ACKNOWLEDGEMENT

We acknowledge our Project guide, Mrs .Mini Shreejath for the guidance and valuable
suggestions during the entire course of the Mini Project titled Battery Charger Circuit Using
SCR.

We also acknowledge with thanks Prof. Madhusudan Singh, Head of the Department of
Electrical Engineering for the support and facilities in the labs.

We record our thanks to our friends in our class for interaction and help during the course of
the Minor Project.

ANKIT CHAURASIA

AMARTYA SISODIA

ARMAAN MALIK

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 7

ABSTRACT
A circuit for battery charging includes an SCR that is periodically gated on for a duration
corresponding to the state of charge of the battery, being gated on for a duration
corresponding to the state of charge on the battery being the gated for only a short interval
when the battery is essentially fully charged to keep it charged. The conduction angle is
determined from the open circuited battery potential and the previous charging history of the
battery obtained from potential sensing circuits. A pedestal and cosine modified ramp circuit
triggers the SCRs through capacitors with a resistor inter coupling the SCR gate and cathode
electrodes. Circuitry prevents the uni-polar junction transistor in the latter circuit from
remaining latched on. A potential circuit for determining the rate of charge includes a resistor
connected to the output terminal that is bypassed when the average value of the signal
connected on the collector of the transistor having the base connected to the output terminal
having a predetermined value. Diodes inter-couple the SCRs and the emitter of the latter
transistor for providing operating potential to the circuits and the starting charging current to
the output terminal when a connected battery is fully discharged.

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[Type text] Page 3
 CONTENTS

Chapter No. Topic Pg. No.

List of figure i
Abbreviation and symbols ii

Chapter 1 Introduction 01

Chapter 2 Problem Definition & Objective 03

Chapter 3 Literature Survey 04

Chapter 4 Tool to be Used 14

Chapter 5 Conclusion 15

References 16

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List of figure

Block Diagram of Battery Charger Using SCR Fig 1.1

Block Diagram of Wind Power System Fig 3.2

Circuit Diagram for Charge Controller Fig 3.4

Circuit Diagram Fig 4.2

SCR Symbol Fig 4.2(a)

SCR in Forward and Reverse Characteristics Fig 4.2(b)

Bottom Layout Fig 4.4(a)

Real World Fig 4.4(b)

Transformer Fig 4.3.1

Diode Fig 4.3.2

BJT Fig 4.3.3

Resistor Fig 4.3.4

Fuse Fig 4.3.5

Copper plated PCB Fig 5.2

PCB Drilling machine Fig 5.3

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Chapter 1
INTRODUCTION
The battery is charged with small amount of AC voltage or DC voltage. So if you want to
charge your battery with AC source then should follow these steps, we need first limit the
large AC voltage, need to filter the AC voltage to remove the noise, regulate and get the
constant voltage and then give the resulting voltage to the battery for charging. Once charging
is completed the circuit should automatically turned off.

1.1. Block Diagram of Battery Charger Using SCR:

Fig 1.1(a) :Block Diagram of Battery Charger Using SCR

The AC source is given to the step down transformer which converts the large AC source into
limited AC source, filter the AC voltage and remove the noise and then give that voltage to
the SCR where it will rectify the AC and give the resulting voltage to the battery for charging.

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Chapter 2
PROBLEM DEFINITION AND OBJECTIVE
The Battery Charger Using SCR is very safe and reliable over normal charger. The stability
of the circuit is high. There is gradual decreasing of current according to the load of battery.
The design is tough and durable. It shows a very low variation of output voltage versus input
voltage. There is full charge time optimisation along with full automatic operation. Although
very economic these chargers have very important features including quality of dc output
signal, full rate power and quick adjustment. The control circuit protects your battery
surcharge and limits the output current under short circuit conditions.

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Chapter 3

LITERATURE SURVEY

Implementation of Wind Turbine Controller Design for Smart Campus

3.1 ABSTRACT
This paper resents the design and construction of charge controller for wind energy source.
The charge controller is a small prototype that is suitable to charge small battery. The
maximum charging current of the charge controller is about 7 A. The charge
Controller is designed using PIC 16F877A microcontroller, liquid-crystal display (LCD),
silicon-controlled rectifier (SCR), rectifier diodes and other electronic components.
The SCR and rectifier diodes in conjunction with other components are used to charge the
battery. The battery charging is controlled by the microcontroller circuit. The LCD module
displays the status of the battery while it is charging. At the same time the voltage level of the
battery is also displayed. The experimental results for charge controller are also mentioned.

