PV Solar Module (61 PAGE)

CONTROLLING EFFICIENCY OF PV SOAR MODULES
BY COMPENSATING TEMPERATURE
A project report submitted in the 7th semester in partial
fulfillment for the degree of
BACHELOR OF ENGINEERING IN ELECTRICAL
Prepared By:
Jani Keyur M. (090180109066)
Rami Tejas V. (090180109055)
Mishra Bipin K. (090180109026)
Daphada Nitinkumar M. (0901801090101)
Project Guide Head of Department

V R Patel V J Upadhyay
Electrical Engineering Department

Government Engineering College, Dahod
Zalod Road, Dahod, Gujarat - 389151
Project Report
On
CONTROLLING EFFICIENCY OF PV SOLAR MODULES

BY COMPENSATING TEMPERATURE
Jani Keyur M. (090180109066)

Rami Tejas V. (090180109055)
Mishra Bipin K. (090180109026)
Daphada Nitinkumar M. (0901801090101)
Of
VIIth Semester B. E. (Electrical)

Guided by
Industrial Co-ordinator: Departmental Guide:
Mukesh Parmar V R Patel
Submitted
At

CERTIFICATE
This is to certify that Jani Keyur M. of 7th semester, Electrical

Engineering department, Government Engineering College, Dahod, with
Gujarat Technological University Enrolment number (090180109066) has
satisfactory completed his project on “CONTROLLING EFFICIENCY OF PV
SOLAR MODULES BY COMPENSATING TEMPERATURE” for the partial
fulfillment of B.E. (Electrical) by term ending in December-2012.
Place: Dahod
Date:
Guide: Head of Department

V R Patel V J Upadhyay
GUJARAT
TECHNOLOGICAL UNIVERSITY
AHMEDABAD
INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM
FIRST NAME 1. Mishra Bipinkumar K.

2. Rami Tejas V.
3. Jani Keyur M.
4. Daphada Nitinkumar M.
MOBILE NO. 1.9722915683

2.9998455644
3.9033560674
4.9687499095
EMAIL bmishra60@yahoo.com
ramitejas@ymail.com
janikeyur1992@gmail.com
nitin.dafda@yahoo.com
COLLEGE NAME Government Engineering Collage, Dahod

ADDRESS Zalod Road,
Dahod -389151
BRANCH ELECTRICAL
SEMESTER 7TH YEAR 4TH
TEAM NAME
SIGNATURE OF
STUDENT
INDUSTRY PARTICULARS
.................... INDUSTRY COORDINATOR

NAME Mukesh Parmar
CONTACT ADDRESS E-49, G.I.D.C.,
Electronics Zone,
Sector-26,
Gandhinagar-382028
MOBILE NO. 9825182831
EMAIL Mukesh.parmar@vimalelectronics.com
.................... INDUSTRY
NAME VIMAL ELECTRONICS
ADDRESS E-49, G.I.D.C.,
Electronics Zone,
Sector-26,
Gandhinagar-382028
CONTACT NO. OFFICE :23287573 Tele fax:+91-79-23287571
NAME OF INDUSTRIAL ESTATE
COMPANY LOGO
TITLE OF PROBLEM/PROJECT
Controlling Efficiency of PV Solar Modules by Compensating Temperature
DISCIPLINARY | INTER-DISCIPLINARY
DISCIPLINE - ELECTTRICAL
ACKNOWLEDGEMENT
Being students we have undertaken this project as a part of the vast learning process.
We take this opportunity to thank one and all involved to help us with, this project. We would
initially like to give our gratitude to Mr. Mukesh Parmar, R&D engineer of Vimal
Electronics. We are thankful to all the staff members for their sincere help during our project.
We cannot be refrained of our humble thanks to our head of the department, Prof. A. M. Shah
for inspiring us throughout. We are obliged to heartily thank our guide Mr. V. R. Patel who
led us through this project. In the end, we like to thank all of them who are directly or
indirectly involved in the completion of this project.
WORK PLAN / SCHEDULE
MONTH WORK
June-20l2 Introduction of project
July, August-20l2 Study different components used in

solar energy system.
September-20l2 Design of solar charge controller.
October, November-20l2 Manufacturing process.
December-20l2 Testing process.
January-2013 Identifying the problems occurring due to

increasing temperature in solar energy
system.
February, March-20l3 Finding solutions
April-20l3 Reporting solution.

ABSTRACT
More energy, and thus higher efficiency, can be extracted from a photovoltaic system if
the photovoltaic (solar) panel is operating at its maximum power point. This maximum power
point represents maximizing the area under the solar panel's intrinsic I-V operating curve. A
DC/DC power converter can be used to electrically match the charge controller's operating
voltage to that of the solar panel. As a solar panel's intrinsic I-V curve shifts depending on
environmental and other factors, the charge controller must move its operating point to the
current maximum power point. This maximum power point tracking (MPPT) system can be
achieved by using a low cost micro-controller to modulate the charge controller's power
point.The charge controller must sample the solar panel's voltage and current output to
evaluate whether the charge controller is operating at panel's current maximum power point.
A boost converter was designed and built to maximize the power delivered from the source.
A microcontroller was used as the control element and firmware was developed to locate the
maximum power point. It was that the maximum power point of the lab power supply was at
approximately 0.33 duty cycle. It was determined that the circuit and algorithm operated to
our design specifications. Future work could address the issue of maximizing converter losses
while maximizing power to the load.
List of Figures
Figure No. Figure Description Page No
Figure 1.1 Solar Charge Controller 3
Figure 1.2 PWM Solar Charge Controllers 6
Figure 1.3 Advanced Lighting Controller. 7
Figure 1.4 MPPT Solar Charge Controllers 7
Figure 1.5 MPPT Lighting Controller (Thin Fllm) 8
Figure 2.1 Solar Charge Controller: Circuit Diagram 11
Figure 2.2 Solar Charge Controller: Working Cycles 12
Figure 2.3 Shunt Type Solar Charge Controller. 14
Figure 2.4 PWM Solar Charge Controller: Circuit Diagram 17
Figure 2.5 MPPT Solar Charge Controller: Circuit Diagram 18
Figure 3.1 Nominal 12-V Solar Module: I-V Curve and Output 32
Power Graph
Figure 3.2 MPPT Solar Charge Controller: Circuital Design 33

List of Tables
Table No. Table Description Page No.
Table 2.1 Specifications of Solar Charge Controller 20
Table 2.2 Characterization of Charge Controllers 23
Table 3.1 MPPT Solar Charge Controller: Components Used 35-36

Theoretical Design of Solar Charge Controller 2012
INDEX
Acknowledgement
Abstract
Work Plan / Shedule
List of Tables
List of Figures
Table of Contents
CHAPTER: 1 INTRODUCTIONS TO SOLAR CHARGE CONTROLLER
1.1 Introduction............................................................................................1
1.2 Definition………………………………………………………………………….1
1.3 Operating Principle……………………………………………………………...2
1.4 Necessity of Solar Charge Controller……………………………………………..2
1.5 General Classification................................................................................4
1.6 Type of Solar Charge Controller……………………………………………….4
1.6.1 PWM Solar Charge Controller……………………………………………..6
1.6.2 MPPT Solar Charge Controller........................................................7
1.7 Comparison between PWM and MPPT Charge Controller.........................9
1.8 Pros and Cons of PMW and MPPT Charge Controller……………………....10

CHAPTER: 2 BASIC OF SOLAR CHARGE CONTROLLER
2.1Introduction……………………………………………………………………………….11
2.2 Working Cycle of a Solar Charge Controller…………………………………………….12
2.3 Shunt Type Solar Charge Controller……………………………………………………..14
2.3.1 Introductin…………………………………………………………………... 14
2.3.2 Specifications………………………………………………………………...15
2.3.3 Theory………………………………………………………………………..16
2.3.4 Use…………………………………………………………………………...17
2.4 PWM Solar Charge Controller…………………………………………………………..17
2.5 MPPT Solar Charge Controlle…………………………………………………………..18
2.6 Difference between Solar Charge Controller and Solar Lightning Charge Controller….18
2.7Features of Solar Charge Controller……………………………………………………...19
2.8 Technical Specification of a Solar Charge Controller…………………………………...20
2.9 Protection Provided by a Solar Charge Controller to the System………………………..21
2.10 Solar Power Charge Controller…………………………………………………………22
2.11 Characterization of a Charge Controller………………………………………………..23
2.12 Advantages of a Solar Charge Controller………………………………………………26
2.13 Functions of a Charge Controller……………………………………………………….27

