Arduino Solar Charge Controller ( Version 2
January 7, 2017 | Author: Thirumal Valavan | Category: N/A
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Bio: I am an Electrical Engineer.I love to harvest Solar Energy and make things by recycling old stuffs. I believe ";";IF YOU TRY YOU MIGHT ... More » (/member/deba168/) (/file/FBYCOOXI1OU2JHH/)
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[ Play Video ] (https://youtu.be/joWzuFZGZcE) One year ago, I began building my own solar system to provide power for my village house.Initially I made a LM317 based charge controller and an Energy meter for monitoring the system.Finally I made PWM charge controller.In April 2014 I posted my PWM solar charge controller designs on the web,it became very popular. Lots of people all over the world have built their own. So many students have made it for their college project by taking help from me.I got several mails every day from people with questions regarding hardware and software modification for different rated solar panel and battery. A very large percentage of the emails are regarding the modification of charge controller for a 12Volt solar system. You can see my other version charge controllers ARDUINO MPPT SOLAR CHARGE CONTROLLER ( Version3.0) (http://www.instructables.com/id/ARDUINOSOLARCHARGECONTROLLER Version30/) ARDUINO SOLAR CHARGE CONTROLLER (Version1) (http://www.instructables.com/id/ARDUINOSOLARCHARGECONTROLLER PWM/) To solve this problem I made this new version charge controller so that any one can use it without changing the hardware and software. I combine both the energy meter and charge controller in this design. Specification of version2 charge controller : 1.Charge controller as well energy meter 2. Automatic Battery Voltage Selection (6V/12V) 3.PWM charging algorithm with auto charge set point according to the battery voltage 4.LED indication for the state of charge and load status 5. 20x4 character LCD display for displaying voltages,current,power,energy and temperature. 6.Lightning protection 7.Reverse current flow protection 8.Short Circuit and Over load protection 9. Temperature Compensation for Charging
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Arduino (/howto/Arduino/)
PWM (/howto/PWM/)
Solar (/howto/Solar/)
Charge Controller (/howto/Charge%20Controller/) Energy (/howto/Energy/) Current (/howto/Current/)
Power (/howto/Power/) LCD (/howto/LCD/)
Battery (/howto/Battery/)
Related ARDUINO SOLAR CHARGE CONTROLLER (Version1) (/id/ARDUINOSOLAR CHARGECONTROLLER (/id/ARDUINOPWM/) ARDUINO ENERGY METER (/id/ARDUINOENERGY METER/) by deba168 (/id/ARDUINO(/member/deba168/) ARDUINO MPPT SOLAR CHARGE CONTROLLER (Version3.0) (/id/ARDUINO SOLARCHARGE (/id/ARDUINOCONTROLLERVersion30/) DIY Portable Solar Powerbank (w/ 110v Outlets & USB Ports) (/id/SlimPanel/) by ASCAS (/member/ASCAS/) (/id/SlimPanel/) Solar Powered Laptop Charger Using MPPT (/id/SolarPoweredLaptop ChargerUsingMPPT/) by inaliwahane (/id/Solar
Electrical specifications : 1.Rated Voltage= 6v /12V 2.Maximum current = 10A 3.Maximum load current =10A 4.Open Circuit Voltage = 811V for 6V system /15 25V for 12V system
Step 1: Parts and Tools Required :
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Parts: 1.Arduino Nano (Amazon ( http://goo.gl/YeeYce) / eBay (http://www.ebay.com/itm/USBNanoV30ATmega32816M5VMicrocontroller CH340GboardForArduino/311064700128? pt=LH_DefaultDomain_0&hash=item486ce6a4e0)) 2.PMOSFET ( Amazon ( http://goo.gl/OR0Ttu) / IRF 9540 (http://www.ebay.com/itm/5xIRF9540PChannelPowerMOSFET23A100V TO220IR/201161974643?pt=LH_DefaultDomain_0&hash=item2ed6302373)