3.2 INTRODUCTION
As the importance of environmental protection and sustainable growth increases, wind
energy, a clean and renewable attracts increasing attention. Wind energy is one of the most
economical forms of alternative energy available today. It can save the environment and
make it cleaner for generations to come. This thesis is intended to emerge the charge
controller for wind energy source. A charge controller is an essential part for nearly all power
systems that charge battery, whether the power source is solar, wind, hydro, fuel, or utility
grid.
The charge controller can control the voltage and regulates the charging of the batteries. Its
purpose is to keep the batteries properly fed and safe for the long term. The basic functions of
a controller are quite simple. Charge controllers block the reverse current and prevent battery

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overcharge. Some charge controllers also prevent battery over discharge and protect from
electrical overload. The controllers also display the status of the battery .The main
components of the wind energy system are the wind turbine, the mechanical drive train, the
generator, the power grid, and the controller. The wind turbine converts the kineticenergy of
the wind into mechanical energy. The generator converts the mechanical energy into
electrical energy. The controller is the brain of the system. It ensures that the whole system
works as expected. The controller consists of two parts. The first part is the master
controller. The second part is the generator controller. During the power optimization stage,
the master controller adjusts the system rotation
speed to keep the optimal tip speed ratio. The speed regulation works by controlling the
power of the generator. During the wind power limitation range, the master controller
regulates the pitch angle to limit the wind power utilization. The generator controller is in
charge of accurately controlling the active power of the system. The generator controller
adopts the stator flux oriented vector control strategy. This thesis intends to propose and
construct the charge controller portion of wind power system. The block diagram of the wind
power system is shown in fig3.2.

Fig 3.2 : Block diagram of wind power system

3.3 PROPOSED CHARGE CONTROLLER

The charge controller intended to design and implement in this research work is a small
power charge controller. Figure 2.6 shows the block diagram of the charge controller. The
charge controller is built around semiconductor switches (silicon controlled rectifier-SCR)
rather the electromechanical switches (relays). The microcontroller is used to control the
overcharging of the battery, to display the battery voltage continuously and to make audible
alarm when the battery is fully charged. Firstly the battery is charged using high
current through the SCR. When the battery almost reaches its full terminal voltage (full
charge) high current charging is cut off and slow charging (trickle charging) is still done. At
full charge condition the charging is totally cut out by the control of the microcontroller. The
current coming from the wind turbine through the converter circuit is diverting to another
load (e.g. lamp). By this means the overcharging of the battery is prevented. The constructed
charge controller can charge the 12 V battery with up to 6 A of current. The amount of

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charging current can be increased by changing some components in the charge controller
without any difficulty.

3.4 IMPLEMENTATION
The operation of the charge controller circuit is explained in this section. The charge
controller circuit will charge the 12 V battery until the battery gets its full terminal voltage.
The charge controller changes from normal charging mode into the tickle charging mode
when the full terminal voltage (full charge) of the battery is reached. In the tickle charging
mode the battery is slowly charged. The charging of the battery is totally cut off by the
control of microcontroller at the end. The battery full charge audible alarm is also activated
when the battery is fully charged. Therefore the damage of the battery from the
overcharging can be avoided. The components used in the circuit can withstand up to 6 A of
charging current. This means that the power of the charge controller circuit
used in this research work is 6A x 12V = 72 W. By changing some components used in the
circuit, the charge controller circuit can be modified to charge the battery up to 300 A of
charging current. Now it is the time to articulate the research work with ideas gathered
in above steps by adopting any of below suitable approaches. At any time the voltage
difference between the anode and the cathode of SCR1 is the instantaneous value of half sine
wave and the voltage of the battery. When the battery voltage is low the voltage difference
between the anode and cathode of SCR1 is high. On the other hand, the voltage difference
between the anode and cathode of SCR1 will be low if the battery voltage is high. Therefore
the battery voltage becomes when the battery is charged. In this condition, the voltage
difference between the anode and cathode of SCR1tends to be low. This fact is the main idea
of this charge controller circuit. The SCR controlled battery charger circuit is shown in Fig3.4

