CHARGE AND LOAD PROTECTION IN SOLAR

POWER MANAGEMENT

A Final year Project submitted to

the Department of Electrical and Electronics at
International university of East Africa
in partial fulfilment of the requirement of the Bachelors
degree of Science
in Electrical engineering

by
MAJIER MAKER

October 2021

DECLARATION
 I MAJIER MAKER declare that this is my original compilation and a true record
of project done and personal findings.

Sign:…………………………………………

Date: ………………………………………..

APPROVED BY;

Project Supervisor:

Name:………………………………………………………………………………

Position:……………………………………………………………………………

Sign…………………………………....... Date: ………………………………………

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Abstract
This project presentation is about designing a solar charging system with a load
protection alert system. The system relies on the relays (to limit charging and discharging
of the battery), and an alarm system that sounds when the system reaches cutoff or over
load with the essence of protecting the battery in use while drawing the attention of the
system owner.

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 CHAPTER 1
INTRODUCTION

1.1 Background

A charge controller is a device that is used to safely charge the battery or energy
storage system used in a solar photovoltaic system. It is also a safe path for discharge of
energy (DC) from the storage or battery. It protects the battery from being over charged
and discharged. Currently most charge controllers or regulators operate to control
charging and discharging by automatically cutting off supply to and from the battery (i.e.
overcharging limit and over discharging limit). They exist in two types i.e. Pulse wave
modulation – PWM (common type and cheap) and Maximum power point tracking –
MPPT (rear, efficient and expensive).
Besides these parameters, they still lack another vital parameter of alerting the
user during moments of discharge when the system is nearing lower cutoff limit (i.e. over
discharge cut-off limit).
Therefore, this project is about designing a charge controller that will alert the
user when the system nears or reaches over discharge limit and automatically disconnects
the load output.
(Background should be at least four pages add more work)

1.2 Problem Statement

Off-grid solar systems that deploy use of charge controllers don’t have an alert
system that warns the user as regards the nearing cutoff and actual cutoff discharge
limit/point. In addition, most of the chargers lack onboard battery level monitors, which
often forces the user to purchase a battery monitor separately. As a result, lack of an alert
system, it will always require the user to inspect or keep an eye on the controller or risk
being taken by surprise when the system reaches power disconnect limit.

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1.3 Justification

This system ensures that the user is notified instantly when their system is about to
disconnect so that they are able to take action when necessary to disconnect their DC
loadings accordingly. This significance of this mechanism is that it;
 Allows users to take action instantly
 Makes users maximize efficiently so that the system can meet its lifespan
 Protect the battery from overloading.
 Encourages users to adhere to energy efficiency and energy saving thus making them
understand and know their system better.

1.4 Objectives of the project

The main objective of this study is to design a charging and load protection solar
system.

1.4.1 Specific objectives

 To make thorough research on solar charging, protection and load management

related literature.
 To identify components required and make a circuit design for the project.
 To construct the hardware for the proposed system.
 To test the system performance.

1.5 Scope of the Project

This device is suitable for applicable in off-grid Direct Current – DC solar systems

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2Chapter 2

2.1 Methodology (introduce the chapter like make an introduction

about the chapter what is aiming at achieving)

SN Specific Methods Description

objectives
1 To make Internet Thorough study on
thorough research research information pertaining
on circuit breakers Physical charge regulators will be
and related examinations made over the internet,
literature Supervision books and other necessary
resources. This will
include; it’s operations,
types, specifications, etc.
relating to project will be
reviewed to study their
operations and the
components used. Existing
charge regulator(s) will be
opened up to check their
build ups and working
Every stage of the
project will be shown to the
supervisor for further help
and guidance.
2 To identify Class lecture Library and lecture
the components notes notes will be revised to
required and make Library identify the necessary
a circuit design for Design components to be used in
the project program software the circuit that will be
Component drawn using design
purchase program software (Circuit
Wizard – Student version)
and then simulated
concurrently to meet
baseline results. After a
suitable design is made, the
components will be
purchased.
3 To Assembly The project
construct the Soldering hardware will be assembled
hardware and Consultation according to the design
program through soldering, cutting,
etc.
4 To test the Record results The constructed
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 system program System project will be tested to
analysis analyze its performance
while recording the
necessary result parameters
to compare them with
expected/baseline results.

2.1.1 Equipment, materials and components used

The following is the list of components/equipment required for the project

Component Value/Model Quantity
Main circuit block
Deep cycle solar battery 12V, 7A 1
Solar panel 15W, 18Vmp, 1
22Voc
DC motor 12Vdc 1
Voltage regulator 7812 7812 1
Relay 12V SPDT 2
Zener diode 1N752 5V6 1
1N4733 5V1 1
Diode 1N4007 4
Light emitting diode – LED Blue 1
Potentiometer 100k 3
Transistor NPN BD139 4
Resistor 0.5k 1
1k 3
10k 2
Switch SPST 1
Capacitor 100µ
1000µ
Terminal block 2pin CN2
Battery monitor and Alert system circuit
Light emitting diode – LED Green 2
Yellow 1
Red 1
Variable resistor 5k 1
Diode 1N4007 1
Zener diode 1N751 5V1 1

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 555Timer IC NE555 1
Operational amplifier LM339 4
Transistor NPN BD139 1
Buzzer 6V 1
Capacitor 0.1µ 1
2.2µ 1
100µ 1
Resistor 1k 5
2.2k 4
5k 2
10k 2
10.5k 1
General tools and equipment
Load DC motor 12V, 1
4W
Soldering iron 40W, 230Vac 1
Soldering wire 0.5mm Ø 1 roll
Prototyping circuit board/bread 1
board

2.1.2 Design of the Project

The design of the project and selection of the components is as below.