x2 ) 3.Power diode ( Amazon ( http://goo.gl/vuKhTm ) / MBR 2045 (http://www.ebay.com/itm/2pcsMBRF2045CTMBR2045DIODESCHOTTKY 45V20ATO220/181383569951? pt=LH_DefaultDomain_0&hash=item2a3b4da21f) for 10A and IN5402 for 2A) 4.Buck Converter ( Amazon (http://goo.gl/yzkorW) / eBay (http://www.ebay.com/itm/310683416079? _trksid=p2060778.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT)) or Voltage Regulator (LM7805 (http://www.ebay.com/itm/5PcsLM7805L78057805TO220 VoltageRegulatorIC/130747602965?pt=LH_DefaultDomain_0&hash=item1e712a1815)) 5.Temperature Sensor( Amazon (http://goo.gl/xHmZ5A) / LM35 (http://www.ebay.com/itm/LM35DZLM35TO92NSCTEMPERATURE SENSORIC/130952243512? pt=LH_DefaultDomain_0&hash=item1e7d5ca938)) 6.Current Sensor ( Amazon (http://goo.gl/xHmZ5A)/ ACS712 (http://www.ebay.com/itm/Newdesign20ArangeCurrentSensorModule ACS712ModuleArduinomoduleACS712T/181026550196? pt=LH_DefaultDomain_0&hash=item2a2605f1b4)) 7.TVS diode ( Amazon ( http://goo.gl/VFHgWD) / P6KE36CA (http://www.ebay.com/itm/P6KE36TVSDO15P6KE36CAE3 54/231357840535? pt=FR_YO_MaisonJardin_Bricolage_ElectroniqueComposants&hash=item35de 007c97)) 8.Transistors ( 2N3904 (http://www.ebay.com/itm/10pcs2N3904TRANSISTORNPN 40V200mATO92/180847922895?pt=LH_DefaultDomain_0&hash=item2a1b604ecf) or 2N2222) 9.Resistors( 100k x 2, 20k x 2,10k x 2,1k x 2, 330ohm x 5) 10.Ceramic Capacitors (0.1uF x 2) 11.Electrolytic Capacitors ( 100uF and 10uF) 12. 20x4 I2C LCD ( Amazon (http://goo.gl/NUSqdE) / eBay (http://www.ebay.com/itm/IICI2CTWISPISerialInterface200420X4 CharacterLCDModuleDisplayBlue/310575296583? pt=LH_DefaultDomain_0&hash=item484fbaf047)) 13.RGB LED ( Amazon (http://goo.gl/Fw1U82) / ebay (http://www.ebay.com/itm/20pcsUltraBright5mm4pinRGBDiffused CommonAnodeLEDRedGreenBlue/181306473181? pt=LH_DefaultDomain_0&hash=item2a36b53add)) 14.Bi Color LED ( Amazon (http://goo.gl/EHKC5Y) ) 15.Jumper Wires/Wires(eBay (http://www.ebay.com/itm/40PCSDupontwire jumpercables20cm254MMmaletomale1P1PFor Arduino/181012025872?pt=LH_DefaultDomain_0&hash=item2a25285210)) 16.Header Pins (Male (http://www.ebay.com/itm/10PCS40Pin254mmSingle RowStraightMalePinHeaderStripPBCArdunio/180974247480? pt=LH_DefaultDomain_0&hash=item2a22e7de38),Female (http://www.ebay.com/itm/10PCS40Pin254mmSingleRowStraightFemale PinHeaderStripPBCArdunio/180974322541? pt=LH_DefaultDomain_0&hash=item2a22e9036d) and right angle (http://www.ebay.com/itm/10Pcs40Pin254mmSingleRowRightAnglePin HeaderStrip/130766517822? pt=LH_DefaultDomain_0&hash=item1e724ab63e))
17.Heat Sink ( Amazon (http://goo.gl/L4rnic) / eBay (http://www.ebay.com/sch/i.html? _odkw=smallheat+sink&_from=R40%7CR40%7CR40%7CR40%7CR40%7CR4 0%7CR40%7CR40%7CR40%7CR40%7CR40%7CR40%7CR40%7CR40%7CR 40%7CR40%7CR40&_osacat=0&_from=R40&_trksid=p2045573.m570.l1313.T R0.TRC0.H0.Xsmall+heat+sink&_nkw=small+heat+sink&_sacat=0)) 18.Fuse Holder and fuses ( Amazon (http://goo.gl/nDureh) / eBay (http://www.ebay.com/itm/5pcsPanelMountPCBFuseHolderCasewCover 5x20mm/181436161574?pt=LH_DefaultDomain_0&hash=item2a3e701e26)) 19.Push Button ( Amazon (http://goo.gl/QPXwuM)) 20.Perforated Board (Amazon (http://goo.gl/WdRs2x) / eBay (http://www.ebay.com/itm/10pcsDIYPrototypePaperPCBUniversalBoard79 cm79cmM27/121343437457? pt=LH_DefaultDomain_0&hash=item1c40a1ea91)) 21.Project Enclosure 22.Screw terminals ( 3x 2pin (http://www.ebay.com/itm/10pcsx2PinScrew TerminalBlockConnector5mmPitchG/400633791779? pt=LH_DefaultDomain_0&hash=item5d47a28523) and 1x6 pin (http://www.ebay.com/itm/6PinTerminalStrip832Screw/200984426384? pt=LH_DefaultDomain_0&hash=item2ecb9af790)) 23.Nuts/Screws/Bolts 24.Plastic Base Tools : 1.Soldering Iron ( Amazon (http://goo.gl/ZuP1Km) ) 2.Wire Cutter and Stripper ( Amazon (http://goo.gl/JmBxUF) ) 3.Screw Driver ( Amazon (http://goo.gl/1y7cPj) ) 4.Cordless Drill ( Amazon (http://goo.gl/ZWjBXQ)) 5.Dremel ( Amazon (http://goo.gl/ZAgCCZ) ) 6.Glue Gun ( Amazon (http://goo.gl/Tq50x2) ) 7.Hobby Knife ( Amazon (http://goo.gl/SSkTXG))
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Step 2: How The Charge Controller Works :
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The heart of of the charge controller is Arduino nano board.The arduino MCU senses the solar panel and battery voltages.According to this voltages it decides how to charge the battery and control the load. The amount of charging current is determined by difference between battery voltage and charge set point voltages. The controller uses two stages charging algorithm.According to the charging algorithm it gives a fixed frequency PWM signal to the solar panel side pMOSFET. The frequency of PWM signal is 490.20Hz(default frequency for pin3). The duty cycle 0100% is adjusted by the error signal. The controller gives HIGH or LOW command to the load side pMOSFET according to the dusk/dawn and battery voltage. The full schematic is attached bellow.
