Solar charge controller circuit that is used to charge inverter batteries and car batteries using the solar energy.
12V, 24V, 36V, 48V, 72V SOLAR SOLAR BATTERY CHARGER CIRCUIT.
A solar battery charger is a charge controller device that controls the charging state of a battery when using solar panels. Solar chargers comes in different forms and types. But the most important aspect of it is to get your batteries charged without over charging them or under charging them since any of the two conditions can reduce your battery life. Also, the charger should not waste power and in that case must be highly efficient.
Today am going to show you how to make for your self a highly efficient two stages solar charger (solar charge controller).
HOW THE SOLAR BATTERY CHARGER CIRCUIT WORKS
The circuit is built around LM358, CD4013 and N-Mosfets. The charging current of this circuit is 60A but can be increased to handle 80A by using appropriate Mosfets or connecting more mosfets in parallel.
The op amp LM358 has two independent comparator within the 148 pins single package. Please download the data sheet from https://www.onsemi.com/pub/Collateral/LM358-D.PDF
The second part of the op amp is configured to give a high output when the battery is low. The high output is sent to pin 5 and pin 9 of CD4013 digital IC which is called data pin. This causes pin one of the CD4013 to go high and turn optocoupler U10 on. When U10 turns on, Q13 also turns on and positive voltage is applied to the gates of the N-Mosfet to turn it on for charging to start.
When solar battery Charging is complete, pin 7 of LM358 which is the op amp 2nd output pin goes low. As the op amp goes low, pin 2 of CD4013 goes high whiles its pin 1 goes Low. The high output from Pin 2 of CD4013 turns U14 on and this turns of the mosfet to stop the charging. I did not add hysteresis because i want the output to be always stable at my set battery full value.
whiles pins 1 and 2 of CD4013 takes care of switching the mosfets, pins 13 and 12 of CD4013 will turn on LED 2 and LED 1 to indicate charging and floating respectively.
The second op amp is configured to generate square wave clock signal and its output is fed to the clock pins of CD4013 flip-flop IC. Download CD4013 datasheet.When clocking is working, output pin 1 of the op amp will measure 2.5V or close.
12V 24V 48V 96V
SOLAR BATTERY CHARGER CIRCUIT
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| Updated Circuit |
To set floating level ( battery full level), connect the battery to the circuit and connect your solar panels to the part labeled panel. Please ensure correct polarity though the circuit has reversed polarity protection.
monitor the charge level with a voltmeter and when battery reaches your desired battery full level, adjust U13 variable 10k resistor until float indicator turns on. In that case, the battery voltage will neither go up nor down but stable. That is called floating, this kind of charging ensures that your battery is always charged.
Other voltage designers should leave their designing voltages in the comment section below and i will be ready to support them. All other comments are also welcome.
Update: U5 should be replaced with LM7812 or any 12V voltage regulator.
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ReplyDeleteHi , Nice Circuit , In case I am not in a position of Solar Panel, Do you have an idea what I can use as a Solar Simulator
ReplyDeleteit can be used in any dc to dc circuit for step-down or buck purposes.
Deletewhat changes to do i need to make to handle 48v input 120 Amp charging 48v battery bank
ReplyDeletebuild two different boards using 5 mosfets on each side (so 20 mosfets in all) and parallel the outputs. The input should also be connected together.
DeleteUse 100V mosfets or higher. eg. irf3710, irf4410, irf4110, irf4310 100Nxx where xx represents the current.
hello, i just noticed in your circuit that gates of Q1/2/3/4/10 are connected to their source therefore these mosfets will be all time off and also are in series of the other mosfets which are controlled by optocoupler, then how will be the battry charged if the series mosfets are permanently off. there will be no charging at all whether mosfets Q5/6/7/8/9 are on or off.
ReplyDeletePlease take your time to read. I said in the write-up that Q1,2,3,4 and Q10 are cofigured as diodes.......you can replace them with gigh current diodes
DeleteHello Opanin,
ReplyDeleteI have successfully build this circuit for 48v solar charging. It is working well. Thanks for sharing such a wonderful and tested circuit diagram.
I have one question though. Will the solar continues to charge the batteries if Drain and Source of MOSFETs gets shorted. MOSFETs handling large current are very likely to get shorted in my experience. If the answer is YES then please suggest how to avoid battery overcharge in such condition.
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ReplyDelete