CHAPTER: 3 DESIGN OF A MPPT SOLAR CHARGE CONTROLLER
3.1 Integrated Charge Controller Circuitry.........................................................28
3.2 MPPT solar charge controller……………………………………………………..28
3.2.1. MPPT solar charge controller schematic (What is MPPT?)...........28
3.2.2. Main features of MPPT solar charge controller………………...29
3.2.3. The benefits of an MPPT solar charge controller………………………….29
3.2.5. Compared with normal solar charge controller by Schematic Diagram...30
3.2.6. The price of MPPT solar charge controller…………………………...31
3.2.7. TRACER MPPT Technology……………………………………………...31
3.2.8 An Advantage over Traditional Controllers…………………………..32
3.3 Design of an MPPT Charge Controller............................................................32
3.4 Components Used in Solar Charge Controller..............................................35
3.5 Things to Consider When Purchasing a Charge Controller..........................37
3.6 Sizing of an MPPT Solar Charge Controller...................................................40
3.7 Requirement of Number of Solar Batteries.................................................40
3.8 How to size your solar home system?..................................................................41

OUR CONTRIBUTION 44
CONCLUSION 45
BIBILIOGRAPHY 46
Introduction to Solar Charge Controller 2012
CHAPTER 1
INTRODUCTION TO SOLAR CHARGE CONTROLLER
1.1 Introduction
Most stand-alone solar power systems will need a charge controller. The purpose of this
is to ensure that the battery is never overcharged, by diverting power away from it once it is
fully charged. Only if a very small solar panel such as a battery saver is used to charge a large
battery is it possible to do without a controller. Most charge controllers also incorporate a
low-voltage disconnect function, which prevents the battery from being damaged by being
completely discharged. It does this by switching off any DC appliances when the battery
voltage falls dangerously low.
The primary function of a PV controller is to prevent the solar battery from being
overcharged by the photovoltaic array and constantly monitors battery voltage.When the
batteries are fully charged, the controller will stop or decrease the amount of current flowing
from the photovoltaic array into the battery. When the batteries are being discharged to a low
level, many controllers will shut off the current flowing from the battery to the DC load(s).
Charge controllers come in a variety sizes from a just a few amps to as much as 80 amps.
Here you will find a wide range of quality PV charge controllers from such quality
manufacturers as Steca, Morningstar, Xantrex and many others.
1.2 Definition
A charge controller, charge regulator or battery regulator limits the rate at which
electric current is added to or drawn from electric batteries. It prevents overcharging and may
prevent against overvoltage, which can reduce battery performance or lifespan, and may pose
a safety risk. It may also prevent completely draining ("deep discharging") a battery, or
perform controlled discharges, depending on the battery technology, to protect battery life.
The terms "charge controller" or "charge regulator" may refer to either a stand-alone device,
or to control circuitry integrated within a battery pack, battery-powered device, or battery
recharger.
1
1.3 Operating Principle
The principle behind a solar charge controller is simple. There is a circuit to measure
the battery voltage, which operates a switch to divert power away from the battery when it is
fully charged. Because solar cells are not damaged by being short or open-circuits, either of
these methods can be used to stop the power reaching the battery.
1.4 Necessity of Solar Charge Controller
Solar charge controllers are necessary for most solar power systems that use batteries.
The solar charge controller functions to control the power as it moves from the solar panels to
the batteries. If overcharged, the life of a battery is reduced, and a good charge controller will
prevent this from happening.
The simplest type of charge controller functions to monitor the battery voltage and
opens the circuit to halt the charging process once the voltage reaches a certain level. Older
charge controllers accomplished this by through the use of a mechanical relay to open and
close the circuit.
More recent charge controllers make use of pulse width modulation (PWM). This is a
process in which, as the battery starts to reach a fully charged state, the amount of power
being transferred to it gradually decreases. PWM extends battery life even more, as it
decreases stress on the battery. It can also keep batteries in a completely charged state, or
"floating," indefinitely. PWM chargers are more complex, but they tend to be more durable,
as they don't use any breakable mechanical connections.
The most recent types of solar charge controllers use maximum power point tracking,
or MPPT. MPPT controllers turn extra voltage into amperage. This feature has a couple of
major benefits.
The majority of solar power systems use 12 volt batteries, not unlike the ones found
in cars, but these features work regardless of voltage. Solar panels can often provide much
more voltage than the batteries require. When the excess voltage is converted into amps, the
charge voltage stays at an optimal level, while the time required to fully charge the batteries
is reduced. A solar power system using this kind of charge controller will perform more
efficiently.
2
Power loss is also reduced with MPPT charge controllers. All electricity in a home
system moves from device to device along wires, and a certain amount of power is Jost
during this process. Higher voltage electricity sees less loss. The power used by a PWM
charge controller used with 12V batteries is in most cases around 18V. An MPPT controller
will use the highest voltage of any type of charge controller currently available. MPPT
controllers have less power loss for this reason.
In comparison to PWM controllers, MPPT charge controllers are somewhat more expensive,
but their performance is significantly enhanced. For this reason, they're highly recommended.
Finally, it's also possible to prevent reverse-current flow with certain modem charge
controllers. Solar panels will cease to generate electricity when the sun isn't out, and the
batteries can actually start sending electricity back to them at these times. This power loss can
certainly be discouraging. When the solar panels stop sending electricity, the charge
controller will open the circuit, preventing any reverse-current flow.
Fig 1.1 Solar Charge Controller
Lead Acid batteries will be damaged if overcharged, or their voltage pushed too high by
continuing to charge with a high charge voltage. Therefore it will be necessary to connect a
controller between the solar panels and the battery. The photograph to the right shows a
typical controller for use in solar power systems.
3
When charging from the battery from a low state, it will effectively connect to the solar
panels to the battery until a certain preset voltage is achieved. This voltage may be something
approaching 30 volts for a 24 system. Therefore, although the controller may disconnect the
solar panels before a voltage of 30 volts is reached in order to avoid battery damage, the
batteries are unlikely to be fully charged at this point. For this reason the controller will then
connect the charge in pulses, to fully charge the battery. Charging voltages should be lower
for gel type lead acid batteries, and should also be lower for batteries at a higher temperature.
A charge controller may be able to be programmed for the particular type of battery and may
also have the facility for a battery temperature sensor.
Charge controllers are sold to consumers as separate devices, often in conjunction with
solar or wind power generators, for uses such as RV, boat, and off-the-grid home battery
storage systems. In solar applications, charge controllers may also be called solar regulators.
1.5 General Classification
Solar charge controllers are generally classified into two types:
1. Series Charge Controllers

2. Shunt Charge Controller
A series charge controller or series regulator disables further current flow into batteries
when they are full. A shunt charge controller or shunt regulator diverts excess electricity to an
auxiliary or "shunt" load, such as an electric water heater, when batteries are full.
1.6 Types of Solar Charge Controllers
Charge controllers will vary in their sophistication but the main choices to be made are
system voltage (though the controller may be designed for more than one voltage) and the
maximum charge current (maximum current to be produced by the solar panels). According
to this the solar charge controllers are classified as:
1. On/Off type Solar Charge Controller
• Disconnects module when high battery voltage is reached (≈14V)

• Reconnects module when battery voltage lowers (≈13V)
• Control may be relay type or solid state
• You will find these in retail outlets and big box stores
4
2. Pulse Width Modulation (PWM) Solar Charge Controller
• When desired battery voltage is reached (≈14 V) output turns on/off quite rapidly
(100Hz - 50KHz)
• Battery voltage held constant, producing a more fully charged battery
• The most popular charge controller series of this time is the C-? series from Xantrex
3. Maximum Power Point Tracking (MPPT)
• Provides PWM type battery voltage control

• Extracts all available power from the PV module
• MPPT technology can increase charge current up to 30% or more compared to
traditional charge controllers
• Manufacturers of MPPT controllers include Outback, Morningstar, Blue Sky and
Xantrex
Solar charge controllers are specified by the system voltage they are designed to operate
on and the maximum current they can handle. The system voltage is usually 12 or 24 Volts,
or occasionally 48 Volts. The maximum current is determined by the number and size of
solar panels used.
Simple charge controllers stop charging a battery when they exceed a set high voltage
level, and re-enable charging when battery voltage drops back below that level. Pulse width
modulation (PWM) and maximum power point tracker (MPPT) technologies are more
electronically sophisticated, adjusting charging rates depending on the battery's level, to
allow charging closer to its maximum capacity. Charge controllers may also monitor battery
temperature to prevent overheating. Some charge controller systems also display data,
transmit data to remote displays and data logging to track the electric flow over time.
Charge controllers may also have a controlled DC output. This may be of use in a
system without an inverter and Will cut off the DC supply when the battery voltage is too
low. This facility is unlikely to be able to supply the current required for an inverter and as an
inverter would have its own control, would not be necessary - an inverter would be connected
direct to the battery.
The simplest type of charge controller would simply stop charging when the battery
voltage reaches a certain level, and start again when the voltage drops. Most controllers
however will use Pulse Width Modulation (short pulses of varying duration) to continue
charging a battery to near its maximum, after a certain voltage has been reached. A further
development of the charge controller is the Maximum Power Point Tracker Controller which
gives improved efficiency.
5
When connecting a solar panel to a rechargeable battery, it is usually necessary to use a

