This document describes a pulse width modulation (PWM) solar charge controller. It begins with an introduction and objectives, then discusses the basic components and workings of solar charge controllers including PWM and MPPT types. The remainder of the document details the specific hardware components used in the implemented PWM solar charge controller prototype including an Arduino Nano microcontroller. It provides schematics, algorithms, and explanations of sections like voltage sensing, PWM signal generation, and MOSFET switching. The conclusion discusses expanding the design to be a hybrid PWM/MPPT controller to reduce costs for large-scale solar installations.
2. CONTENTS
• AIM
• OBJECTIVE
• SOLAR CHARGE
CONTROLLER
• BASIC CONNECTION
SETUP OF SOLAR
CHARGE
CONTROLLER
• WHY WE USE SOLAR
CHARGE
• MULTI STAGE
CHARGING
• ADVANTAGES OF
SCC
• APPLICATIONS OF
SCC
• CHARGING STAGES
OF SCC
• TYPES OF SCC
• MPPT (MAXIMUM
POWER POINT
TRACKING)
• HOW MPPT WORKS?
• MAIN FEATURES OF
MPPT SOLAR
CHARGE
CONTROLLER
• CONCEPTUAL
DIAGRAM OF MPPT
3. CONTENTS
• WHAT IS PWM
SOLAR CHARGE
CONTROLLER
• ABOUT PWM SOLAR
CHARGE
CONTROLLER
• ADVANTAGES
OFPWM (PULSE
WIDTH
MODULATION)
• USE OF PWM SOLAR
CHARGE
• CONCEPTUAL
DIAGRAM OF PWM
• PWM OR MPPT ?
• WORKING OF A PWM
CONTROLLER
• REGULATING THE
ELECTRICITY OF
SOLAR CHARGE
CONTROLLER
• SPECIFICATIONS OF
THIS PRODUCT
• PRINCIPLE CONCEPT
OF PWM SCC
• DC-DC
CONVERSION UNIT
• SCHEMATIC
DIAGRAM OF
IMPLEMENTED PWM
SOLAR CHARGE
CONTROLLER
• HARDWARE
REQUIREMENTS FOR
PWM SOLAR
4. CONTENTS
• POWER MOSFET
(IRF9630)
• POWER
MOSFET(IRF540)
• METERING AND
DISPLAY OF THE
CHARGE
CONTROLLERS
• TRANSISTOR
(BC547)
• DIODE(1N4007)
• BATTERY
• SOLAR PANEL(10V)
• MICROCONTROLLER
(ARDUINO NANO)
• ARDUINO NANO PIN
LAYOUT
• CORE ALGORITHM
OF PWM CHARGE
CONTROLLER
• CHARGING
OPERATION
FLOWCHART
• SECTIONS OF PWM
SOLAR CHARGE
CONTROLLER
• MOSFET DRIVERS
• CONCLUSION
• FUTURE SCOPE OF
WORK
5. AIM
The aim of this project is to design and construct a solar charge
controller using mostly discrete components.
The charge controller will be designed for the solar panel located in
The Neotia University. The designed system is very functional durable
economical and reliable using locally sourced and affordable
component
This work is a prototype of a commercial solar charge controller with
protection system that will prevent damages to battery associates with
Deregulating charging and discharging mechanism.
6. OBJECTIVE
• The intent is to create an extremely efficient charge controller
that would be able to monitor the power generated by the
photovoltaic array and deliver the maximum amount to the
battery bank during varying atmospheric conditions.
• Advance Controller make it an efficient system.
7. SOLAR CHARGE CONTROLLER
• A Solar Charge
Controller(SCC) is an
electronic component
that controls the amount
of charge entering and
exiting the battery , and
regulates the optimum
and most efficient
performance of the
battery
9. WHY WE USE SOLAR CHARGE CONTROLLER
To Prevent Battery Overcharge
Block Reverse Current
Under Voltage Protection
Displays and Metering
Low Voltage Disconnect
Multi Stage Charging
10. MULTI STAGE CHARGING
• Full Flow when battery is low
• Slow down flow when close to full
• Trickle flow when full
ITS LIKE FEEDING AS PER NEED
11. ADVANTAGES OF SCC
• Protects the battery from overcharging.
• Reduces system maintenance and increases battery lifetime.
• Auto charged indication
• Reliability is high
• Monitors the reverse current flow
12. APPLICATIONS OF SCC
• Street Lights use photovoltaic cells to convert sunlight into
DC electric charge . This system uses solar charge controller to
store DC in the batteries and uses in many areas.
• Home systems use PV module for house-hold application.
• Hybrid solar system uses for multiple energy sources for
providing full time backup supply to other sources.
14. TYPES OF SCC
A solar charge controller is available in three different
technologies
1> Simple 1 or 2 stage controls,
2> PWM (Pulse Width Modulation)
and
3> MPPT (Maximum Power Point Tracking)
their perform in a system is very different from each other.
15. SIMPLE 1 OR 2 STAGE CONTROLS
• They rely on relays or shunt transistors to control the voltage
in one or two steps.
• These essentially just short or disconnect the solar panel
when a certain voltage is reached.
