Diagram for Reference

The use of solar photovoltaic (PV) energy sources is increasing due to global warming concerns on the one hand, and cost effectiveness on the other. Many engineers involved in power electronics find solar power tempting and then addictive due to the ‘green’ energy concept. The circuit discussed here handles up to 4 amps of current from a solar panel, which equates to about 75 watts of power. A charging algorithm called ‘pulse time modulation’ is introduced in this design. The current flow from the solar panel to the battery is controlled by an N-channel MOSFET, T1. This MOSFET does not require any heat sink to get rid of its heat, as its RD-S(on) rating is just 0.024 Ω.

Schottky diode D1 prevents the battery discharging into the solar panel at night, and also provides reverse polarity protection to the battery. In the schematic, the lines with a sort-of-red highlight indicate potentially higher current paths. The charge controller never draws current from the battery—it is fully powered by the solar panel. At night, the charge controller effectively goes to sleep. In daytime use, as soon as the solar panel produces enough current and voltage, it starts charging the battery. The battery terminal potential is divided by resistor R1 and trimpot P1.

4 Amps Photovoltaic (Solar) Charge Controller Circuit Diagram

The resulting voltage sets the charge state for the controller. The heart of the charge controller is IC1, a type TL431ACZ voltage reference device with an open-collector error amplifier. Here the battery sense voltage is constantly compared to the TL431’s internal reference voltage. As long as the level set on P1 is below the internal reference voltage, IC1 causes the MOSFET to conduct. As the battery begins to take up the charge, its terminal volt- age will increase. When the battery reaches the charge-state set point, the output of IC1 drops low to less than 2 volts and effectively turns off the MOSFET, stopping all current flow into the battery.


With T1 off, LED D2 also goes dark. There is no hysteresis path provided in the regulator IC. Consequently, as soon as the current to the battery stops, the output of IC1 remains low, preventing the MOSFET to conduct further even if the battery voltage drops. Lead-acid bat- tery chemistry demands float charging, so a very simple oscillator is implemented here to take care of this. Our oscillator exploits the negative resistance in transistors—first discovered by Leo Esaki and part of his studies into electron tunneling in solids, awarded with the Nobel Prize for Physics in 1973. In this implementation, a commonplace NPN transistor type 2SC1815 is used.

When the LED goes out, R4 charges a 22-μF capacitor (C1) until the voltage is high enough to cause the emitter-base junction of T2 to avalanche. At that point, the transistor turns on quickly and discharges the capacitor through R5. The voltage drop across R5 is sufficient to actuate T3, which in turn alters the reference voltage setting. Now the MOSFET again tries to charge the battery. As soon as the battery voltage reaches the charged level once more, the process repeats. A 2SC1815 transistor proved to work reliably in this circuit. Other transistors may be more temperamental—we suggest studying Esaki’s laureate work to find out why, but be cautioned that there are Heavy Mathematics Ahead.

As the battery becomes fully charged, the oscillator’s ‘on’ time shortens while the ‘off’ time remains long as determined by the timing components, R4 and C1. In effect, a pulse of current gets sent to the battery that will shorten over time. This charging algorithm may be dubbed Pulse Time Modulation. To adjust the circuit you’ll need a good digital voltmeter and a variable power supply. Adjust the supply to 14.9 V, that’s the 14.3 volts bat- tery setting plus approximately 0.6 volts across the Schottky diode.

Turn the trimpot until at a certain point the LED goes dark, this is the switch point, and the LED will start to flicker. You may have to try this adjustment more than once, as the closer you get the comparator to switch at exactly 14.3 V, the more accurate the charger will be. Disconnect the power supply from the charge controller and you are ready for the solar panel. The 14.3 V setting mentioned here should apply to most sealed and flooded-cell lead-acid batter- ies, but please check and verify the value with the manufacturer. Select the solar panel in such a way that its amps capability is within the safe charging limit of the battery you intend to use.


Resistors:
R1 = 15kΩ
R2,R3 = 3.3kΩ 1% R4 = 2.2MΩ
R5 = 1kΩ
P1 = 5kΩ preset

Capacitors:
C1 = 22μF 25V, radial

Semiconductors:
D1 = MBR1645G (ON Semiconductor) D2 = LED, 5mm
IC1 = TL431ACLP (Texas instruments)
T1 = IRFZ44NPBF (International Rectifier)
T2 = 2SC1815 (Toshiba) (device is marked: C1815)
T3 = BC547

Miscellaneous:
K1,K2 = 2-way PCB terminal block, lead pitch 5mm

Some of you might wonder why a charger is needed at all, to charge a 12 Volt battery from a 12 Volt source! Well, firstly the "12 Volt" source will typically vary anywhere from 11 Volt to 15 Volt, and then a battery needs a controlled charge current and voltage, which cannot result from connecting it directly to a voltage source. The charger described here is intended for charging small 12 Volt lead acid batteries, such as the gelled or AGM batteries of capacities between about 2 and 10 Ah, using a cars electrical system as power source, regardless of whether the car engine is running or not.