charge controller circuit to prevent the battery from overcharging. Charge control can be
performed with a number of different circuit types. Lower power solar systems can use a
series analog charge controller. Series regulators control the charging current by interrupting
the flow of current from the solar panel to the battery when the battery reaches a preset full
voltage. MPPT controllers use an inductor for energy storage and a high frequency switching
circuit to transfer the energy to the battery.
A single panel would need a controller of between 4 and 6 Amps rating, while larger
arrays may need controllers of 40 Amps or more. Different settings are needed if sealed
batteries are used to prevent the loss of electrolyte through gassing. The example controller
shown is available with ratings of 8, 12, 20 and 30 Amps, and automatically selects between
12 and 24 Volts.
1.6.1 PWM Solar Charge Controller
Fig 1.2 PWM Solar Charge Controller
PWM controllers employ the technique of pulse-width modulation to gradually lower the
amount of power provided to battery as it get close to being fully charged. This method
charges batteries at a lower stress level and helps maintaining battery life. Also capable of
holding batteries at a fully charged state, or float charge, PWM controllers do a great job in
charging and protecting batteries at reasonable costs. They are also the most widely available
type of solar controllers on the market.
PWM controllers are available in sizes from 15A to 45A, supporting small (12/24V) to
large (48V) battery systems. These CE certified controllers are designed primarily for lead
acid batteries, but the 12/24 V models can also be used for NiCd batteries. In addition, they
offer protections including overload, output short circuit, over temperature, reverse polarity,
and reverse current. PWM offers advanced programming capabilities for large PV systems
and is ideal for PV array up to 3000W PV array. Parallel connection is also possible up to 10
units.
6
ADVANCED LIGHTING CONTROLLER
Fig 1.3 Advanced Lighting Controller
Solar lighting controllers are PWM controllers with advanced lighting controls. They
can be used for home lighting or street lighting applications and can support either 12V or
24V systems. Lighting controllers have built-in output to directly power DC light loads. In
addition to automatic on/off light switch, they also have 8 different lighting schedules
available to suit your needs. To program different lighting schedules, these controllers come
with computer software which allows you to modify parameters on the convenience of your
any PC. They are capable of controlling lights very precisely through the built-in
microcontroller and RTC (real-time clock). Power-saving feature like automatic brightness
control is also available.
1.6.2 MPPT Solar Charge Controller
Fig 1.4 MPPT Solar Charge Controller
MPPT controllers use a brand new technology, Maximum Power Point Tracking, to
safely and successfully charge batteries. In principle, controllers with MPPT functionality
will target the highest output possible from array and convert the excess voltage into higher
charging amperage. On average MPPT controllers can typically generate 20 to 30% more
power output from array in comparison to their PWM counterparts. Despite costing more
than PWM controllers, the higher efficiency of MPPT controllers is well worth the cost.
7
MPPT controllers come with large LCD display and range from 9A to 80A and are
capable for handling small to large PV systems (12V/24V/36V/48V). Parallel connections are
also possible on large size MPPT controllers to handle very large array. Intelligent and highly
efficient, these controllers are the best choice in any off-grid application.
MPPT LIGHTING CONTROLLER (TIDN FILM)
Fig 1.5 MPPT Lighting Controller(Thin Film)
Solar lighting controllers are reliable devices that support thin-film PV modules, which
are marked with high voltage properties. Standard 12V charge controllers usually have a
maximum voltage input of 24-25V, but our PCL-MT controller can support up to 80V. In
addition, its MPPT (maximum power point tracking) capability enables one to maximize
power generation from PV module. With automatic day/night detection, 16 smart load control
programs, and full-feature system protections, this controller is your ideal device to lighting
control when working with thin-film PV modules.
Main features:
• MPPT capability
• Supports thin-film PV modules with high voltage support up to 80V
• Charging current 6A
• Efficiency >90%
• 16 smart load control built-in programs
• Direct load support output up to 8A
• LED displays for PV, battery, and load status
• Power-saving SLEEP MODE
8
1.7 Comparison Between PWM and MPPT Charge Controllers
Maximum Power Point Tracking charge controllers or MPPT charge controllers are
relatively new to the renewable energy industry. These charge controllers are different than
the traditional PWM charge controllers in that they are more efficient and in many cases
more feature rich. The most basic charge controller simply monitors the battery voltage and
opens the circuit, stopping the charging, when the battery voltage rises to a certain level.
Older charge controllers used a mechanical relay to open or close the circuit, stopping or
starting power going to the batteries.
More modern charge controllers use pulse width modulation (PWM) to slowly lower
the amount of power applied to the batteries as the batteries get closer and closer to fully
charged. This type of controller allows the batteries to be more fully charged with less stress
on the battery, extending battery life. It can also keep the batteries in a fully charged state
(called "float") indefinitely. PWM is more complex, but doesn't have any mechanical
connections to break.
The most recent and best type of solar charge controller is called maximum power
point tracking or MPPT. MPPT controllers are basically able to convert excess voltage into
amperage. This has advantages in a couple of different areas.
Most solar power systems use 12 volt batteries, like you find in cars. (Some use other
voltages and the same advantages apply to these systems as well.) Solar panels can deliver far
more voltage than is required to charge the batteries. By, in essence, converting the excess
voltage into amps, the charge voltage can be kept at an optimal level while the time required
to fully charge the batteries is reduced. This allows the solar power system to operate
optimally at all times.
Another area that is enhanced by an MPPT charge controller is power loss. The lower
voltage in the wires running from the solar panels to the charge controller results in higher
energy loss in the wires than higher voltage. With a PWM charge controller used with 12V
batteries, the voltage from the solar panel to the charge controller typically has to be 18V.
Using an MPPT controller allows much higher voltages in the wires from the panels to the
solar charge controller. The MPPT controller then converts the excess voltage into additional
amps. By running higher voltage in the wires from the solar panels to the charge controller,
power loss in the wires is reduced significantly.
MPPT charge controllers are more expensive that PWM charge controllers, but the
advantages are worth the cost. If you can afford it, you should definitely use an MPPT charge
controller.The final function of modem solar charge controllers is preventing reverse-current
flow. At night, when the solar panels aren't generating electricity, electricity can actually flow
backwards from the batteries through the solar panels, draining the batteries. You've worked
hard all day using solar power to charge the batteries, you don't want to waste all that power!
The charge controller can detect when no energy is coming from the solar panels and open
the circuit, disconnecting the solar panels from the batteries and stopping reverse current
flow.
9
PWM Pros
• PWM charge controller are built on a time tested technology. They have been used for
years in PV systems and are well established.
• These charge controllers are inexpensive, usually selling for less than $250.
• PWM charge controllers are available in sizes up to 60 amps
• PWM charge controllers are durable, most with passive heat sink style cooling.
• These charge controllers are available in many sizes for a variety of applications
PWM Cons
• The PV input nominal voltage must match the battery bank nominal voltage if you're
going to use PWM.
• There is no single controller sized over 60 amps DC as of yet.
• Many smaller PWM charge controller units are not UL listed
• Many smaller PWM charge controller units come without fittings for conduit.
• PWM charge controllers have limited capacity for system growth.
MPPT Pros
• MPPT charge controllers offer a potential increase in charging efficiency up to 30 %.

• These charge controllers also offer the potential ability to have array with higher input
voltage than battery bank
• You can get sizes up to 80 amps.
• MPPT charge controller warranties are typically longer than PWM units
• MPPT offer great flexibility for system growth
MPPT Cons
• MPPT charge controllers are expensive, sometimes costing twice as much as a PWM
controller and are certainly more expensive than PWM controllers.
• MPPT units are generally larger in physical size.
• Sizing an appropriate PV array can be challenging without MPPT charge controller
manufacturer guides.
• Using an MPPT controller forces the PV array to be comprised of like photovoltaic
modules in like strings.
10
Basic of Solar Charge Controller 2012
CHAPTER 2
BASICS OF SOLAR CHARGE CONTROLLER
2.1 Introduction
Here is the schematic diagram of Solar Charge Controller (Solar Regulator). You may
want to print it out, and then go on reading. Solar Charge Controller (Solar Regulator) is
designed for 12V systems employing panels of up to 7A total current, and loads of not over
20A.It can be easily modified for greater currents.
Fig 2.1 Circuit Diagram of a Solar Charge Controller
11
2.2 Working Cycles of a Solar Charge Controller
Since the brighter the sunlight, the more voltage the solar cells produce, the excessive
voltage could damage the batteries. A charge controller is used to maintain the proper
charging voltage on the batteries. As the input voltage from the solar array rises, the charge
controller regulates the charge to the batteries preventing any overcharging.
Modem multi-stage charge controllers and most quality charge controller units have
what is known as a 3 stage charge cycle that goes like this:
1) BULK: During the Bulk phase of the charge cycle, the voltage gradually rises to the
Bulk level (usually 14.4 to 14.6 volts) while the batteries draw maximum current. When Bulk
level voltage is reached the absorption stage begins.
2) ABSORPTION: During this phase the voltage is maintained at a bulk voltage level
for a specified time (usually an hour) whiles the current gradually tapers off as the batteries
charge up.
3) FLOAT\: After the absorption time passes the voltage is lowered to float level
(Usually 13.4 to 13.7 volts) and the batteries draw a small maintenance current until the next
cycle.
The relationship between the current and the voltage during the 3 phases of the charge
cycle can be shown visually by the graph below.
Fig 2.2 Working Cycle of a Solar Charge Controller