Fig 3.4 Circuit Diagram for Charge Controller

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Chapter 4

RELATED THEORY
ion to SCR: SCR is abbreviation for Silicon Controlled Rectifier. SCR has three pins
anode, cathode and gate as shown in the below figure. It is made up of there PN
junction diodes also; it is solid state equivalent of gas filled triode and has around
four semi conductor layers. SCR can conduct the current in a single direction or
we can say SCRs are unidirectional. The SCR can be triggered only at the gate
through the current. SCR will combine the features of rectifier and transistor.
They are mainly used in switching applications. They can also be triggered with
the break over voltage (if the forward voltage is more than the break down
voltage of the component). They are mainly used in the high voltage and high
power for controlling purpose. They are also used in the light dimming, voltage
regulators, motor control etc. SCR Operating Modes: To turn on the SCR the
small amount of voltage or voltage equal to break over voltage is required to the
gate which will trigger the SCR and when the SCR is turned on, it will have very
low resistance and allow the power to conduct and also increase the anode
current. Even if we remove the gate voltage also it will be in conduction. The only
way to make the SCR to turn off is to make the voltage to zero or make the
current less than the handling current between the anode and cathode. There
are two ways to turn on the SCR is the first way is to turn on by opening the gate
and compensate the power supply to the break over voltage. And second way is
to supplying the voltage to operate the SCR with less than break over voltage
and applying the small amount of about 1.5V applied to the gate which will
trigger the SCR. When the SCR is turned off it will have high resistance and
restrict the current to the leakage current. To turn off the SCR from on state also
have only one ways normally people think that if we stop the gate current the
SCR will become turn off, but it will not this state is called loss of control, the
only way is turnoff the SCR is reducing the supply voltage to zero. SCR in Forward
and Reverse Characteristics: In Forward bias the anode will be at positive
terminal and cathode will be at negative terminal. The supply voltage will
increased from initial value zero when it reached to A as shown in the graph
below and start conduction from this point also it there will be the voltage drop
due to the load resistance and fall down to point B. to turn on the SCR
completely or for heavy condition small current is required to the gate. This
current triggers the gate and switch on SCR and decreases the resistance and
start conduction and goes to point C. In Reverse bias that is cathode will be at
positive terminal and anode will be at negative terminal at this point there will be
very small leakage current at anode . PEAK REVERSE VOLTAGE play the key role,
when the voltage exceeded the peak reverse voltage the at some point SCR will
go to the avalanche break down and starts conduction in reverse direction
fashion. This voltage is called reverse break down voltage. Parameters of SCR:
1. Break Over Voltage: minimum forward voltage which will make the SCR to turn
on for conduction. Normally SCR break over voltage is around 50V to 500V. 2.
Peak Reverse Voltage: maximum reverse voltage which help the SCR not to