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2.1.3 Block diagram

INPUT
MAIN CONTROL OUTPUT
Power supply CIRCUIT Load (DC motor
(Battery and Solar Charge controller and Battery)
panel)

INDICATOR AND
ALARM
Alert system
Battery monitor

The Circuit Layout Diagram of the Project.

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 (explain those circuit diagrams in details don’t just show them)

Power Supply and Main Control Circuit Block

The power supply constitutes of the solar power (extracted from the solar panel)
as the main (primary) source of power for charging the battery and powering the load
under normal conditions. The battery as well takes over as the secondary source of power
in the absence of the solar power.
The two SPDT relays (RL1 and RL2) and potentiometers (VR2 and VR3) in the
circuit are used for setting the upper cutoff (over charge) and lower cutoff (over
discharge) limits. The voltage regulator (RG1) and other components in the circuit are
used to supply a constant power supply the required to operate the relays, transistors, and
other electronic components in the network.

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 The Light emitting Diode (LED) D9 (labeled NORMAL) is used to indicator the
normal state of operation in system. It also shows that there is power at the output of the
system.

Battery Monitor Circuit Block

This consists of operational amplifiers (Op-amps), whose outputs are connected to

LED lights. These sense and compare the constantly variable voltage level of the battery
under charge and displays the levels (25%, 50%, 75% and 100%) at real time as it varies.
The resistors and other components in the network, are used for attaining the required
voltage and current for safe operation of the main components (op-amps and LED
diodes).

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 2.2 Alert System

This block consists mainly of the 555Timer IC chip and the buzzer. The timer is
used to determine the timing of the buzzer connected to its output pin 3. This alarm is
triggered whenever the battery voltage is nearing the maximum discharge and cutoff limit
as determined in the control circuit block. The alert system is deactivated once the battery

voltage goes above the over discharge point. The resistors and capacitors, and other
components are used to attain safe operation mode of the electronic components.

Output Terminal

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 The output of the circuit is demonstrated by connection of the load (DC motor),
which only operates under normal conditions. In the event of over discharge, the
output is automatically disconnected with an alert warns before disconnection as
shown below.

2.3 Methods and Procedures

The following are the implementation procedures.

a) Using the circuit wizard program installed on the computer, design the required
circuit and simulate the design blueprint (prototype) and adjust the variable key
electronic circuit parameters until the desired output is achieved.
b) Assemble the required components and solder the components on the Prototyping
Circuit Board (PCB) as in the blueprint/design.
c) Test all the connecting points for continuity.
d) Adjust the potentiometers and variable resistor until upper and lower cutoff limits are
achieved for the main block and the battery monitor respectively.
e) Power the circuit, measure and record the output parameters (voltage) at the various
set points.
f) Turn off the circuit and then connect the load. Measure and record your observations
under normal and abnormal circuit conditions.

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3CHAPTER 3

3.1 Results and Results Discussion

3.1.1 Observation

The following are the observations and results

CASE I: Maximum Charging Limit
Observation: For this case, the maximum occurs when the battery attains a voltage
of 13.6V
CASE II: Over Discharge Limit
Observation: Allowed over discharge of 11.0V (Over discharge disconnect
voltage)
CASE III:
When the load is switched on, the circuit operates normally. As the voltage droops
to 50% or nears disconnect point (yellow indicator) the Alert system is triggered
to inform the user, the that the system will soon disconnect. It’s also observed that
the normal indicator (Blue LED) lights until to show that there is power at the
output. And once the battery level reaches 25% (red LED), the normal indicator
(Blue LED) turns off as well as the load.
When the solar panel is connected, the battery is observed to gradually increase
from 25% to 100% and once it surpasses the 50% indicator, the alert system is triggered
off automatically.
(explain more about you results)

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4CHAPTER 4

4.1 Conclusion

(write your conclusion)

4.2 Recommendations

(write you recommendations)

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References
(where are your references)

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Appendix
Project Budget

S U Q
Item Unit price Amount
N nit ty
(Ugx) (Ugx)
Research and
1  
consultation
2 Components  
3 Tools  
Stationary and
4  
printing
5 Others  
Total
The Timeline

Below is the implementation timeline for the project

Activity Start End Amount

(Ugx)
Project planning
Preliminary study
Title selection
Title approval
Proposal writing
Proposal presentation
Literature review
Project design
Component purchase
and tools
Project implementation

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 Project testing and
presentation

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