12
MPPT Maximum Power Point Tracking Most multi-stage charge controllers are Pulse
Width Modulation (PWM) types. The newer Maximum Power Point Tracking (MPPT)
controllers are even better. They match the output of the solar panels to the battery voltage to
insure maximum charge (amps).
For example: even though your solar panel is rated at 100 watts, you won't get the full
100 watts unless the battery is at optimum voltage. The Power/Watts is always equal to Volts
times Amps or P=E*I (see Ohm's law for more info). With a regular charge controller, if your
batteries are low at say 12.4 volts, then your 100 watt solar panel rated at 6 amps at 16.5 volts
(6 amps times 16.5 volts = 100 watts) will only charge at 6 amps times 12.4 volts or just 75
watts.You just lost 25% of your capacity! The MPPT controller compensates for the lower
battery voltage by delivering closer to 8 amps into the 12.4 volt battery maintaining the full
power of the 100 watt solar panels! 100 watts = 12.4 volts times 8 amps = 100 (P=E* I). The
Charge Controller is installed between the Solar Panel array and the Batteries where it
automatically maintains the charge on the batteries using the 3 stage charge cycle just
described.
The Power Inverter can also charge the batteries if it is connected to the AC utility grid
or in the case of a stand alone system, your own AC Generator. Summary If you are using
four 75 to 80 Watt solar panels, your charge controller should be rated up to 40 amps. Even
though the solar panels don't normally produce that much current, there is an 'edge of cloud
effect'. Due to this phenomenon I have seen my four 6 amp panels (4*6=24) pump out over
32 amps.
This is well over their rated 24 amps maximum. A good 3 stage 40 amp Charge
Controller will run about $140 to $225 depending on features like LCD displays. For eight 75
to 80 watt solar panels you would need two 40 amp Charge Controllers to handle the power
or you could increase your system voltage to 24 volts and still use just one 40 amp Charge
Controller.
13
2.3 Shunt Type Solar Charge Controller
Fig 2.3 Shunt Type Solar Charge Controller
2.3.1 Introduction
When connecting a solar panel to a rechargeable battery, it is important to use a charge

controller circuit to prevent the battery from overcharging. Charge control can be performed
with a number of different circuit types. Low-power solar systems can use a series analog
charge controller (voltage regulator), an example is shown as the upper part of this circuit.
Higher power systems can use a series switching charge controller, such as my SCC3 design.
Very large systems, such as grid-tied installations, often use a maximum power-point
(MPPT) charge controller. This shunt-mode circuit is best suited for low-power systems, it is
more efficient than charge controllers based on series-mode voltage regulators.
14
Series regulators (both analog and switching) control battery charging by interrupting
the flow of current from the solar panel to the battery when the battery reaches a preset full
voltage. MPPT controllers use controllable switching regulator circuits to convert PV power
to high voltage and back down to lower voltages, they are complicated and require a bit of
power to operate, but offer excellent efficiency on high power systems.
This circuit is for a switching shunt-mode charge controller. In a shunt-mode circuit, the
solar panel is connected directly to the battery via a series diode. The diode prevents battery
current from flowing back through the PV panel at night. When the solar panel charges the
battery up to the desired full voltage, the shunt circuit connects a resistive load across the
battery in order to absorb the excess PV charging current. An alternate but similar approach
to this switching shunt-mode PV regulator is the Analog Shunt-Mode circuit.
The main advantage of shunt-mode over series mode regulation is the lack of a switching
transistor in the power path between the solar panel and battery. Switching transistors are
non-perfect devices. They waste a percentage of available solar power as heat. Inefficiency in
the shunt-mode controller's switching transistor does not affect charging efficiency, it only
turns on when excess power is purposely being wasted. The main disadvantage of a shunt-
mode regulator is that the load resistor needs to be tuned to a particular type of PV panel.
This makes it harder to design as a general-purpose device. Also, for higher current designs,
the load resistor becomes large and expensive.
Another difference between series-mode and shunt-mode regulators is the load that the
power source (PV panel) sees. In series controllers, when the battery reaches the full point,
the power source current path is opened up. In shunt-mode controllers, the power source is
always presented with a load. This difference makes shunt-mode regulators suitable for use as
a regulator for a DC-output wind generator. Wind generators should always be connected to a
load in order to keep the blades from spinning too fast in gusts of wind. If a wind generator is
operated with no load, the rapid spinning can damage the blades and wear out the bearings.
2.3.2 Specifications
Solar Panel Open Circuit Voltage: 18V (36 cells)

Solar Panel Short Circuit Current: 200mA max (up to 1 A with a different load resistor).
Battery Voltage: 12V (nom.)
Battery Capacity: 0.1 to 20 Amp-Hours
15
2.3.3 Theory
Solar current is routed from the PV panel through the IN5818 Schottky diode to the
battery. When the battery reaches the full set-point, the circuit turns on the IRFD110
MOSFET transistor and the 68 ohm 3W dump load resistor is connected across the battery,
absorbing the unneeded charge current.
The 78L09 IC provides 9V regulated power for running the comparator circuitry.
Operational power for this circuit is provided entirely from the PV panel, there is virtually no
power taken from the battery at night. The two 100K resistors in series provide a regulated
4.5V reference point for use by both comparator circuits. The 2N3906 transistor is wired with
a zener diode in its base circuit. When the PV voltage is above 12V, the 2N3906 transistor
turns on and enables the comparator circuit. This stabilizes the comparator circuit in low-
sunlight conditions.
The battery voltage is scaled down by the 47K resistor and 100K potentiometer. The
lower half of the TLC2272 dual op-amp compares the scaled down battery voltage to the
4.5V reference voltage. When the battery voltage is above the full set-point voltage, the lower
opamp's output goes high and turns on the IRFD110 MOSFET which connects the dump load
resistor This activates the IRFD110 MOSFET transistor and the dump load resistor. It is
important to use a rail-to-rail op-amp such as the TLC2272CP here, standard op-amps will
not turn the MOSFET fully on and off.
When the load across the battery causes the battery voltage to drop, the comparator
circuit turns back off. This oscillation continues while solar power is available. The 300nF
capacitor across the op-amp slows the oscillation frequency down to a few hertz.
The upper half of the TLC2272 op-amp inverts the dump load control signal, and acts as
a buffer for driving the high intensity red LED. The LED turns on when the battery reaches
the full set point. The LED does not waste any useful charging power since it only turns on
when the battery is full; this is a useful feature since this charge controller is designed for low
power systems.
It should be possible to modify this circuit to run at more than 1 Amp, although your
author has not tried this. Higher current operation would mainly be useful as a wind generator
Regulator; a series-mode controller such as the SCC3 is a better choice for higher current PV
systems. Higher current operation would require replacing the IN5818 diode, the dump
resistor and IRFD110 MOSFET with higher power components. The dump load resistor
should be tuned as above to keep the battery voltage below the full point.
Caution should be used when constructing high power versions of the circuit. If any of
the components in the shunt circuit were to open up, the battery could become overcharged
and may even rupture or explode. Experimenters assume all liability for their work, be careful
out there.
16
2.3.4 Use
Place the PV panel in the sun, when the battery reaches the full set-point, the LED will
start to flash with short on-pulses and long off times. As the battery charging continues, the
LED flashing will change to long on-pulses and short off times. In cold climates, it may be
useful to use the load resistor's heat to keep the battery warm. The load resistor and the
battery can be mounted inside of an insulated container. Important: A suitably rated fuse
should always be placed between the battery's positive terminal and the rest of the circuitry.
2.4 PWM Solar Charge Controllers
Modem solar charge controllers use pulse width modulation (PWM) to extend battery
life. That means that the amount of power applied to the batteries is slowly lowered as they
get close to fully charged. It can also be used for float charging. PWM solar charge
controllers can also keep batteries in a fully charged state, also called float charging.
Fig 2.4 PWM Solar Charge Controller
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2.5 MPPT Solar Charge Controller
A maximum power point tracking controller (MPPT) is the most recent and complex
type of solar charge controller. It is able to convert excess voltage into amperage and can
control power loss. When electricity runs from the solar panels to the charge controller,
power loss can especially occur when the power voltage is low.
Power loss occurs when lower voltage in the wires runs from the solar panels to the
charge controller. A MPPT solar charge controller allows higher voltages in the wires and
reduces power loss significantly.
A MPPT solar charge controller might be more expensive than a PWM solar charge
controller, but is more effective and therefore worth the cost.
Fig 2.5 MPPT Solar Charge Controller
2.6 Difference between Solar Charge Controller and Solar Lighting Charge
Controller
The difference between SHS (Solar Home System) Controller and Solar Lighting
Controller is the timer function basically, controllers with timer enable you to take full use of
your electricity generated from you solar system. SHS controller is working at 7*24, that
means the load terminal on the controller will always has the voltage output, to supply power
to your home all day long. It can be turned off manually.
18
2.7 Features of Solar Charge Controller
Charge controllers, which protect battery from over charging and/or excessive discharge,
are the essential components of Solar PV systems. Solar Charge Controllers protects battery
from over charging and/or excessive discharge. The solar charge controller uses PWM
charging technology, so that as the battery reaches full charge, the PWM pulses slower,
gradually tapering off the charge. Pulsing is good for the batteries since it gently mixes the
electrolyte, preventing stratification and sulphation. Low voltage disconnect protects the
batteries from severe discharge by shutting off loads before the battery voltage drops to
damaging levels. Temperature compensation adjusts the set point voltages according to the
ambient temperature.
Features
• Excellent charging algorithm
• Temperature compensated set points
• Adequate protections and indications
• Negligible voltage drops
• Self consumption less than 5 mA
• Offers long life to batteries
• Non-corrosive terminals
• Compact in size and easy to install
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2.8 Technical Specifications of a Solar Charge Controller
Table 2.1 Specifications of a Solar Charge Controller
General
Application Solar electrification
Use Battery Charge controller
Operating temperature -10°C to 65°C
Storage temperature -10°C to 85°C
Charge controller type Micro controller based
Charging type Two step series PWM
charging algorithm
Battery temperature compensation -3m V to -4m V/°C /Cell
Solar Module size (Max.) 90Wp
Indications Charging, Low Battery, Full
Charge
Electrical
Nominal system voltage 12V DC
Charging current 6A
Load current 6A
Charge controller efficiency >95%
Idle consumption <5mA
Protections Against module revers
current flow,reverse battery
and overload,short circuit,
under and over voltage,under
and over temperature
Mechanical
Fixing Wall mounting with screws
Case Injection Moulded
Engineering Plastic
Connectors Heavy duty terminal
connectors
Size (Shipping) (mm) 115 X 100 X 40
Weight (Shipping) 180gm
20
2.9 Protections Provided by a Solar Charge Controller to a System
Overcharge Deep discharge Reverse polarity and lightning protections are incorporated
in the electronic control card. Temperature compensation and blocking diodes are also built
in control units.
Provided all three panels are of the same type and are located in the same sun exposure
you can simply parallel them and use one diode to prevent the battery from discharging into
them when in the dark. No need for equalizing resistors because the panels are current
limited. I would look for a charge controller designed for use with solar panels rather than
trying to use a automotive regulator. You'll find a bunch of them with an Internet search.
Series controllers develop less heat than parallel controllers but you have to be careful that
they do not generate RFI that might get into your receiver (many of the series mode units
utilize switch mode power supplies to generate the gate voltage for the switch FETs - the
Micro-M does not).
An automotive regulator uses considerable power at all times it is in operation (even