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conduct in the reverse direction. Reverse direction implies cathode is at positive
and anode is negative. This is very important in power electronic application
because in the negative half of AC supply is also given to the SCR, in this SCR
should not go to the reverse bias, if the peak reverse voltage is high then SCR
will go to the avalanche break down always a external circuit is needed to limit
the Peak reverse voltage. The maximum peak reverse voltage for SCR is around
2.5KV. 3. Holding Current: maximum anode current required to turn off the SCR
from on state when gate being open. Suppose if holding current of SCR is 5ma, to
turnoff the SCR we need make current less than 5ma. 4. Forward Current Rating:
maximum forward current that allowed by the SCR without any damage to it.
Commercial SCR have forward current rating around 30ma to 300ma. If the
forward current will exceed the maximum forward current then automatically
SCR will be damage due to overheating. There are also other factors like Critical
Rate of Raise of Voltage which is defined as the rate at which the voltage will
raise in forward direction without triggering the SCR, Snubber Circuit which avoid
the triggering of SCR due to parasitic capacitance in RC circuits. Applications of
SCR: SCR as Switch: SCR can be used as switch, because SCR has two states ON
and OFF state. We know that to turn on the SCR we need to increase the supply
voltage equal to break over voltage or by giving the small voltage to the gate for
triggering, by this we can turn on the SCR; we can turn off the SCR by decreasing
the current to less than holding current, or we have another method called force
communication in this we discharge a capacitor in parallel with SCR to make it
turn off; by this we can use SCR as typical SWITCH. There is lot of advantages
using SCR as switch like Switching speed of SCR is very high like switching
operation per second. It allows huge current up to 100 ma through the load just
by triggering the gate with very low voltage to turn it on. Small in size and has
low noise which give high efficiency and reliable. SCR can be used in half wave
rectifier, full wave rectifier, inverter circuits, power control circuits, static
contactor, over light detector, speed control circuit, crowbar circuit, automobile
ignition circuits, etc. NOTE SCR is a current trigger device. SCR is made up of
silicon and some time SCR is called as thyristor. Gate is the control element of
SCR. Angle of conduction can be changed by changing the gate voltage.
Introduction to Battery Charger Using SCR: The battery is charged with small
amount of AC voltage or DC voltage. So if you want to charge your battery with
AC source then should follow these steps, we need first limit the large AC
voltage, need to filter the AC voltage to remove the noise, regulate and get the
constant voltage and then give the resulting voltage to the battery for charging.
Once charging is completed the circuit should automatically turned off. Block
Diagram of Battery Charger Using SCR: The AC source is given to the step down
transformer which converts the large AC source into limited AC source, filter the
AC voltage and remove the noise and then give that voltage to the SCR where it
will rectify the AC and give the resulting voltage to the battery for charging.
Circuit Diagram of Battery Charger Using SCR: Circuit diagram of the Battery
Charger Circuit using SCR can be seen below: Circuit Diagram Explanation: The
AC main voltage is given to the step down transformer the voltage should be
down to 20V approx. the step down voltage is given to the SCR for rectification

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and SCR rectifies AC main voltage. This rectified voltage is used to charge
battery. When the battery connecter to the charging circuit, the battery will not
be dead completely and it will get discharged this will give the forward bias
voltage to the transistor through the diode D2 and resistor R7 which will get
turned on. When the transistor is turned on the SCR will get off. When the
battery voltage is dropped the forward bias will be decreased and transistor gets
turned off. When the transistor is turned off automatically the diode D1 and
resistor R3 will get the current to the gate of the SCR, this will triggers the SCR
and gets conduct. SCR will rectifies the AC input voltage and give to the battery
through Resistor R6. This will charge the battery when the voltage drop in the
battery decreases the forward bias current also gets increased to the transistor
when the battery is completely charged the Transistor Q1 will be again turned on
and turned off the SCR.

4.1CIRCUIT DIAGRAM

Circuit diagram of the Battery Charger Circuit using SCR can be seen below:

Fig 4.1 Circuit Diagram

4.2SCR
4.2(a) Introduction to SCR:

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SCR is abbreviation for Silicon Controlled Rectifier. SCR has three pins anode, cathode and
gate as shown in the below figure. It is made up of there PN junction diodes also; it is solid
state equivalent of gas filled triode and has around four semi conductor layers. SCR can
conduct the current in a single direction or we can say SCRs are unidirectional. The SCR can
be triggered only at the gate through the current. SCR will combine the features of rectifier
and transistor. They are mainly used in switching applications. They can also be triggered
with the break over voltage (if the forward voltage is more than the break down voltage of the
component). They are mainly used in the high voltage and high power for controlling
purpose. They are also used in the light dimming, voltage regulators, motor control etc.

Fig 4.2(a) SCR Symbol

4.2(b) SCR Operating Modes:

To turn on the SCR the small amount of voltage or voltage equal to break over voltage
is required to the gate which will trigger the SCR and when the SCR is turned on, it will
have very low resistance and allow the power to conduct and also increase the anode
current. Even if we remove the gate voltage also it will be in conduction. The only way to
make the SCR to turn off is to make the voltage to zero or make the current less than the
handling current between the anode and cathode.
There are two ways to turn on the SCR is the first way is to turn on by opening the
gate and compensate the power supply to the break over voltage. And second way is to
supplying the voltage to operate the SCR with less than break over voltage and applying
the small amount of about 1.5V applied to the gate which will trigger the SCR.
When the SCR is turned off it will have high resistance and restrict the current to the
leakage current. To turn off the SCR from on state also have only one ways normally
people think that if we stop the gate current the SCR will become turn off, but it will not
this state is called loss of control, the only way is turnoff the SCR is reducing the
supply voltage to zero.