• Their only real claim to fame is their reliability - they have so
few components, there is not much to break.
16. MPPT (MAXIMUM POWER POINT TRACKING)
• Converts voltage input to battery voltage
• Increases current when voltage drops
• More expensive than PWM
• Efficiency upto 96%
17. HOW MPPT WORKS?
• algorithm that included in charge controllers
• used for extracting maximum available power from PV
module How it works
• MPPT checks output of PV module
• compares it to battery voltage
• It can also supply power to a DC load
18. MAIN FEATURES OF MPPT SOLAR CHARGE
CONTROLLER
MPPT solar charge controller is used to correct for detecting
the variations MPPT solar charge controller is necessary for any
solar power systems need to extract maximum power
MPPT solar charge controller allows users to use PV module
with a higher voltage output
20. WHAT IS PWM SOLAR CHARGE
CONTROLLER
• Pulse Width Modulation (PWM) is the most effective means to
achieve constant voltage battery charging by adjusting the duty
ratio of the switches ( MOSFET ). In PWM charge controller, the
current from the solar panel tapers according to the battery’s
condition and recharging needs.
21. ABOUT PWM SOLAR CHARGE CONTROLLER
• When a battery voltage reaches the regulation set point, the
PWM algorithm slowly reduces the charging current to avoid
heating and gassing of the battery, yet the charging continues
to return the maximum amount of energy to the battery in the
shortest time.
22. PWM (PULSE WIDTH MODULATION)
Operates by making a connection directly from Solar
Array
Voltage Pulled Down to Battery voltage
Cheaper than MPPT
Efficiency upto 70%
ADVANTAGES
23. ADVANTAGES OF PWM CHARGE
CONTROLLER
• Longer battery life
• Reduce battery over heating
• Minimizes stress on the battery
• Ability to desulfate a battery.
24. USE OF PWM SOLAR CHARGE CONTROLLER
• Charging the batteries used in solar home system
• Solar lantern in rural area
• Cell phone charging
26. PWM OR MPPT ?
What is yourbattery
voltage?
12V 24V 48V
How manycells
does your PV
panel have?
36 60 72
How manycells
does your PV
panel have?
36 60 72
How manycells
does your PV
panel have?
36 60 72
Do you already have a
solar panel?
How manypanels/strings
are wired in series?
No
Series
Wiring
2 3 4 5+
How many
panels/stringsare
wired in series?
No
Series
Wiring
2 3+
Hot/Sunny
Upfront Savings
Lifetime Savings
PWM
What type ofclimate
will the system be
installed in?
Cold/Cloudy
Add one more
panel/string in
series. Start
process over.
Add three more
panel/string in
series. Start
process over.
Add two more
panel/string in
series. Start
process over.
Add one more
panel/string in
series. Start
process over.
Do you prefer
upfront or
lifetimesavings?
How many days of
autonomy is yourbattery
bank designed for?
1-2 2-3 3-4 4+
(Either)
MPPT
27. WORKING OF A PWM CONTROLLER
•For the PWM charger working mechanism which
is two stages regulation the controller initially
holds the voltage to the unit of safe maximum
point until the battery gets fully charged.
28. WORKING OF A PWM CONTROLLER
•After that it drops he voltage lower for
sustaining the trickle or finish charge. Two
stage regulations are very important for the
battery which is used now a day. It maintains
full charge but decreases the loss of water and
stress.
29. SPECIFICATIONS OF THIS PRODUCT
•Accurate: The accuracy is maintained by a
digital microcontroller
•User friendly : The system is designed to
PlugnPlay
•Cost efficient
•Energy efficient
33. DC-DC CONVERSION UNIT
• As shown two BOOST Convertor are used in series to
get the desired DC output.
• Boost Convertor–I is used to boost the low voltage
input DC from the panel.
• Boost Convertor–II is used to boost the total
incoming DC voltage from Boost Convertor–I & high
voltage from PV cell.
37. POWER MOSFET (IRF9630)
• FEATURES
• • Dynamic dV/dt rating
• • Repetitive avalanche rated
• • P-channel
• • Fast switching
• • Ease of paralleling
• • Simple drive requirements
• • Material categorization: for definitions of
compliance
38. POWER MOSFET (IRF9630)
• DESCRIPTION Third generation power
MOSFETs from Vishay provide the
designer with the best combination of
fast switching, ruggedized device
design, low on-resistance and cost-
effectiveness. The TO-220AB package is
universally preferred for all commercial-
industrial applications at power
dissipation levels to approximately 50
W. The low thermal resistance and low
package cost of the TO-220AB
39. POWER MOSFET(IRF540)
• FEATURES
• • Dynamic dV/dt Rating
• • Repetitive Avalanche Rated
• • 175 °C Operating Temperature
• • Fast Switching
• • Ease of Paralleling
• • Simple Drive Requirements
• • Compliant to RoHS Directive
2002/95/EC
40. POWER MOSFET(IRF540)
• DESCRIPTION
• Third generation Power MOSFETs
from Vishay provide the designer with
the best combination of fast switching,
ruggedized device design, low on-
resistance and cost-effectiveness. The
TO-220AB package is universally
preferred for all commercial-industrial
applications at power dissipation
levels to approximately 50 W. The low
thermal resistance and low package
cost of the TO-220AB contribute to its
wide acceptance throughout the
industry.