I built this charger many years ago, I think I was still in school back then. On request of a reader of my web site, Im publishing it now, despite being a rather crude circuit. It works, it is uncritical to build, and uses only easy-to-find parts, so it has something in its favor. The downside is mainly the low efficiency: This charger wastes about as much power as it puts into the battery. The charger consists of two stages: The first is a capacitive voltage doubler, which uses a 555 timer IC driving a pair of transistors connected as emitter followers, which in turn drive the voltage doubler proper.



The doubler has power resistors built in, which limit the charging current. The second stage is a voltage regulator, using a 7815 regulator IC. Its output is applied to the battery via a diode, which prevents reverse current and also lowers the voltage a bit. The resulting charge voltage is about 14.4V, which is fine for charging a gelled or AGM battery to full charge, but is too high as a trickle charger, so dont leave this charger permanently connected to a battery.

If you would like to do just that, then add a second diode in series with D3! There is a LED connected as a charge indicator. It will light when the charge current is higher than about 150mA. The maximum charge current will be roughly 400mA. There is an auxiliary output, that provides about 20V at no load (depending on input voltage), and comes down as the load increases. I included this for charging 12V, 4Ah NiCd packs, which require just a limited current but not a limited voltage for charging.



Note that if the charge output is short-circuited, the over-current protection of U2 will kick in, but the current is still high enough to damage the diodes, if it lasts. So, dont short the output! If instead you short the auxiliary output, the fuse should blow. I built this charger into a little homemade aluminum sheet enclosure, using dead-bug construction style. Not very tidy, but it works. Note the long leads on the power resistors. They are necessary, because with shorter leads the resistors will unsolder themselves, as they get pretty hot! The transistors and the regulator IC are bolted to the case, which serves as heat sink. The transistors dont heat up very much, but the IC does.

It is the time when the shipment of phone booster has been arranged.
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Switch on the power supply of phone booster

This Wien bridge oscillator (after Max Wien, 1866–1938) produces a low-distortion sine wave of constant amplitude, from about 15 Hz to 150 kHz. It requires just four opamps and will work off a single 9-volt battery. Also, unlike most Wien bridge oscillators, it does not require a dual-gang potentiometer for tuning. Op amp IC2b provides an artificial ground so that the circuit will operate from a unipolar supply (9 V battery or power pack). IC2a is the main amplifier for the oscillator. The frequency range is divided into four decades by 2-pole, 4-way rotary switch SW1.

Only one arm of the Wien network is varied, but the change in positive feedback that would normally result is compensated for by IC1b, which works to bootstrap R2, thereby changing the negative feedback enough to maintain oscillation. A linear change in the resistance of the tuning pot results in a roughly logarithmic change in frequency. To get a more conventional linear change a log-taper pot is used wired so that rotating the knob anticlockwise causes frequency to increase.


You could use an anti-log pot the other way around if you prefer, but these things are notoriously hard to find. IC1A is an integrator that monitors the amplitude of the output signal and drives an LED (D2). This must be mounted facing the LDR (light dependent resistor) and shielded from ambient light (for example, with a piece of heat-shrink tubing). IC1a is then able to control the gain of IC2a so that oscillation is maintained with minimum distortion.

The maximum output amplitude of the generator is about 2 Vp-p when the LED and LDR are mounted as close as possible. Distortion is less than 0.5 % in the lowest range, and too low for the author to measure in the higher ranges. Any LDR should work, provided its dark resistance is greater than 100 kO. If you do not have an LDR with such high resistance, try increasing R5 until oscillation starts. Breadboarded prototypes of the circuit were built by the author using dual and quad opamp packages, and both work equally well.

Author: Merlin Blencowe (Elektor)

Resistors:
R1,R2,R3,R6,R10,R11 = 10kO
R7 = 100kO
R4,R9,R12 = 100O
R5 = 12kO
R8 = 1kO
P1,P2 = 10kO potentiometer, logarithmic law
R13 = LDR, R(dark) >100kO, e.g. Excelitas Tech type
VT90N1 (Newark/Farnell # 2568243)

Capacitors:
C1,C5 = 1µF solid
C2,C6 = 100nF
C3,C7 = 10nF
C4,C8 = 1nF
C9-C12 = 47µF 16V, electrolytic, radial

Semiconductors:
D1,D2,D3 = 1N4148
D4 = LED, red, 5mm
IC1,IC2 = TL072ACP

Miscellaneous:
SW1 = 2-pole 4-position rotary switch, C&K Compo-
nents type RTAP42S04WFLSS
K1,K2 = PCB terminal block, 5mm pitch

Some cell phone jammer do not own the cooling function or cooling mechanism.
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