charge controller version 2.pdf (/files/orig/F2S/BFVU/I8SLPCIY/F2SBFVUI8SLPCIY.pdf)
Step 3: Main functions of solar charge controller: The charge controller is designed by taking care of the following points. 1.Prevent Battery Overcharge: To limit the energy supplied to the battery by the solar panel when the battery becomes fully charged.This is implemented in charge_cycle() of my code. 2.Prevent Battery Over discharge: To disconnect the battery from electrical loads when the battery reaches low state of charge.This is implemented in load_control() of my code. 3.Provide Load Control Functions: To automatically connect and disconnect an electrical load at a specified time. The load will ON when sunset and OFF when sunrise.This is implemented in load_control() of my code.
4.Monitoring Power and Energy : To monitor the load power and energy and display it. 5.Protect from abnormal Condition: To protect the circuit from different abnormal situation like lightening,over voltage,over current and short circuit etc. 6.Indicating and Displaying: To indicate and display the various parameters 7.Serial Communication: To print various parameters in serial monitor
Step 4: Sensing Voltages,Current and temperature :
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1.Voltage Sensor: The voltage sensors are used to sense the voltage of solar panel and battery.It is implemented by using two voltage divider circuits.It consists of two resistors R1=100k and R2=20k for sensing the solar panel voltage ans similarly R3=100k and R4=20k for battery voltage.The out put from the R1and R2 is connected to arduino analog pin A0 and out put from the R3 and R4 is connected to arduino analog pin A1. 2.Current Sensor : The current sensor is used for measuring the load current.later this current is used to calculate the load power and energy.I used a hall effect current sensor (ACS71220A)
3.Temperature Sensor : The temperature sensor is used to sense the room temperature. I used LM35 temperature sensor which is rated for −55°C to +150°C Range. Why Temperature monitoring is Required ? The battery’s chemical reactions change with temperature.As the battery gets warmer, the gassing increases. As the battery gets colder,it becomes more resistant to charging. Depending on how much the battery temperature varies, it is important to adjust the charging for temperature changes.So it is important to adjust charging to account for the temperature effects. The temperature sensor will measure the battery temperature, and the Solar Charge Controller uses this input to adjust the charge set point as required.The compensation value is 5mv /degC/cell for lead acid type batteries.(–30mV/ºC for 12V and 15mV/ºC for 6V battery).The negative sign of temperature compensation indicates,increase in temperature require a reduction in charge set point. For more details on Understanding and Optimizing Battery Temperature Compensation (http://solarprofessional.com/articles/designinstallation/understandingandoptimizingbattery temperaturecompensation)
Step 5: Sensors Callibration Voltage Sensors : 5V = ADC count 1024 1 ADC count = (5/1024)Volt= 0.0048828Volt Vout=Vin*R2/(R1+R2) Vin = Vout*(R1+R2)/R2 R1=100 and R2=20 Vin= ADC count*0.00488*(120/20) Volt Current Sensor: As per seller information for ACS 712 current sensor Sensitivity is =100mV / A =0.100V/A No test current through the output voltage is VCC / 2= 2.5 ADC count= 1024/5*Vin and Vin=2.5+0.100*I (where I=current) ADC count= 204.8(2.5+0.1*I) =512+20.48*I => 20.48*I = (ADC count512) => I =(ADC count/20.48) 512/20.48 Current (I) =0.04882*ADC 25 More details on ACS712 ( http://www.arduinothaishop.com/productdetail.html? id=6827) Temperature Sensor : As per data sheet of LM35 (http://www.ti.com.cn/cn/lit/ds/symlink/lm35.pdf) Sensitivity=10 mV/°C Temp in deg C =(5/1024)*ADC count*100 Note : The sensors are calibrated by assuming the arduino Vcc= 5V reference.But in practical it is not 5V always.So there may be chance of getting wrong value from the actual value.It can be solved by following way.