when it is dark, in this case). Their design is not concerned with wasted power. A three
terminal voltage regulator chip might do the job, and these are available in multi amp
versions (up to 5 amps, 1 think) but they waste 2 or 3 volts so you will get reduced output
from your solar cells.
On the assumption you are charging Lead-Acid leisure (deep cycle) batteries:
1) Solar panels usually have a reverse blocking diode included. If not, fit 1 diode in
series with each panel.
2) Depending on the nominal panel voltage output you might not need a charge
regulator, meaning that at full sunlight the output voltage might not get above
13.8 V (or 13.5 V when using sealed batteries).
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2.10 Solar Power Charge Controllers
A solar charge controller is needed only when an off-grid or hybrid solar system is
installed. These two types of systems utilize batteries, which are charged and discharged
daily. It is the charge controller's responsibility to. regulate the charging of the batteries from
the photovoltaic panels in order to. maximize the life of the batteries, and to. ensure
maximum power is transferred from the PV array to.the batteries.
Why Can't the Pbotovoltaic Panels be wired directly to the batteries?
Your battery array voltage is going to. be different than the voltage produced by your
PV array.
Let's say you have a 48VDC battery bank and a 650W PV array that has a max power
output of 10A at 65VDC. If we were to wire this directly to, the batteries, the batteries would
"pull" the PV array voltage down to 48VDC. This means the PV array is now pushing 10A at
48VDC into. the batteries, and not 10A at 65VDC.
Now power equals voltage times current. In other words, we are going to go from
65VDCx10A=650W, to 48VDCx10A=480W. In this scenario, you are losing 170W (650W-
480W), which equals 26% of the power your photovoltaic panels are producing. A charge
the controller will allow you to step down the voltage coming from the solar panels, without
losing this power.
It does this by reducing the voltage, but increasing the current So for our example
above, it would go from 10A at 65VDC to. 13.54A at 48VDC, giving you 48VDC x 13.54A
=650W. Hence photovoltaic panels cannot be wired directly to the batteries and a solar
charge controller is needed as a mediator.
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2.11 Characterization of Charge Controllers
The following table contains the typical parameters given on a charge controller data sheet.
This data is from the Xantrex XW-MPPT60-150 Solar Charge Controller.
Table 2.2 Characterization of Charge Controllers
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1. Nominal Battery Voltage
These are the array voltages at which the charge controller will work with.
2. Max. PV Array Voltage (operating)
This is the maximum PV array voltage that can be present at the input of the charge
controller while under full power operation.
3. Max. PV Array Open Circuit Voltage
This is the maximum PV array voltage that can be present at the input of the charge
controllers when no power is flowing from the PV array, i.e. open circuit.
4. Array Short-Circuit Current
This is the maximum current that the charge controller will accept, and is best rated at the
PV array short-circuit current.
5. Maximum and Minimum Wire Size in Conduit
This is the range of wire sizes that can be used to make connections to the charge
controller.
6. Total Power Consumption While Operating
This is the amount of power that the charge controller needs to operate. This power can be
considered power lost, and is not transferred to the output.
7. Charge Regulation Method
This is how the charge controller regulates the battery charging. This is best described
through a plot of charging over time. The following plot shows a voltage and current plot
over time for a 3-stage charging cycle. A two stage cycle would be identical, just lacking
the third or "float" stage.
24
8. Dimensions
Height, width, and depth of the charge controller unit.
9. Weight
Weight of the charge controller is in pounds and kilograms.
10. Mounting
How the charge controller is mounted.
11. Standard Warranty
The time duration of the manufacturer's warranty.
12. Enclosure Type
The type of physical enclosure that the charge controller unit is housed in.
13. Operating Temperature Range (full power)
The range of temperatures at which the charge controller can operate while at full power.
14. Storage Temperature
A temperature range at which the charge controller must be stored when not in use.
15. Altitude Limit
The maximum altitude at which the charge controller can operate at a given temperature.
This limitation is due to the decreasing density of air as you increase in elevation, which
reduces the ability of the charge controller to dissipate heat through convection.
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2.12 Advantages of a Solar Charge Controller
• A solar charge controller is needed in virtually all solar power systems that utilise
batteries. The job of the solar charge controller is to regulate the power going from the
solar panels to the batteries. Overcharging batteries will at the least significantly
reduce battery life and at worst damage the batteries to the point that they are unusable.
• The most basic charge controller simply monitors the battery voltage and opens the
circuit, stopping the charging, when the battery voltage rises to a certain level. Older
charge controllers used a mechanical relay to open or close the circuit, stopping or
starting power going to the batteries.
• More modern charge controllers use Pulse Width Modulation (PWM) to slowly lower
the amount of power applied to the batteries as the batteries get closer and closer to
fully charged. This type of controller allows the batteries to be more fully charged with
less stress on the battery, extending battery life. It can also keep batteries in a fully
charged state (called "float") indefinitely. PWM is more complex, but does not have
any mechanical connections to break.
• The most recent and best type of solar charge controller is called Maximum Power
Point Tracking or MPPT. MPPT controllers are basically able to convert excess
voltage into amperage. This has advantages in a couple of different areas.
• Most solar power systems use 12 volt batteries, Iike you find in cars. (Some use other
voltages and the same advantages apply to these systems as well.) Solar panels can
deliver far more voltage than is required to charge the batteries. By, in essence,
converting the excess voltage into amps, the charge voltage can be kept at an optimum
level while the time required to fully charge the batteries is reduced. This allows the
solar power system to operate optimally at all times.
26
• Another area that is enhanced by an MPPT charge controller is power loss. Lower
voltage in the wires running from the solar panels to the charge controller results in
higher energy loss in the wires than higher voltage. With a PWM charge controller used
with 12v batteries, the voltage from the solar panel to the charge controller typically has
to be 18v. Using an MPPT controller allows much higher voltages in the wires from the
panels to the solar charge controller.
• The MPPT controller then converts the excess voltage into additional amps. By running
higher voltage in the wires from the solar panels to the charge controller, power loss in
the wires is reduced significantly.
• MPPT charge controllers are more expensive that PWM charge controllers, but the
advantages are worth the cost. If you can afford it, you should definitely use an MPPT
charge controller.
• The final function of modem solar charge controllers is preventing reverse-current flow.
At night, when solar panels are not generating electricity, electricity can actually flow
backwards from the batteries through the solar panels, draining the batteries. You've
worked hard all day using solar power to charge the batteries; you don't want to waste all
that power! The charge controller can detect when no energy is coming from the solar
panels and open the circuit, disconnecting the solar panels from the batteries and stopping
reverse current flow.
2.13 Functions of a Charge Controller
1. Blocks reverse current

