by the graph below.

MPPT Maximum Power Point Tracking Most multi-stage charge controllers are Pulse Width Modulation (PWM) types. I would recommend using one of at least this design. The newer Maximum Power Point Tracking (MPPT) controllers are even better. They match the output of the solar panels to the battery voltage to insure maximum charge (amps). For example: even though your solar panel is rated at 100 watts, you won't get the full 100 watts unless the battery is at optimum voltage. The Power/Watts is always equal to Volts times Amps or P=E*I (seeOhm's law for more info). With a regular charge controller, if your batteries are low at say 12.4 volts, then your 100 watt solar panel rated at 6 amps at 16.5 volts (6 amps times 16.5 volts = 100 watts) will only charge at 6 amps times 12.4 volts or just 75 watts. You just lost 25% of your capacity! The MPPT controller compensates for the lower battery voltage by delivering closer to 8 amps into the 12.4 volt battery maintaining the full power of the 100 watt solar panel! 100 watts = 12.4 volts times 8 amps = 100 (P=E*I). The Charge Controller is installed between the Solar Panel array and the Batteries where it automatically maintains the charge on the batteries using the 3 stage charge cycle just decribed. The Power Inverter can also charge the batteries if it is connected to the AC utility grid or in the case of a stand alone system, your own AC Generator.

If you are using four 75 to 80 Watt solar panels, your charge controller should be rated up to 40 amps. Even though the solar panels don't normally produce that much current, there is an 'edge of cloud effect'. Due to this phenomenon I have seen my four 6 amp panels (4*6=24) pump out over 32 amps. This is well over their rated 24 amps maximum. A good 3 stage 40 amp Charge Controller will run about $140 to $225 depending on features like LCD displays. For eight 75 to 80 watt solar panels you would need two 40 amp Charge Controllers to handle the power or you could increase your system voltage to 24 volts and still use just one 40 amp Charge Controller. PV : Photovoltaic (PV) is a technology that converts sunlight directly into electricity. It was first observed in 1839 by the French scientist Becquerel who detected that when light was directed onto one side of a simple battery cell, the current generated could be increased. In the late 1950s, the space programme provided the impetus for the development of crystalline silicon solar cells; the first commercial production of PV modules for terrestrial applications began in 1953 with the introduction of automated PV production plants.

Figure 1: A photovoltaic panel being used in rural Nepal for solar lighting. Photo credit: Practical Action. Today, PV systems have an important use in areas remote from an electricity grid where they provide power for water pumping, lighting, vaccine refrigeration, electrified livestock fencing, telecommunications and many other applications. However, with the global demand to reduce carbon dioxide emissions, PV technology is also gaining popularity as a mainstream form of electricity generation. Several million solar PV systems are currently in use worldwide, with an installed capacity of over 6.6GW globally (2006), yet this number is a tiny proportion of the vast potential that exists for PV as an energy source. Photovoltaic modules provide an independent, reliable electrical power source at the point of use, making it particularly suited to remote locations. However, solar PV is increasingly being used by homes and offices to provide electricity to replace or supplement grid power, often in the form of solar PV roof tiles. The daylight needed is free, but the cost of equipment can take many years before receiving any payback. However, in remote areas where grid connection is expensive, PV can be the most cost effective power source. Solar PV systems While in developed countries there has been a rapid increase in grid connected PV systems, in developing countries the majority of PV systems are stand-alone offgrid systems. The off-grid systems can be used to drive a load directly; water pumping is a good example -water is pumped during the hours of sunlight and stored for use; or a battery can be used to store power for use for lighting during the evening. If a battery charging system is used then electronic control apparatus will be needed to monitor the system. All the components other than the PV module are referred to as the balance-of-system (BOS) components. The figure below shows a typical configurations for an off-grid PV system. Such systems can often be bought as kits and installed by semi-skilled labour. For correct sizing of PV systems, the user needs to estimate the demand on the system, as well as acquiring information about the solar insolation in the area (approximations can be made if no data is readily available). It is normally assumed that for each Wp of rated power the module should provide 0.85watt hours of energy for each kWhm-2 per day of insolation (Hulscher 1994). Therefore

if we consider a module rated at 200 Wp and the insolation for our site is 5 kWhm2 per day (typical value for tropical regions), then our system will produce 850Wh per day (that is 200 x 0.85 x 5 = 850).

Some benefits of photovoltaics: No fuel requirements - In remote areas diesel or kerosene fuel supplies are erratic and often very expensive. The recurrent costs of operating and maintaining PV systems are small. Modular design - A solar array comprises individual PV modules, which can be connected to meet a particular demand. Reliability of PV modules - This has been shown to be significantly higher than that of diesel generators. Easy to maintain - Operation and routine maintenance requirements are simple. Long life - With no moving parts and all delicate surfaces protected, modules can be expected to provide power for 15 years or more. National economic benefits - Reliance on imported fuels such as coal and oil is

reduced. Environmentally benign - There is no pollution through the use of a PV system nor is there any heat or noise generated which could cause local discomfort. PV systems bring great improvements in the domestic environment when they replace other forms of lighting - kerosene lamps, for example.

Solar Charge Controller Features: voltage regulation PWM shunt Battery charging floating charge automatic reconnection automatic selection of voltage (12V/24V) temperature compensation Electronic Protections: overloading protection short circuit protection reverse current protection reverse polarity protection lightning protection overcharge protection overdischarge protection Technical Data at 25: Model Max. load current Voltage Drop Rated Voltage High Voltage Disconnection Low Voltage Disconnection Low Voltage Reconnection Temperature Compensation Working Temperature Max. own consumption Biggest connection terminal Size Weight CMP12- CMP126A 12A <=6A <=12A <140mv <210mv 12V / 24V auto 13.7V/12V 27.4V/24V 10.5V/12V 20.8V/24V 12.6V/12V 25.2V/24V -3mv//cell -20 to +60 <=20mA 2.5mm 102x45x107mm 0.168kg

Few circuits