CHAPTER 4

CIRCUIT OPERATION AND CALCULATION

4.1. Charge Controller Circuit Operation

Figure 4.1. Circuit diagram of charge controller

The wind turbine charge controller circuit is made up of four stages, namely;
the current booster, the power supply unit, the battery level indicator and the battery
charge controller. The complete circuit diagram of charge controller is shown in
Figure 4.1. The current booster ensures that maximum current is got from the output
of the solar panel through the use of a pass transistor (MJ2955); this current goes
through to charge the battery, a variable voltage regulator (LM317) sets a constant
output voltage of 14.3V to charge the battery and blocking diodes ensure that current
flows in the required direction. The battery level indicator monitors the charge of the
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battery through the use of a comparator which compares a reference voltage, to the
voltage of the battery and indicates through LEDs if the battery is fully charged or
undercharged. The power supply unit supplies a constant output voltage of 12V to the
comparator circuits in the design to ensure that unstable power output is avoided and
this is used as the reference voltage which is compared to the battery’s voltage. The
battery charge controller cuts off the battery from charging when fully charged
through the use of a comparator IC and a relay. When the battery is not full, the IC is
positively saturated, the transistor conducts, the relay is energized and the contact
closes ensuring that the current flows through to charge the battery. When the battery
is charged full, the IC is negatively saturated, the transistor doesn’t conduct, the relay
is de-energized and the contact opens and current seizes to flow to the battery.

4.2. Current Booster

Figure 4.2. Current booster circuit

The LM317 keeps the voltage constant and can handle a maximum of 1A; so
if the panel produces a current of less than 1A, the transistor does not conduct and the
current flows through the LM317 to charge the battery. If current is above 1A, the
transistor conducts because there is a voltage drop across R 1 that is large enough to be
the base voltage of the transistor to be turned on. Current booster circuit is shown in
Figure 4.2. To ensure that the transistor does not conduct when the current is still less
than or equal to 1amp, can be calculated the value of R 1. The drop should be less than
0.7V for the transistor not to conduct so; hence
V=IR1 (4.1)
V=0.7V; I=1A, the value of R1 is 0.7Ω
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At above 1amps, the voltage drops exceeds 0.7V and the transistor conducts
and the excess current flows through to the battery via the pass transistor.

To get Vout, can be calculated by using voltage divider rule;

R2= 220Ω, R3 = 2.3kΩ, Vref= 1.25V (LM317 rating),
R3
Vout= (1+ R2 ) Vref (4.2)
2. 3k
Vout= (1+220 ) x 1.25V = 14.3V
Diode D1 and D2 are blocking diodes. The diodes used here should be able to
withstand a fault current of more than 10A. The diode 6A1D is used in this circuit
with forward current I f=15A and peak inverse voltage PIV=100V.

4.3. Battery Level Indicator

This circuit monitors the level of charge of the battery. The circuit diagram of
battery level indicator is shown in Figure 4.3.

Figure 4.3. Battery level indicator

The circuit used an Op amp, LM358 as comparator. If the voltage that appears
across the inverting terminal is higher than the reference voltage, the output of the
comparator is low, which will be forward biased with the diode close to R 5, making it
come on, indicating that it is fully charged and it needs to stop charging and it is cut
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off with the help of the charge controller circuit. The diode near R6 is reverse biased
and doesn’t conduct.
The values of R5 and R6 can also be calculated by using Equation (4.3),
V S −V D
R = ID (4.3)
When VS = 12V, VD = 2V, ID = 20mA
12V-2V
R5 = R6 = 20mA = 500Ω

4.4. Battery Charging Control Circuit

Figure 4.4. Battery charging control circuit

The circuit makes use of a comparator IC (LM358) and a relay with a contact
of 30A. Figure 4.4 shows the battery charging control circuit. When the IC is
positively saturated, it means the battery needs to charge; the transistor conducts,
collector current flows, the relay is energized and the contact closes, current then
flows to the battery to charge it. When negatively saturated (when full), the transistor
doesn’t conduct, the relay is de-energized and the contact opens and current seizes to
flow to the battery and it doesn’t charge. The transistor used is BC547 and to ensure
that it operates at cut off or saturation,
RB = 10RC (4.4)
Where, RB = Base resistance of the transistor (RB=RB)
RB = 10×400 = 4000Ω (4.7 kΩ was use as a practical value)
RC = Impedance of coil relay (A value of 400Ω was used for RC)
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The diode used is 6A1D. It is a free-wheeling diode. It removes residual

current generated by the inductor as it creates a free wheel till the current dampens
out.

4.5. Fixed Voltage Regulator

Figure 4.5. Fixed voltage regulator

This circuit acts as a stable power supply to the battery level indicator. The
reason why this circuit is embedded in the charge controller is because it curtails
unstable power output through the use of a fixed voltage regulator (7812) that gives a
constant (fixed) regulated output voltage of 12V; the reference voltage for all
comparator circuits which the voltage of the battery is compared with. The circuit
diagram fixed voltage regulator is shown in Figure 4.5.
C1 is an optional filter capacitor (100 µF); it is present in the circuit, in case
there is an AC signal. The fixed voltage regulator is a DC device and won’t regulate,
if there is an AC signal. The fixed voltage regulator (7812) has a regulated output
voltage of 12V.
R1 is a current limiting resistor connected in series with an LED (power
indicator) that indicates that the circuit is on.
VS= 12V, VD = 2V, ID= 100 mA
V S −V D 12V−2V
R1= ID = 0 .01 = 1kΩ

4.6. Testing and Results

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The functionality of the charge controller depends on the fixed voltage output
of 14.2V from the current booster block of the solar charge controller; hence the test
data includes reading from an 80Ah, 12V battery charged for approximately four
hours under varying weather conditions.
1. Initial battery voltage level was 9.83V.
2. Battery voltage level after first four hours under exposure of panel to intense
sunlight was 11.3V.
3. Battery voltage level after approximately four hours under exposure of panel
to reduced sunlight intensity was 12.2V.

4.7. Result Analysis

1. After proper connection of the wind turbine and battery leads to their
respective terminals on the wind turbine charge controller, the power and
undercharging LEDs turn on to indicate battery charging.
2. After about 4 hours of charge, the optimum charge LED turns on indicating
full charge and undercharge LED turns off indicating that no more current is
getting to the battery. Generally the circuit performed satisfactorily.