2. Prevents overcharge
3. Control set points versus temperature
4. Control set points versus battery type
5. Disconnect load at low voltages (i.e. LVD)
6. Overload protection
7. Displays and monitoring
27
Design of MPPT Solar Charge Controller 2012
CHAPTER 3
DESIGN OF A MPPT SOLAR CHARGE CONTROLLER
3.1 Integrated Charge Controller Circuitry
Circuitry that functions as a charge regulator controller may consist of several electrical
components, or may be encapsulated in a single microchip; an integrated circuit (IC) usually
called a charge controller IC or charge control IC.
Charge controller circuits are used for rechargeable electronic devices such as cell
phones, laptop computers, portable audio players, and uninterruptible power supplies, as well
as for larger battery systems found in electric vehicles and orbiting space satellites.
Charge controller circuitry may be located in the battery-powered device, in a battery

pack for either wired or wireless (inductive) charging, in line with the wiring, or in the AC
adapter or other power supply module.
3.2 MPPT solar charge controllers
Adding an MPPT solar charge controller to an existing system is a very popular upgrade
these days as people improve and expand their systems. MPPT controllers will get the most
out of your PV array, and actually are more beneficial in off-grid applications because they
produce the most benefit in the cold winter months when the batteries tend to be at a lower
state-of-charge-right when you need the energy the most!
3.2.1. MPPT solar charge controller schematic (What is MPPT?)
Solar arrays have a power curve with a maximum power point and the device that sets
this point is called a Maximum Power Point Tracker.
A MPPT, or maximum power point tracker is an electronic DC to DC converter that

optimizes the match between the solar array (PV panels), and the battery bank or utility grid.
To put it simply, they convert a higher voltage DC output from solar panels (and a few wind
generators) down to the lower voltage needed to charge batteries.
A maximum power point tracker (or MPPT) is a high efficiency DC to DC converter

which functions as an optimal electrical load for a photovoltaic (PV) cell, most commonly for
a solar panel or array, and converts the power to a voltage or current level which is more
suitable to whatever load the system is designed to drive.
28
3.2.2. Main features of MPPT solar charge controller
In any applications which PV module is energy source, MPPT is used to correct for
detecting the variations in the current-voltage characteristics of solar cell and shown by I-Y
curve.
MPPT solar charge controller is necessary for any solar power systems need to extract
maximum power from PV module; it forces PV module to operate at voltage close to
maximum power point to draw maximum available power.
MPPT allows users to use PV module with a higher voltage output than operating
voltage of battery system.
For example, if PV module has to be placed far away from charge controller and
battery, its wire size must be very large to reduce voltage drop. With a MPPT solar charge
controller,users can wire PY module for 24 or 48 V (depending on charge controller and PV
modules) and bring power into 12 or 24 Vbattery system. This means it reduces the wire size
needed while retaining full output of PY module.
MPPT solar charge controller reduces complexity of system while output of system is
high efficiency. Additionally, it can be applied to use with more energy sources. Since PV
output power is used to control DC-DC converter directly.
MPPT solar charge controller can be applied to other renewable energy sources such as
small water turbines, wind-power turbines, etc.
3.2.3. The benefits of MPPT solar charge controller
The benefits of MPPT solar charge controllers are greatest during cold weather, on
cloudy or hazy days or when the battery is deeply discharged. Solar MPPT can also be used
to drive motors directly from solar panels. The benefits seen are huge, especially if the motor
load is continuously changing. This is due to the fact that the AC impedance across the motor
is related to the motor's speed. The MPPT will switch the power to match the varying
resistance.
29
3.2.4. Compared with normal solar charge controller by Schematic Diagram
MPPT solar charge controller Schematic Diagram: Picture 2 shows typical 12V battery solar
charge system V-A curve.
Normal Solar Charge Controller: Solar Panel works at point A state, the solar panel working
voltage is a little higher than battery voltage.
Charge Voltage: UA=13.2V
Charge Current:: lA=9.8A
Charge Power: PA=13.2*9.8=129.36w
Area in drawing: ?+3
MPPT Solar Charge Controller: Solar Panel works at point B state, the solar panel working
voltage much higher than battery voltage.
Charge Voltage: UB=18.4V,
Charge Current:: lB=9.3A
Charge Power: PB=18.4*9.3= 171.12w
Area in drawing: ?+2
30
3.2.5. The price of MPPT solar charge controller
MPPT charge controllers are more expensive that PWM charge controllers, but the
advantages are worth the cost. If you can afford it, you should definitely use an MPPT charge
controller.
3.2.6. TRACER MPPT Technology
The TRACER utilizes Maximum Power Point Tracking technology to extract maximum
power from the solar module(s). The tracking algorithm is fully automatic and does not
require user adjustment, TRACER technology will track the array maximum power point
voltage (Vmp) as it varies with weather conditions, ensuring that maximum power is
harvested from the array through the course of the day.
• Current Boost
In many cases, TRACER MPPT technology will "boost" the solar charge current.
For example, a system may have 8 Amps of solar current flowing into the
TRACER and 10 Amps of charge current flowing out to the battery. The
TRACER does not create current! Rest assured that the power into the TRACER
is the same as the power out of the TRACER. Since power is the product of
voltage and current (Volts Amps), the following is true:
1. Power Into the TRACER-Power Out of the TRACER

2. Volts In into Amps In=Volts Out into Amps Out
o Assuming 100% efficiency. Losses in wiring and conversion ignored.

If the solar module's Vmp is greater that the battery voltage, it follows that the
battery current must be proportionally greater than the solar input current so that
input and output power are balanced. The greater the difference between the
maximum power voltage and battery voltage, the greater the current boost.
Current boost can be substantial in systems where the solar array is of a higher
nominal voltage than the battery.
31
3.2.7. An Advantage over Traditional Controllers
Traditional controllers connect the solar module directly to the battery when recharging.
This requires that the solar module operate in a voltage range that is below the module's
Vmp. In a 12V system for example, the battery voltage may range from 11-15Vdc but the
module's Vmp is typically around 16 or 17V. Figure 3-1 shows typical Current v/s Voltage
output curve for a nominal 12V off-grid module.
Fig 3.1 Nominal 12V Solar Module: I-V curve and output power Graph
The array vamp is the voltage where the product of current and voltage (Amps Volts) is
greatest, which falls on the "knee" of the solar module I-V curve as shown in Figure3-1.
Because Traditional controllers do not operate at the Vmp of the solar array, energy is wasted
that could otherwise be used to charge the battery and power system loads. The greater the
difference between battery voltage and the mp of the module, the more energy is wasted.
TRACER MPPT technology will always operate at the Vmp resulting in less wasted energy
compared to traditional controllers.
3.3 Design of a MPPT Charge Controller
Sustainable electrical sources like solar photovoltaic arrays are becoming increasingly
important as environmentally friendly alternatives to fossil fuels. But, while they're nice for
the environment, sustainable sources aren't always easy to apply.
These sources are characterized by both stringent peak-power limitations and "use it or
lose it" availability. Successful application of sustainable energy sources therefore depends
on strict attention to efficiency in both power conversion and energy storage. For small
systems, workable energy-management schemes usually include a rechargeable battery and
battery charger.
A shortcoming of this solution is that ordinary battery chargers, even efficient ones, do
an imperfect job of squeezing the last mill milli-watt from sustainable sources over realistic
combinations of ambient and battery conditions.
32
The circuit shown addresses this problem in small solar power systems.
Fig 3.2 This MPPT Charger,used in small solar system,overcomes the shortcoming of
ordinary battery charger
It works by continuously optimizing the interface between the solar array and battery.
The principle in play, sometimes called Maximum Power Point Tracking, is illustrated in the
I-V and P/V curves for a typical photovoltaic array exposed to "standard" sunlight intensity
(insolation) of 1 kW/m2.
To accommodate a useful range of insolation and battery voltage variation, designers