Measure the voltage between arduino 5V and GND by a multimeter.Use this voltage instead of 5V for Vcc in your code.Hit and try to edit this value until it matches the actual value. Example: I got 4.47V instead of 5V.So the change should be 4.47/1024=0.0043652 instead of 0.0048828.
Step 6: Charging Algorithm
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1.Bulk :At this mode, a preset maximum constant amount of current (amps) is fed into the battery as no PWM is present. As the battery is being charged up , the voltage of the battery increases gradually
2. Absorption: When the battery reaches the bulk charge set voltage, the PWM begins to hold the voltage constant. This is to avoid overheating and over gassing the battery. The current will taper down to safe levels as the battery becomes more fully charged. 3. Float: When the battery is fully recharged, the charging voltage is reduced to prevent further heating or gassing of the battery This is the ideal charging procedure. The present charge cycle block of code is not implements 3 stages charging.I use a easier logic in 2 stages.It works good. I am trying the following logic for implementing the 3 stages charging. Future Planning for Charging Cycle : The bulk charge begins when solar panel voltage is larger than battery voltage. When the battery voltage reaches 14.4V, absorption charge will be entered. The charging current will be regulated by PWM signal to maintain the battery voltage at 14.4V for one hour. Float charge will then enter after one hour. The float stage generates a trickle charge to keep the battery voltage at 13.6V. When the battery voltage falls below 13.6V for 10mins, the charging cycle will be repeated. I request community members to help me for writing the piece of code to implement the above logic.
Step 7: Load Control To automatically connect and disconnect the load by monitoring dusk/dawn and battery voltage,load control is used. The primary purpose of load control is to disconnect the load from battery to protect it from deep discharging. Deep discharging could damage the battery. The DC load terminal is designed for low power DC load such as street light. The PV panel itself is used as the light sensor. Assuming solar panel voltage >5V means dawn and when Battery Status RED > Voltage is LOW GREEN > Voltage is Healthy BLUE > Fully Charged Load LED : A bi color (red/green) led is used for load status indication.Refer the above schematic for connection. Load LED >Load Status GREEN > Connected (ON) RED > Disconnected (OFF) I include a third led for indicating the solar panel status.
Step 11: LCD display
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To display the voltage,current,power,energy and temperature a 20x4 I2C LCD is used.If you do not want to display the parameter then disable the lcd_display() from the void loop() function.After disable you have indication led to monitor the battery and load status. You can refer this instructable for I2C LCD (http://www.instructables.com/id/I2C LCDControllertheeasyway/) Download the LiquidCrystal _I2C library from here (http://LiquidCrystal) Note : In code you have to change the I2C module address.You can use the (/contest/tech2014/) (/contest/micro2014/) address scanner (http://www.instructables.com/id/I2CLCDControllertheeasy ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by way/)code given in the link. deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
Step 12: Bread Board Testing
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It is always a good idea to test your circuit on a breadboard before soldering it together. After connecting everything upload the code.The code is attached bellow. The entire software is broken into small functional block for flexibility.Suppose the user is not interested to use a lcd display and happy with the led indication .Then just disable the lcd_display() from the void loop().Thats all. Similarly according to the user requirement he can enable and disable the various functionality. Download the code from my GitHub Account ARDUINOSOLARCHARGECONTROLLERV2 (https://github.com/deba168/ARDUINOSOLARCHARGECONTROLLERV2)
solar charge controller code.txt
(/contest/tech2014/) (/contest/micro2014/)
(/files/orig/FXU/IHN4/I283QTG2/FXUIHN4I283QTG2.txt) ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
Step 13: Power Supply and Terminals : h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Terminals : Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf) Add 3 screw terminals for solar input,battery and load terminal connections.Then solder it.I used the middle screw terminal for battery connection,left to it is for h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) 26 Steps . solar panel and the right one is for load.
Power Supply:
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In my previous version the power supply for arduino was provided by a 9V battery.In this version the power is taken from the charging battery itself.The battery voltage is step down to 5V by a voltage regulator(LM7805). Solder LM7805 voltage regulator near to the battery terminal.Then solder the electrolytic capacitors as per schematic.At this stage connect the battery to the screw terminal and check the voltage between pin 2 and 3 of LM7805.It should be near to 5V.
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When I used a 6V battery the LM7805 works perfectly.But for 12V battery it heated up after some time.So I request to use a heat sink for it.
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Efficient Power supply : After few testing I found that the voltage regulator LM7805 is not the best way to power the arduino as it waste lots of power in the form heat.So I decide to change it by a DC DC buck converter which is highly efficient.If you plan to make this controller, I advice to use a buck converter rather than LM7805 voltage regulator. Buck Converter Connection: IN+ > BAT+ IN > BAT OUT+ > 5V OUT > GND Refer the above pictures. You
can
buy
it
from
eBay
(http://www.ebay.com/itm/310683416079?