4.2(c) SCR in Forward and Reverse Characteristics:

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In Forward bias the anode will be at positive terminal and cathode will be at negative
terminal. The supply voltage will increased from initial value zero when it reached to A as
shown in the graph below and start conduction from this point also it there will be the voltage
drop due to the load resistance and fall down to point B. to turn on the SCR completely or for
heavy condition small current is required to the gate. This current triggers the gate and switch
on SCR and decreases the resistance and start conduction and goes to point C.

In Reverse bias that is cathode will be at positive terminal and anode will be at negative
terminal at this point there will be very small leakage current at anode . PEAK REVERSE
VOLTAGE play the key role, when the voltage exceeded the peak reverse voltage the at some
point SCR will go to the avalanche break down and starts conduction in reverse direction
fashion. This voltage is called reverse break down voltage.

Fig 4.2(c) SCR Forward and Reverse Characteristics

4.2(d) Applications of SCR:

SCR as Switch: SCR can be used as switch, because SCR has two states ON and OFF state.
We know that to turn on the SCR we need to increase the supply voltage equal to break over
voltage or by giving the small voltage to the gate for triggering, by this we can turn on the
SCR; we can turn off the SCR by decreasing the current to less than holding current, or we
have another method called force communication in this we discharge a capacitor in

parallel with SCR to make it turn off; by this we can use SCR as typical SWITCH. There is
lot of advantages using SCR as switch like

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 Switching speed of SCR is very high like switching operation per second.
It allows huge current up to 100 ma through the load just by triggering the gate with
very low voltage to turn it on.
Small in size and has low noise which give high efficiency and reliable.
SCR can be used in half wave rectifier, full wave rectifier, inverter circuits, power control
circuits, static contactor, over light detector, speed control circuit, crowbar circuit, automobile
ignition circuits, etc

4.3 COMPONENT DESCRIPTION

4.3.1 TRANSFORMER

A transformer is an electrical device that transfers energy between two or more circuits
through electromagnetic induction.

A step down transformer: is one whose secondary voltage is less than its primary voltage. It is
designed to reduce the voltage from the primary winding to the secondary winding. This kind
of transformer steps down the voltage applied to it.

As a step-down unit, the transformer converts high-voltage, low-current power into low-
voltage, high-current power.

4.3.2 DIODE

Fig 4.3.2 Diode

In electronics, a diode is a two-terminal electronic component with asymmetric conductance;

it has low (ideally zero) resistance to current in one direction, and high (ideally infinite)
resistance in the other. Semiconductor diodes were the first semiconductor electronic devices.

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Today, most diodes are made of silicon, but other semiconductors such
as selenium or germanium are sometimes used.

4.3.3 BJT

Fig 4.3.3 BJT

A bipolar junction transistor is a type of transistor that relies on the contact of two types
of semiconductor for its operation. BJTs can be used as amplifiers, switches, or in oscillators.
Bipolar transistors are so named because their operation involves both electrons and holes.
These two kinds of charge carriers are characteristic of the two kinds
of doped semiconductor material; electrons are majority charge carriers in n-type
semiconductors, whereas holes are majority charge carriers in p-type semiconductors.

4.3.4 RESISTOR

Fig 4.3.4 Resistor

A resistor is a passive two-terminal electrical component that implements electrical

resistance as a circuit element. Resistors act to reduce current flow, and, at the same time, act
to lower voltage levels within circuits. In electronic circuits resistors are used to limit current
flow, to adjust signal levels.

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4.3.5 FUSE

Fig 4.3.5 Fuse

In electronics and electrical engineering, a fuse is a type of low resistance resistor that acts as
a sacrificial device to provide over current protection, of either the load or source circuit. Its
essential component is a metal wire or strip that melts when too much current flows through
it, interrupting the circuit that it connects. Fuses are an alternative to circuit breakers.

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4.4 PCB LAYOUT

The PCB Layout of the solder side of the circuit has been made using PCB Wizard Software.