of solar panels make the number of cells large enough so that a useful level of charging
current is provided even when the light level is low and the battery voltage is high.
Consequently, when lighting conditions happen to be more favorable, these panels can
produce up to 50% more voltage and 30% more power than the battery wants. Simple direct
connection of panel to battery will therefore cause inefficient operation at point "A," with the
excess power lost as heat in the solar panel.
33
Figure 4.3 does better than that by combining a high-efficiency (»95%) SMPS circuit
(LTC I 149) with an analog power-conversion optimization loop. To understand how it
works, assume battery BI is in a state of discharge. In this condition, EI Will accept all of the
current the SMPS can supply (subject to the »2. 5-A current limit set by RSENSE) at a
voltage around 12 V.
The MPPT technique has much wider application than just photovoltaic alone. That's
because conceptually similar functionality of power output versus loading can be seen in the
I-V curves of other sustainable energy sources.
Such sources are small water turbines (e.g. the "Pelton wheel" impulse turbine of
Figure 3) and fixed-pitch-rotor wind-power turbines, when either is combined with constant
field alternators. The voltage, current, and power produced by any of these sources is highly
variable in response to ambient conditions (insolation, hydrostatic head, or wind-speed) and
dramatically dependent on the electrical impedance of the imposed load (V vs. J).
Under any combination of ambient conditions, each of these sources is characterized

by exactly one ideal load impedance, which will result in operation at VMPPT and maximum
power transfer. Also of benefit is the simplifying absence of confusing local maxima in the
power versus voltage curves.
Of course, the actual physics behind the I-V curves for the various sources are very
different. In the case of photovoltaic, the primary energy-producing process is recombination
of photoelectric charge carriers and how the rate of such recombination varies with output
voltage,temperature, and insolation. For wind-power generators, the dominant parameter is
the interaction of "Tip Speed Ratio" (defined as turbine peripheral velocity divided by wind
speed) with the aerodynamic design of the turbine. For small hydroelectric generators, it's the
fluid dynamics of the turbine or "runner" as they relate to the pressure and volume of the
available water source.
34
3.4 Components Used
Table 3.1 Compnents
35
Table 3.1 Components
36
3.5 Things to Consider When Purchasing a Charge Controller
Those are the basic requirements for a properly chosen charge controller. Beyond these
requirements, you'll also want to consider what types of features and protections you desire in
a charge controller:
• Efficiency:
Look for a charge controller with a minimum of 90% efficiency while operating at full
load and rated output voltage.
• Monitoring:
The best charge controllers will come with built-in monitoring systems that make it easy
for you to determine the performance of your solar system. These can include things like
audio and visual indications, alpha numeric displays including LCD screens, and so on.
These monitoring systems provide information such as output voltage (and alarms for
when it's low or high). battery levels (and alarms for low battery levels), kWh generated,
indicators for battery reverse polarity, alarms for over loads, and equipment circuit
breaker trips. Having a manual reset switch on your monitoring component can be helpful
for disabling alarms and resetting the system.
• Battery Discharge:
When not properly configured, batteries can discharge through the solar modules during
non-sunlight hours, which will decrease your system's efficiency. Look for a reverse flow
protection system to prevent these problems.
• Psophometric Noise:
Some charge controllers produce an excess of psophometeric noise which can disrupt the
signals for televisions, radios, telephones, and other electronic equipment within close
proximity. Look for a charge controller that limits this noise level to 2 mV.
37
• Overload Circuit:
Overloading and short circuiting of your system can occur. To prevent and protect against
this, look for a charge controller with a load/short circuit protection system to prevent fires
and other hazards.
• Reverse Polarity:
If you want to protect the other components in your electrical system, look for a charge
controller that has safeguards in place to protect against the potential damage caused by a
reversed polarity.
• Burn In Test:
This test helps determine that the charge controller is running as anticipated and therefore
is a handy function to have. The bum-in test should run tor 72 hours with the equipment
working at full rated load.
Of course, it is one thing to look for these ratings, but you should also verify that any
claims about the charge controller are true. Do these by asking for a test certificate that shows
any given charge controller to meet all of your requirements.
Other Considerations When Purchasing a Charge Controller
There are some other basic design specifications you may wish to consider. Though these
seem somewhat rudimentary, they will play a role in how well your charge controller suits
your needs:
• Dimensions:
The charge controller should be large enough (including battery and lightning protection
system) to house all of the components without hindering functionality, but not so large
as to require significant space.
38
• Distance Considerations:
Some charge controllers require close proximity between the batteries and the solar
panels, which can create problems with installation. The charge controller with flexibility
in distance requirements will make your life a whole lot easier.
• Expandability:
If you're planning on expanding your solar system in the future to accommodate

additional modules, ensure that your charge controller will be able to handle such system
design changes
• Quality:
Your solar modules will be with you for 20 years or more, and though your charge
controller isn't likely to last quite that long, it's important to choose one made with
quality materials. Look for ones that come in metallic boxes with captive screws and
washers. A hinged easy to operate door will also aid in making it easier for you to access
your charge controller and batteries. And look for components that are surfaced with
corrosion resistant finishes to prevent corrosion.
• Ventilation:
Your charge controller should have proper ventilation while protecting the charge
controller from inclement weather, including rain, snow, hail, and so on. Ideally the
hardware will be designed to cool the components through natural ventilation.
• Standards:
It's important that your charge controller meet minimum safety standards to protect you
and your system. Look for UL and cUL rated charge controllers whenever possible. It's
also recommended that you look for charge controllers that come with wiring and cabling
rated to be fire retardant as per IS 1554 with amendment 1 (June 94). A further test of
quality and workmanship would be to look for the charge controller to be made to
ISO9001-2000 (or later) standards).
39
• Instructions and Diagrams:
Be sure that your charge controller comes with basic circuit and cabling diagrams, safety
measures to be observed in handling the equipment, precautions for installation, detailed
drawings of the charge connector modules, procedures for routine maintenance,
preventive maintenance, troubleshooting, and replacement, and illustrations of internal
and external mechanical parts, all in your language to make the job of putting the system
in place as hassle-free as possible.
• Name Plate:
Be sure that your charge controller includes a name plate with all of the specifications for
your future reference, including name of the user, manufacturer's name and
identification, model number, type of unit, serial number, input voltage, output voltage
and current, and so on.
3.6 Sizing of a MPPT Solar Charge Controller
Most Solar Charge Controllers are rated by the amount of array amperage (current) and
voltage they can handle. Amperage ratings run from 1 amp to 60 amps, voltages from 6 to 60
volts. Cold weather, reflection and edge-of-cloud light refraction can increase PV panel
output. The charge controller should be sized to handle 25% more current than the panels are
rated for. Most people add solar panels as they go along; size the charge controller to handle
your needs into the future.
3.7 Requirement of Number of Solar Batteries
If you are going to have any sort of reliable long lasting solar power system, you need
configure a right battery or batteries. When we design a power system, we should consider
the weather of your location; maybe there are two or three rainy days. So when we configure
the power system, we need the batteries to supply those badly days.
Here I can show you a rough arithmetic to work out it. You want 500 watt hours of
battery backup. You want your battery bank to have a 12V DC voltage. Maybe there are three
continuous overcast and rainy days. (500W/12V/0.75)*3=167Amp hours. Amp Hours is how
battery storage is rated.
40
3.8 How to size your solar home system?
Sample Sizing Calculation
In order to size the system correctly, you need to note the power rating of each
appliance that will be drawing power from the system.
For this example, we will calculate the power requirements for a campervan with:
• 2 x 15W 12VDC Fluorescent Lights

• 1 x 60W 12VDC Water Pump
• 1 x 48W 12VDC Fridge
• 1 x 50W 240VAC TV
• 1 x 600W 240V AC Microwave
(Note that a 600W microwave will consume approximately 900W of power)
1. Calculate Loads: Calculate total DC and AC loads:
DC Loads
• Lighting - 2 x 15W DC Lights - each used 2 hours per day = 60Wh/day

• Pump - 1 x 60W DC Pump - used 1/4 hour per day = 15Whlday
• Fridge - 1 x 48W Fridge - runs 8 hours per day = 384 Wh/day
Total for DC Loads = 459Wh/day
AC Loads
• Television - 1 x 50W - used 2 hours per day = 100Wh/ay