_trksid=p2060778.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT)
Step 14: Mount the Arduino :
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) (/file/F7QK3KMI1OU388V/)
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Cut 2 female header strips of 15 pins each.Place the nano board for reference.Insert the two headers according to the nano pin.Check it whether the nano board is perfect to fit into it.Then solder it back side. Insert two rows of male header on both sides of nano borad for external connections.Then join the solder points between arduino pin and header pins.See the above picture. Initially I forgot to add Vcc and GND headers.At this stage you can put headers with 4 to 5 pins for Vcc and GND. As you can see I connected the voltage regulator 5V and GND to the nano 5V and GND by red and black wire.Later I removed it and soldered at the back side for better look of the board.
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Step 15: Solder the components ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/)
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h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
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Before soldering the components make holes at corners for mounting. Solder all the components as per schematic.
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Apply heat sink to two MOSFETs as well as power diode. Note: The power diode MBR2045 have two anode and one cathode.So short the two anode. I used thick wire for power lines and ground and thin wires for signal.signal. Thick wire is mandatory as the controller is designed for higher current.
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Step 16: Connect the Current Sensor
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After connecting all the components solder two thick wire to the load mosfet's drain and upper terminal of load side fuse holder.Then connect these wires to (/contest/tech2014/) (/contest/micro2014/) the screw terminal provided in current sensor( ACS 712).
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
Step 17: Make the Indication and temperature sensor panel h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) 26 Steps . Collection
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) (/file/FBHGG9ZI1T4BZUD/)
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I have shown two led in my schematic.But I added a third led(bi color) for indicating the solar panel status in future. Prepare small size perforated board as shown.Then make two holes (3.5mm) by drill on left and right( for mounting). Insert the leds and solder it to the back side of the board. Insert a 3 pins female header for temperature sensor and then solder it. Solder 10 pins right angle header for external connection.
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Now connect the RGB led anode terminal to the temperature sensor Vcc(pin1).
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Solder the cathode terminals of two bi color led. Then join the solder points the leds terminal to the headers.You can paste a sticker with pin name for easy identifications.
Step 18: Connections for Charge controller
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by (/file/FPRBCT3I2R9UFYH/) deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf) (/file/FUMR1Z2I28OLTX1/) 26 Steps .
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Connect the Charge Controller to the Battery first, because this allows the Charge Controller to get calibrated to whether it is 6V or 12V system. Connect the negative terminal first and then positive. Connect the solar panel(negative first and then positive) At last connect the load. The charge controller load terminal is suitable for only DC load. How to run an AC Load ? If you want to run AC appliances then you must need an inverter. Connect the inverter directly to the battery.See the above picture.
Step 19: Final Testing :
(/file/FAR5C87I1T4DTJ6/)
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
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(/file/FKE33NUI1T4DVVO/)
(/file/FH50CGCI1T4FG5S/)
After making the main board and indication board connect the header with jumper wires(femalefemale) Refer the schematic during this connection.Wrong connection may damage the circuits.So be care full in this stage.
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Plug the usb cable to the arduino and then upload the code.Remove the usb cable.If you want to see the serial monitor then keep it connected.
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Fuse Rating: In demo I have put a 5A fuse in the fuse holder.But in practical use, put a fuse with 120 to 125% of short circuit current. Example :A 100W solar panel having Isc=6.32A needs a fuse 6.32x1.25 = 7.9 or 8A How to test ?
I used a buck boost converter and black cloth to test the controller.The converter input terminals are connected to battery and the output is connected to the charge controller battery terminal. Battery status :
Rotate the converter potentiometer by a screw driver to simulate different battery voltages.As the battery voltages change the corresponding led will turn off and turn on. Note: During this process Solar panel should be disconnected or covered with a black cloth or card board. Dawn/Dusk : To simulate dawn and dusk use a black cloth.
Night : Cover the solar panel entirely. Day: Remove the cloth from the solar panel. Transition : slow the remove or cover the cloth to adjust different solar panel voltages. Load Control : According to the battery condition and dawn/dusk situation the
load will turn on and off. Temperature Compensation : Hold the temperature sensor to increase the temperature and place any cold things like ice to decrease the temp.It will be immediately displayed on the LCD. The compensated charge set point value can be seen on the serial monitor. In the next step onward I will describe the making of enclosure for this charge controller.
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Step 20: Mounting the main board: ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
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(/file/F0ZH7DTI1TR8N6J/)
(/file/FTK6MITI1TQW9VO/)
(/file/F7RJAHMI1TQVUUC/)
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by (/file/FC99WE3I1TR73UI/) deba168 (/member/deba168/)
(/file/FUXP8X5I1TR73XE/)
(/file/FUBMXS0I1TR73Z9/)
Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf) (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) 26 Steps h . Place the main board inside the enclosure.Mark the hole position by a pencil.