41. METERING AND DISPLAY OF THE CHARGE
CONTROLLERS
•Solar Charge controllers come in various kinds
of displays. The range starts from single red
light displays to digital displays which are used
for displaying the unit of voltage and currents.
42. METERING AND DISPLAY OF THE CHARGE
CONTROLLERS
•These displays are useful for monitoring the
battery charges. This display is also used in the
car which shows the amount of power in and
out of the system. It also indicates the
approximate charge of the battery of your car
and the limit results.
43. TRANSISTOR (BC547)
• BC547 is an NPN bi-polar junction
transistor. A transistor, stands for transfer
of resistance, is commonly used to amplify
current. A small current at its base controls
a larger current at collector & emitter
terminals.
• BC547 is mainly used for amplification and
switching purposes. It has a maximum
current gain of 800.
44. DIODE(1N400
7)
• Features:
• Average forward current is 1A
• Non-repetitive Peak current is 30A
• Reverse current is 5uA.
• Peak repetitive Reverse voltage is 1000V
• Power dissipation 3W
• Available in DO-41 Package
A 11V ZENER DIODE USED IN THIS PRODUCT
45. BATTERY
An electrical battery is a
combination of one or
more electrochemical
cells, used to convert
stored chemical energy
into electrical energy. The
battery has become a
common power source for
many household, robotics
and industrial
46. SOLAR PANEL
Expose the cell to light, and the
energy from each photon (light
particle) hitting the silicon, will
liberate an electron and a
corresponding hole.
47. SOLAR PANEL
•If this happens within
range of the electric field’s
influence, the electrons
will be sent to the N side
and the holes to the P one,
resulting in yet further
disruption of electrical
neutrality
48. SOLAR PANEL
•This flow of electrons is a current
the electrical field in the cell
causes a voltage and the product
of these two is power
49. MICROCONTROLLER (ARDUINO NANO)
• The Arduino Nano is a small, complete, and
breadboard-friendly board based on the
ATmega328 (Arduino Nano 3.x) or
ATmega168 (Arduino Nano 2.x).
• It lacks only a DC power jack, and works with
a Mini-B USB cable instead of a standard
one.The Arduino Nano can be powered via
the Mini-B USB connection, 6-20V
unregulated external power supply (pin 30),
or 5V regulated external power supply (pin
27). The power source is automatically
51. CORE ALGORITHM OF PWM CHARGE
CONTROLLER
for(int i=0;i<150;i++)
{ sample1+=analogRead(A0); //read the input voltage from solar panel
sample2+=analogRead(A1); // read the battery voltage
delay(2);
}
sample1=sample1/150;
sample2=sample2/150;
solar_volt=(sample1*4.673* 3.127)/1000;
bat_volt=(sample2*4.673* 3.127)/1000;
53. SECTIONS OF PWM SOLAR CHARGE
CONTROLLER
1.Voltage sensing
2. PWM signal generation
3. MOSFET switching and driver
4.Filter and protection
5. Display and Indication
6. LOAD On/OFF
54. MOSFET DRIVERS
• A gate driver is a power amplifier that
accepts a low-power input from a
micro controller and produces a
high-current drive input for the gate
of a high-power MOSFET.
• MOSFETs have a large stray
capacitance between the gate and the
other terminals, which must be
charged or discharged each time the
MOSFET is switched on or off. As a
transistor requires a particular gate
voltage in order to switch on, the gate
capacitor must be charged to at least
the required gate voltage for the
transistor to be switched on.
Similarly, to switch the transistor off,
55. MOSFET DRIVERS
• When a transistor is switched on or off, it
does not immediately switch from a non-
conducting to a conducting state; and
may transiently support both a high
voltage and conduct a high current.
Consequently, when gate current is
applied to a transistor to cause it to
switch, a certain amount of heat is
generated which can, in some cases, be
enough to destroy the transistor.
Therefore, it is necessary to keep the
switching time as short as possible, so as
to minimize switching loss
• Therefore the circuit that drives the gate
terminal should be capable of supplying
a reasonable current so the stray
56. CONCLUSION
•In future, we will have to depend on renewable
energy. The only source available around us is
sunlight, and we can easily convert sunlight energy
into electrical energy by using PV cells to meet our
requirement.
•However to extend use of solar power energy to
industrial and commercial areas, the price of PV
cells need to be brought down through low-cost
57. CONCLUSION
By using the solar energy power generation
technology the usage of nonconventional
resources can be minimized which not only
reduces the resource extinction but helps widely
in reducing the environmental pollution.
58. FUTURE SCOPE OF WORK
Its still costly for large scale solar photovoltaic system installation
So what we can do is try to develop hybrid solar charge controller
which can work in PWM and MPPT both mode based upon preference.
o It will reduce cost because some electronics components like
display, microcontroller and sensor will be common for PWM
and MPPT circuitry both.
