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 insu
cient 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.
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 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
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.

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.

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
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

• Monocrystalline
• Polycrystalline III. Thin film
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
20.1%.Update (April, 2013): Sun Power has now released the X-series at a
recordbreaking 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 HYPERLINK
"http://energyinformative.org/are-solar-micro-inverters-better-than-central-
inverters/"- HYPERLINK "http://energyinformative.org/are-solar-micro-
inverters-better-than-central-inverters/"inverters instead of central string
inverters HYPERLINK "http://energyinformative.org/are-solar-micro-
inverters-better-than-central-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 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 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.

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.

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.
 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
• 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

• Now electrons are contained by N-type semiconductor and holes are

contained by Ptype semiconductor, an electro motive force (emf) is
generated in electrodes.
• When these electrodes are connected together by a conductor electrons run
toward Otype 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.
 Fig 2.9 Series connection of solar cell

Fig 2.10 Parallel connection of solar cell

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

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.
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 HYPERLINK

"http://www.electroschematics.com/wp-
content/uploads/2011/05/LM317-datasheet.pdf"
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 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

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.

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

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.
4.2 Solar Battery Charger Circuit Diagram:

Fig 4.1 Solar Battery Charger Circuit diagram

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

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.
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.

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.

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?

• Give the connections according to the circuit diagram.
• Place the solar panel in sunlight.
• 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.

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:

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