Then apply hot glue to the marking position. Place the plastic base over the glue.
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Then place the board over the base and screw the nuts.
Step 21: Make Space for LCD:
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(/file/FM5ABEHI1TR8SAB/)
(/file/FDMVZFCI1TR75TP/)
(/file/FZGS8HOI1TR7TK4/)
Mark the LCD size on the front cover of the enclosure. Cut out the marked portion by using a dremel or any other cutting tool.After cutting finish it by using a hobby knife. (/contest/tech2014/) (/contest/micro2014/)
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf) Step 22: Drill Holes:
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(/file/FG37J4YI1TR7W5B/)
(/file/FAGWJPXI1TR7WGR/)
(/file/FE0AYXII1TR7WU4/)
Drill holes for mounting the LCD,Led indication panel,Reset button and external terminals (/contest/tech2014/) (/contest/micro2014/)
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Step 23: Mount Everything: Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
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(/file/F3HCNA3I1TR7Z0X/)
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(/file/FJCGY2LI1TR8XCT/)
After making holes mount the panels, 6 pin screw terminal and reset button.
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Step 24: Connect the External 6 pin terminal :
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(/file/FDF4U2FI1TR84UE/)
(/file/FWACZ2RI1TR87TD/)
(/file/FVIWO4UI1TR86BO/)
(/file/FF8DHZCI1TR87CD/)
For connecting the solar panel,battery and load a external 6pin screw terminal is used. Connect the external terminal to the corresponding terminal of the main board.
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Step 25: Connect the LCD, Indicator panel and Reset Button : by ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
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(/file/FFR69N4I1TR8W27/)
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) (/file/F5T3JR8I1TR8C9T/)
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Connect the indicator panel and LCD to the main board as per schematic.(Use femalefemale jumper wires) One terminal of the reset button goes to RST of Arduino and other goes to GND. After all connections.Close the front cover and screw it.
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Step 26: Ideas and Planning
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(/file/FPUS4KYI1XEL2M8/)
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ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
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How to plot real time graphs ? It is very interesting, if you can plot the serial monitor parameters (like battery and solar voltages) on a graph on your laptop screen.It can be done very easily, if you know little bit on Processing. To know more you can refer Arduino and Processing ( Graph Example ). (http://arduining.com/2013/08/05/arduinoandprocessinggraphexample/)
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How to save that data ?
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This can be done easily by using SD card but this include more complexity and cost.To solve this I searched through internet and found a easy solution.You can save data in Excel sheets. For details you can refer seeingsensorshowtovisualizeandsavearduinosenseddata (http://www.dustynrobots.com/news/seeingsensorshowtovisualizeandsavearduino senseddata/)
The above pictures downloaded from web.I attached to understand what I want to do and what you can do. Future Planning : 1. Remote data logging via Ethernet or WiFi. 2. More powerful charging algorithm and load control 3.Adding a USB charging point for smart phone/tablets Hope you enjoy my instructables. Please suggest any improvements.Raise a comments if any mistakes or errors. Follow me for more updates and new interesting projects. Thanks :)
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Collection Hspedro (/member/Hspedro)
8 days ago
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i had build your desing and code into a Solar System I'm also using a 3000w Inverter to power a fridge but now I'm looking Into getting the Arduino controler to switch Between ac solar and grid ac when the Batteries are drained to a dafe low Level and keep my fridge running un interructed... Any sugestión i was thinking using triacs to accomplish the switch over?
rajat.kalyan.54 (/member/rajat.kalyan.54)
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Reply The problem that i am facing is that whenever the mosfet a month ago q1 turns on the panel gets connected to the voltage divider circuit of the battery and then it first measures the panel voltage excluding the drop and shows full charged battery and blue led turns on and after that it measures the battery voltage and shows the battery status.Is it normal or there is some problem .Reply Please.All in all it was a great project :).
IchsanA4 (/member/IchsanA4)
a month ago
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good project ! can u give me another substitute for tvs diode and mbr diode ? because i cant find it in my city thank you
DavidW385 (/member/DavidW385)
2 months ago
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What are the full complete values for the ceramic capacitors? I'm on mouser.com and I've set the .1uF value but what about the rest of the values: Voltage Rating DC, Dieletric, Tolerance, Diameter, Lead Spacing, Minimum Operating Temp, Maximum Operating Temp, and Series?