• Microwave - 1 x 900W - used 15 min per day = 22SWh/day
Total for AC Loads = 325Wh/day
Allowing for inverter efficiency of 85% = 382Wh per day (ie. 325/0.85)
Total for AC and DC Loads = 841Wh per day
41
2. Calculate Required Solar Input
In Central to Northern NSW expect a usable average of around 5 peak sun hours per day.
Required solar panel input = (841 Wh/5h) * 1.4 = 235W
Note: The 1.4 used in this formula is a factor we have found that can be used to simplify
the calculations for basic systems.
To ensure that adequate power is produced in the winter months, use a figure of around
4.0 to 4.5 peak sun hours per day instead of 5.
3. Select Solar Panels
Select solar panels to provide a minimum of235W. Always best to go bigger if possible:
• 2 x 123W solar panels chosen which, when connected in parallel, will provide 246W or
14.32 Amps.
4. Select Solar Regulators
The rated short circuit current of the 123W solar panels is 8.1 Amps each, giving a total
of 16.2 Amps.
Select a solar regulator that is more than capable of handling the total short circuit
current: 16.2 x 1.25 = 20.25 Amps
• Steca 30Amp regulator chosen.
Note that, as described in the notes above, you must allow 25% extra capacity in the regulator
rating as solar panels can exceed their rated output in particular cool sunny conditions. A 30A
regulator will allow for an additional panel in the future.
42
5. Select Inverter
Select an inverter that is more than capable of supplying the maximum anticipated combined
AC
load required. In this example, maximum load would occur if the microwave and TV were
running at the same time. Load in this case would be 900W + 50W = 950W.
Note that this calculation assumes that the inverter selected has a suitable surge rating to cope
with the start-up surges of the microwave or other loads. A 1000W inverter would appear to
be suitable, but a 1200W - 1500W inverter would be recommended.
• 1200Watt pure sine wave inverter chosen.
Note: A pure sine wave inverter is the preferred choice, but if the budget is tight, a modified
sine wave unit could be used.
6. Select Battery
Select a battery, or a matched combination of batteries, that is capable of supplying the

total power usage without being discharged more than 70%.
In most cases it is recommended that the batteries are sized such that they have around 3
to 4 days back-up capacity. This allows for days with low sunlight and reduces the daily
depth of
discharge resulting in longer battery life.
With 3 days storage capacity, the battery sizing would be as follows:
• Ah Required = (841 Wh * 3/12V) / 0.7 * 1.1 = 330Ah.
43
OUR CONTRIBUTION
We will provid the solutions for increasing the efficiency of solar system by
compensating temperature of the system.Now,Most efficient solution is the inclusion of a
solar charge controller in the solar energy system.
The principle behind a solar charge controller is simple. There is a circuit to measure the
battery voltage, which operates a switch to divert power away from the battery when it is
fully charged. Because solar cells are not damaged by being short or open-circuits, either of
these methods can be used to stop power reaching the battery.
Out of many charge controllers available, a MPPT solar charge controller is the most
efficient solution. Hence we have decided to provide a design for developing a MPPT solar
charge controller. The industry, VIMAL ELECTRONICS is satisfied from our provided
solution to their problem. MPPT charge controller is costly as compared to its other
counterparts but is more effective and therefore worth the cost.
Difficulties of Our Solution
Our project i.e. MPPT solar charge controller can be implemented but the initial cost of
this controller is very high compared to other charge controllers. On the contrary, the
efficiency of the system can be increased more than any other charge controller by a MPPT
charge controller as it targets the highest output possible from array and convert the excess
voltage into higher charging amperage. On average MPPT controllers can typically generate
20 to 30% more power output from array in comparison to their PWM counterparts.
44
CONCLUSION
More energy, and thus higher efficiency, can be extracted from a photovoltaic system if
the photovoltaic (solar) panel is operating at its maximum power point. This maximum power
point represents maximizing the area under the solar panel's intrinsic 1-V operating curve. A
DC/DC power converter can be used to electrically match the charge controller's operating
voltage to that of the solar panel. As a solar panel's intrinsic 1-V curve shifts depending on
environmental and other factors, the charge controller must move its operating point to the
current maximum power point This maximum power point tracking (MPPT) system can be
achieved by using a low cost micro-controller to modulate the charge controller's power
point. The charge controller must sample the solar panel's voltage and current output to
evaluate whether the charge controller is operating at panel's current maximum power point.
A boost converter was designed and built to maximize the power delivered from the source.
A microcontroller was used as the control element and firmware was developed to locate the
maximum power point. It was that the maximum power point of the lab power supply was at
approximately 0.33 duty cycle. It was determined that the circuit and algorithm operated to
our design specifications. Future work could address the issue of maximizing converter losses
while maximizing power to the load.
45
BIBILIOGRAPHY
1. Solar Cells and their Applications Second Edition, Lewis Fraas, Larry Partain, Wiley,
2010, ISBN 978-0-470-44633-1 , Sectionl0.2.
2. "Invert your thinking: Squeezing more power out of your solar panels".
www.scientijicamerican.com. Retrieved 2011-06-09.
3. "Characteristic Resistance "www. pveducation.org. Retrieved 2011-06-09.
4. "Evaluation of Micro Controller Based Maximum Power Point Tracking Methods Using
dSPACE Platform ..www. ltee.uq.edu.au. Retrieved 2011-06-14.
5. Comparative Study of Maximum Power Point Tracking Algorithms. doi: 10.1002/pip. 459.
6. "How Inverters Work". solar.gwu.edu. p. 3. Retrieved 2011-06-10.
7. "UL 1741 UPDATE A SAFETY STANDARD FOR DISTRIBUTED GENERATION".

eere.energy.gov. Retrieved 2011-06-10.
8. "Hi-MW Electronics - One key to a Future Grid which is Smarter, Greener, more
Robust and more Reliable". nist.gov. Retrieved 20/1-06-10.
9. Photovoltaics: Design and Installation Manual. Newsociety Publishers. 2004. pp. 80.
10. "Summary Report on the DOE High-tech Inverter Workshop". Sponsored by the US
Department of Energy, prepared by McNeil Technologies. eere.energy.gov. Retrieved
2011-06-10
11. "Charge Controllers for Stand-Alone Systems" (Web page), part of A Consumer's Guide
to Energy Efficiency and Renewable Energy, u.s. Department of Energy. Retrieved on
2007-08-20.
12. Brown, David. "Technical Article: Battery Charging Options for Portable
Products." (Commercial website). Analogic Tech, 2006-07-01. Retrieved on 2007-08-21.
13. "United States Patent 5475294: Charge controller for ballery charger. " (Website)
Freepatentsonline.com. Retrieved on 2007-08-21.
14. "Remote Observation Station, Entry #F2040: Abstract. " Circuit Cellar Flash Innovation
2003 Design Contest, via circuitcellar.com. 2003. Retrieved on 2007-08-21.
46

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CONTROLLING EFFICIENCY OF PV SOAR MODULES

Project Guide Head of Department

Electrical Engineering Department

CONTROLLING EFFICIENCY OF PV SOLAR MODULES

Jani Keyur M. (090180109066)

VIIth Semester B. E. (Electrical)

Industrial Co-ordinator: Departmental Guide:

Mukesh Parmar V R Patel

Electrical Engineering Department

Government Engineering College, Dahod

This is to certify that Jani Keyur M. of 7th semester, Electrical

Guide: Head of Department

INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM

FIRST NAME 1. Mishra Bipinkumar K.

MOBILE NO. 1.9722915683

COLLEGE NAME Government Engineering Collage, Dahod

.................... INDUSTRY COORDINATOR

Controlling Efficiency of PV Solar Modules by Compensating Temperature

June-20l2 Introduction of project

July, August-20l2 Study different components used in

September-20l2 Design of solar charge controller.

October, November-20l2 Manufacturing process.

December-20l2 Testing process.

January-2013 Identifying the problems occurring due to

February, March-20l3 Finding solutions

April-20l3 Reporting solution.

Figure No. Figure Description Page No

Figure 1.1 Solar Charge Controller 3

Figure 1.2 PWM Solar Charge Controllers 6

Figure 1.3 Advanced Lighting Controller. 7

Figure 1.4 MPPT Solar Charge Controllers 7

Figure 1.5 MPPT Lighting Controller (Thin Fllm) 8

Figure 2.1 Solar Charge Controller: Circuit Diagram 11

Figure 2.2 Solar Charge Controller: Working Cycles 12

Figure 2.3 Shunt Type Solar Charge Controller. 14

Figure 2.4 PWM Solar Charge Controller: Circuit Diagram 17

Figure 2.5 MPPT Solar Charge Controller: Circuit Diagram 18

Figure 3.2 MPPT Solar Charge Controller: Circuital Design 33

Table No. Table Description Page No.

Table 2.1 Specifications of Solar Charge Controller 20

Table 2.2 Characterization of Charge Controllers 23

Table 3.1 MPPT Solar Charge Controller: Components Used 35-36

Work Plan / Shedule

1.3 Operating Principle……………………………………………………………...2

1.4 Necessity of Solar Charge Controller……………………………………………..2

1.5 General Classification................................................................................4

1.6 Type of Solar Charge Controller……………………………………………….4

1.6.1 PWM Solar Charge Controller……………………………………………..6

1.6.2 MPPT Solar Charge Controller........................................................7

1.7 Comparison between PWM and MPPT Charge Controller.........................9

1.8 Pros and Cons of PMW and MPPT Charge Controller……………………....10

2.2 Working Cycle of a Solar Charge Controller…………………………………………….12

2.3 Shunt Type Solar Charge Controller……………………………………………………..14

2.4 PWM Solar Charge Controller…………………………………………………………..17

2.5 MPPT Solar Charge Controlle…………………………………………………………..18

2.7Features of Solar Charge Controller……………………………………………………...19

2.8 Technical Specification of a Solar Charge Controller…………………………………...20

2.9 Protection Provided by a Solar Charge Controller to the System………………………..21

2.10 Solar Power Charge Controller…………………………………………………………22

2.11 Characterization of a Charge Controller………………………………………………..23

2.12 Advantages of a Solar Charge Controller………………………………………………26

2.13 Functions of a Charge Controller……………………………………………………….27

3.1 Integrated Charge Controller Circuitry.........................................................28