(A)Bottom layout

Fig 4.4(a) Bottom Layout

(B) Real world

Fig 4.4(b) Real World

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4.5 CIRCUIT OPERATION

The AC main voltage is given to the step down transformer the voltage should be
down to 20V approx. the step down voltage is given to the SCR for rectification and SCR
rectifies AC main voltage. This rectified voltage is used to charge battery.
When the battery connecter to the charging circuit, the battery will not be dead
completely and it will get discharged this will give the forward bias voltage to the
transistor through the diode D2 and resistor R7 which will get turned on. When the
transistor is turned on the SCR will get off.
When the battery voltage is dropped the forward bias will be decreased and transistor
gets turned off. When the transistor is turned off automatically the diode D1 and resistor
R3 will get the current to the gate of the SCR, this will triggers the SCR and gets conduct.
SCR will rectifies the AC input voltage and give to the battery through Resistor R6.
This will charge the battery when the voltage drop in the battery decreases the
forward bias current also gets increased to the transistor when the battery is completely
charged the Transistor Q1 will be again turned on and turned off the SCR.

4.6 SCOPE OF PROJECT

1) Switches large levels of current using only a small control current.

2) Can switch high voltages.

4.7 LIMITATIONS
1)SCRs capable of handling greater than 600 V may be hard to find. Though SCRs rated at
voltages as high as 8000 V can be manufactured.

2)Though SCRs rated at currents as high as 4000 A can be manufactured.

4.8 APPLICATIONS
1) Adjustable motor speed controllers. 2)Adjustable light dimmers.
3) Switching power supplies and battery chargers
4) Inverters

5) Charge Controller Ciruit.

Chapter 5

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TOOLS TO BE USED

5.1 PCB LAYOUT WIZARD SOFTWARE

PCB Wizard is a powerful package for designing single-sided and double-sided printed
circuit boards (PCBs).

It provides a comprehensive range of tools covering all the traditional steps in PCB
production, including schematic drawing, schematic capture, component placement,
automatic routing, Bill of Materials reporting and file generation for manufacturing. In
addition, PCB Wizard offers a wealth of clever new features that do away with the steep
learning curve normally associated with PCB packages.

5.2 COPPER PLATED PCB

Fig 5.2 Copper Plated PCB

A printed circuit board (PCB) mechanically supports and electrically connects electronic
components using conductive tracks, pads and other features etched from copper sheets
laminated onto a non-conductive substrate. PCBs can be single sided (one copper layer),
double sided (two copper layers) or multi-layer. Conductors on different layers are connected
with plated-through holes called via(A via (Latin for path or way) is an electrical
connection between layers in a physical electronic circuit that goes through the plane of one
or more adjacent layers). Advanced PCBs may contain components - capacitors, resistors or
active devices - embedded in the substrate.

Printed circuit boards are used in all but the simplest electronic products.

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5.3 DRILLING MACHINE FOR PCB

Fig 5.3

A compact tabletop High speed PCB drilling machine with a Quick change Chuck.

Feature:

Drill holding by precision chuck with lapped jaws

Mains operated DC motor Direct drive ( no belt and pulley)

3 Step Speed Control and Illumination of work Area

Specification:

Motor Speed : upto 20,000 R.P.M

Range : 0.6 to 3.0 mm

Base : Metal

Working Area : 280 mm x 170 mm

Electrical Power : 230/ 50Hz, 5 A Socket required

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Chapter 6
CONCLUSION
Battery is a device which we can use in our daily life in multiple circuits like a torch lights,
toys, mobile and laptop , automobile starter etc. Rechargeable batteries are inexhaustible ,
pollution free and environmental friendly. So we have chosen Battery Charger Circuit Using
SCR as a mini project topic. Thus we conclude that the circuit works as per is designment
and requirement.

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REFERENCES
For a paper in a Proceedings/Transactions/Journal
International Journal of Scientific and Research Publication, Volume 4, Issue 5,May
2014.ISN-2250-3153

For an authored book

George A. Sites, BSEET An Introduction to SCR Power Controls published on 1st January
2014.

Allen Mottershed Tata McGraw-Hill Publication Electronic Devices and Circuits, 2 nd

Edition, 2005.

For a website
http://www.electronicshub.org/battery-charger-circuit-using-scr/

http://www.eleccircuit.org/battery-charger-circuit-using-scr/

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APPENDIX

COMPONENT LIST AND PRICE

Sr no. Components Quantity required Price(in rupees)

1 Step down 1 80
transformer
2 Diodes 4 8
3 Resistors 5 4
4 SCR 1 10
5 Potentiometer 1 8
6 BJT 1 5
7 Fuse 1 5
Total: 120Rs

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