Mohd ZainolZ (/member/Mohd ZainolZ)
2 months ago
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Can i use this charger controller circuit for a dynamo to charge a SLA battery ?
lane5625 (/member/lane5625)
2 months ago
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Do you have any reference voltages to test the circuit? I'm getting incorrect voltages displayed for the battery and the solar panel.
kvoos (/member/kvoos)
2 months ago
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Your instructables are great. I so appreciate your hard work in design, implementation and in explaining things so well. I am hoping to build this one to run a garden stream project I have in mind. Maybe combine w/ ESP8266 to get status of the setup on the web. Did you ever get someone to help write the multistage charging cycle? I may be able to help with the code, I am better at the software than the hardware ;) (/contest/tech2014/) (/contest/micro2014/)
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) Do you have any references for the threestage charging showing the benefits? by deba168 (/member/deba168/) I watched the video of the 8stage charging and could see how the pulsing and
reconditioning cycles (not part of the 3stages you are proposing) could help Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
(not that I am a battery expert). If there are no references, I guess we could just
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) do it and write up the results!
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deba168 (/member/deba168) (author) . kvoos (/member/kvoos)
Thanks for your valuable words.
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2 months ago
If you can help me to write the software, we can make a better version of controller. Instead of 3 stages we should try 4 stages charging.I think most of the commercial charge controller are 4 stages. You can use these references
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https://www.batterystuff.com/blog/3stagesofsmar... (https://www.batterystuff.com/blog/3stagesofsmartchargers.html) http://batteryuniversity.com/learn/article/chargin... (http://batteryuniversity.com/learn/article/charging_the_lead_acid_battery) http://www.batterytender.com/BatteryBasics/ (http://www.batterytender.com/BatteryBasics/)
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For further discussion you can pm me.I have designed a new hardware set up also.
BurraakK (/member/BurraakK)
a year ago
Reply
As you mentioned in bulk stage 10A current would be fed into batteries wich means your design will handle small or large batteries equally which is bad for battery health, For small batteries 30% and for large batteries only 10% current of the total capacity is recomended , for example if someone is using 12v 7ah battery then total charging current should not exceed 2 amp,
X | 8
Volthaus Electronics Laboratory (/member/Volthaus Electronics Laboratory) 3 months ago Reply . BurraakK (/member/BurraakK)
Good point. Making the amperage output adjustable to meet the required protocol would be a good idea and probably not difficult to implement.
MuhammadH36 (/member/MuhammadH36) made it!
6 months ago
Reply
Sir i using a 5watt solar panel and 12volt battery. In my case I got a negative Energy and ampere. Now I have check the connection that's all ok, I had try to fine the error but I don't no what are the error. Please help me.
(http://cdn.instructables.com/F13/6A9T/IJEMPTXF/F136A9TIJEMPTXF.LARGE.jpg) (/contest/tech2014/) (/contest/micro2014/)
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
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nasruls (/member/nasruls) . MuhammadH36 (/member/MuhammadH36)
im on the same boat as you guys,does anyone found the solution for the sign,pls update.Thank you
X | 8
deba168 (/member/deba168) (author) . nasruls (/member/nasruls)
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3 months ago
Reply
3 months ago
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Hey, I think it is due to wrong calibration of current sensor (ACS712) All the calculation are based on arduino vcc ( 5V) but in practical it is not 5V.As the the current (amps) reading is difference between actual adc reading and offset (which is Vcc/2 ), there may be chance of gettimng negative reading.
nasruls (/member/nasruls) . deba168 (/member/deba168) 3 months ago
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thanks for the reply,i will check it and update here.Anyway 1000 thanks for your guidance for this project,really easy to understand,well explained.
extrafried (/member/extrafried) . MuhammadH36 (/member/MuhammadH36)
Have you tried using a multimeter to test the direction of the current?
3 months ago
Reply
Perhaps you need to swap the cables in the current sensor. The ACS712 is bidirectional.
mark kennethc (/member/mark kennethc) . MuhammadH36 (/member/MuhammadH36)
4 months ago
Reply
may be the code hehe
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ArifSae (/member/ArifSae) . MuhammadH36 (/member/MuhammadH36)
found any solution ?
Reply
4 months ago
fahmiwak (/member/fahmiwak) . MuhammadH36 (/member/MuhammadH36)
same problem with me. i don't know how to solve it
MicahD1 (/member/MicahD1)
6 months ago
Reply
3 months ago
Reply
Epic guide Deba, Well documented and explains everything for a beginner (me), no need for(/contest/tech2014/) (/contest/micro2014/)
questions I just read it twice and its all there! ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/)
Many thanks.
Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) X | 8
26 Steps . deba168 (/member/deba168) (author) . MicahD1 (/member/MicahD1) Reply I Made it! Collection 3 months ago
Glad you like it.
Thanks for your appreciation.
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3 months ago
This is a great and careful project..... thanks for doing a lot of explaining.
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My pleasure :)
3 months ago
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deba168 (/member/deba168) (author) . tumwesigyea (/member/tumwesigyea)
X | 8
deba168 (/member/deba168) (author) . tumwesigyea (/member/tumwesigyea)
3 months ago
My pleasure :)
My pleasure :)
BrandonR62 (/member/BrandonR62)
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3 months ago
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3 months ago
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Will this work for 4 12v 85w panels?
X | 8
|
deba168 (/member/deba168) (author) . BrandonR62 (/member/BrandonR62)
It is suitable up to 100W /12V panel.
Dashing Rainbow Dash (/member/Dashing Rainbow Dash)
3 months ago
Reply
4 months ago
Reply
I was wondering. How could this be modified with a low voltage cutoff? I know a relay or a mosfet ais in order, but what would need to be changed in the code?
CHETHAN KUMARB (/member/CHETHAN KUMARB)
4 months ago
Reply
Sir i tried to upload the code u have mentioned in the project but i am not getting any output in serial monitor even though no error in compiling can you tell me why so..
mark kennethc (/member/mark kennethc) made it!
4 months ago
Reply
Hello sir can i use 100 watts 12volts solar panel.. and also we are guided in project 2 charge up 3 electronic devices and 1 a.c devices.. does i work with this schematic? is there will be any changes? (/contest/tech2014/) (/contest/micro2014/)
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf)
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
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MortezaA5 (/member/MortezaA5)
4 months ago
How supply arduino power when the battery is empty or in first use is dead??! Is there any better idea for supplying arduino power?
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ArifSae (/member/ArifSae)
4 months ago
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Thankyou for sharing, a great resource. In process of building one myself, this tutorial is a good reference.
asrianpane (/member/asrianpane)
9 months ago
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Hi sir why you choose arduino? why you don't use another microcontroller? thanks
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ArifSae (/member/ArifSae) . asrianpane (/member/asrianpane)
i guess because its most beginner friendly
X | 8
Reply
4 months ago
deba168 (/member/deba168) (author) . asrianpane (/member/asrianpane)
I am much comfortable with Arduino platform.
Reply
7 months ago
You can use other
X | 8
deba168 (/member/deba168) (author) . asrianpane (/member/asrianpane)
I am much comfortable with Arduino platform.
Reply
7 months ago
You can use other :)
X | 8
deba168 (/member/deba168) (author) . asrianpane (/member/asrianpane)
I am much comfortable with Arduino platform.
Reply
7 months ago
You can use other :)
X | 8
deba168 (/member/deba168) (author) . asrianpane (/member/asrianpane)
I am much comfortable with Arduino platform.
Reply
7 months ago
You can use other :) (/contest/tech2014/) (/contest/micro2014/)
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by deba168 (/member/deba168/) CrankyCoderBlog (/member/CrankyCoderBlog)
5 months ago
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Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf) In this circuit you use the voltage regulators, which from what I understand
dissipates the excess power at heat. Is there any reason to not use a buck 26 Steps . converter?
h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/)
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ArifSae (/member/ArifSae) . CrankyCoderBlog (/member/CrankyCoderBlog)
he later said to have done it. indeed linear regulator waste a lot of energy
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5 months ago
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hello sir,i,m still new in adruino..i have question,can i add program to control solar panel tracker to same adruino uno for thos solar charge controller..and can this version 2 i add usb for charge hphone
meetmithilesh (/member/meetmithilesh)
6 months ago
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hello sir, can we use any other micro controller IC instead of Arduino nano keeping your code and other components same, as auduino ic costs higher...if yes pls inform which ic & how can we feed the code in it...
X | 8
deba168 (/member/deba168) (author) . meetmithilesh (/member/meetmithilesh)
Hi,
6 months ago
Reply
You can use Atmega328 microcontroller instead of Nano.Just search how to use Atmega328 as an Arduino, there are lot of tutorials on it.
kalusharma (/member/kalusharma) . deba168 (/member/deba168)
hello sir ji please help you.arduino solar charger error aa rha h please help?
fritzstoop (/member/fritzstoop)
Reply
5 months ago
5 months ago
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6 months ago
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What is the cap values? what volts?
AronuC (/member/AronuC)
hello sir, please what is the power rating and energy of the solar charge controller you built and how did u calculate it.
Afzal cassim (/member/Afzal cassim)
6 months ago
Reply
Thanks!
James EduardA (/member/James EduardA)
8 months ago
(/contest/tech2014/) (/contest/micro2014/) Reply
ARDUINO SOLAR CHARGE CONTROLLER ( Version 2.0) by Can we use arduino uno r3 here? deba168 (/member/deba168/)
Download (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/?download=pdf) 26 Steps deba168 (/member/deba168) (author) . James EduardA (/member/James EduardA) X h (/id/ARDUINOSOLARCHARGECONTROLLERVersion20/) .
| 8
Yeah you can use
7 months ago Collection
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James EduardA (/member/James EduardA) . deba168 (/member/deba168)
we already purchase the arduino nano, can you give me updated source code and how to's
7 months ago
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James EduardA (/member/James EduardA) . James EduardA (/member/James EduardA)
7 months ago
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im getting this error thanks
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http://prntscr.com/9olwmr
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