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Relay Based Solar Charge Control

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6A, 6V Relay Based Solar

Charge Control
JIM KEITH (HTTP://WWW.ELECTROSCHEMATICS.COM
/AUTHOR/J-KEITH/)

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/sharer.php?u=http://www.electroschematics.com
LM339 (/tag/lm339) solar chargers (/tag/solar-charger-circuits)
This
/10288/6a-6v-relay-based-solar-charge-control/)
6V solar charge regulator meets most small-scale 6V
application
(https://twitter.com/share)
requirements. With a (/qa/)
current rating of 6A, it
can handle up to a 50W solar(/)
panel. Its principle of
operation is very simple and there is only one adjustment:
cut-out voltage. Many inexpensive commercial solar
charges available use, I believe, this technique. However,
this particular design is superior in that it is powered via
the solar panel rather than the battery –the implications
of this are obvious: low battery discharge current. The
switching is accomplished via an inexpensive 10A relay.

One of the interesting features is the secondary load

output that can be used for other purposes within speci�c
loading limits –in other words, there are two outputs: one
for charging the battery and the other for use when the
battery is not charging so that the solar power may be
more fully utilized. This is a low voltage extension of the
6A, 12V relay based solar charge control
(http://www.electroschematics.com/10186/12v-relay-solar-
charge-control/)
. While the new schematic may appear very similar, there
are subtle di�erences that are geared to make it function
for 6V applications. Also, I have speci�ed an alternative
10A Schottky recti�er in order to stretch the current
rating.

The application for this type of charge control is one in

which the battery capacity is large in respect to the
charging current; e.g. 6A solar panel charging a 60AH
battery in which it takes perhaps a full day’s sunshine to
fully charge the battery. For much smaller batteries, the
high charging rate and relatively high battery internal
resistance results in excessive terminal voltage so that
the control immediately interrupts charging –the end
result is that the battery cannot charge fully –a linear
charge regulator is more appropriate in such cases. Most
of the chargers that I have posted on electroschematics to
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date have been of the linear type. I have plans for at least
two more solar chargers, so keep watching.
(/)
Schematic of the Solar Charge Control Circuit

(http://www.electroschematics.com/wp-content/uploads
/2014/04/6A-6V-Relay-Based-Solar-Charge-Control-
Schematic.jpg)

555 datasheet (http://www.electroschematics.com

/650/lm555-datasheet/)
LM339 datasheet (http://www.electroschematics.com
/7068/lm339-lm239-lm2901-datasheet/)
LM317 datasheet (http://www.electroschematics.com
/6553/lm317-datasheet/)
Bill of materials

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 (/)

(http://www.electroschematics.com/wp-content/uploads
/2014/04/6A-6V-Relay-Based-Charge-Control-BOM.jpg)

6v relay charge control bom.xls

(http://www.electroschematics.com/wp-content/uploads
/2014/04/6A-6V-Relay-Based-Charge-Control-BOM.rar)
Circuit function
U2 provides a 2.5V reference voltage. U1 is a LM339 quad
comparator connected as a S-R �ip �op with wired OR
outputs so that it may be conveniently driven via open
collector output structure. U3 is a CMOS 555 clock
generator that generates 30mS pulses every 30S. Its
function is to set the �ip �op so that charging may
commence. (Another descriptive name for this topology is
“minimum on-time regulator.”) D1 e�ectively changes
the totem pole output of the 555 to open collector. As soon
as the battery terminal voltage exceeds the set point (7.2V
or so), comparator U1D resets the �ip �op and drops the
relay. At this point, it remains dormant until the next
clock pulse. When fully charged, the relay �ips on and o�
brie�y upon each clock pulse. U1C and Q1 constitute a
relay driver –the NPN open collector output of the LM339
and Q1 (PNP) make up the classic composite transistor
connection. This is necessary to boost the low power
output ofSearch
the LM339 su�ciently for driving the relay coil.
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Clock timing issue
Unlike the 12V version, the 555 is powered via a variable
(/)
voltage –when the relay drops or closes, the solar panel
input voltage makes step voltage changes. The timing
capacitor (C2) cannot follow this change in voltage and
causes the clock pulse timing to be somewhat variable.
Fortunately, this is of no consequence as the circuit
continues to function. This info is for the observant
technician.

Secondary output limitation

While this neat feature is provided, its application is
limited. Note that the load resistance is not allowed to
drag the solar panel output below about 5V under
marginal lighting conditions or else the relay may not
have su�cient voltage to pick up. This load could
conceivably operate a low-power heater etc. The big
challenge is to obtain the proper load resistance –a
number of aluminum resistors such as the Vishay /Dale
TMC50 series may be a good solution. Also, before
selecting the resistors make actual measurements to see
what works –even then, experimentation may be required
for best results.

Alternative recti�er for 10A current rating

(Note that this upgrade is applicable for just about all
previously published solar charge controls.)
The current rating is limited by D5 (6A) and the relay
contacts (10A). By using a 10A recti�er such as the Micro
Commercial Schottky SR1045, a 10A current rating is
feasible. To go beyond this, both a high current recti�er
and relay must be selected. Note that these recti�ers run
hot at the rated current, so additional PCB foil area or
other heat sink is be required. On one previous project, I
fabricated heatsinks by hammering pieces of AWG#14
wire into Search
�at strips and
4 million soldering them to both ends of
+ Products 
the recti�er. Note that the Schottky recti�er is very
desirable and well suited for this low voltage application
due to its low voltage drop (0.48V
(/) @ 6A or 0.55V @ 10A).
This means that it will function well if the solar panel
generates only 8V instead of the speci�ed 9 to 10V.

Setup
To set the Max Voltage Adjust (R12) potentiometer, start
with it turned CW, monitor the voltage and wait for the
battery terminal voltage to reach the desired voltage (e.g.
7.2V). At this point, turn R12 CCW until the relay drops.
When the relay picks up again, recheck the voltage at
which it drops.

Charging a dead battery

If the battery voltage is too low (e.g. 2 or 3V), the relay
may drop out immediately due to undervoltage. To get
around this problem, connect the solar panel directly to
the battery until the voltage charges to at least 5V or so, or
�ash it by connecting it directly across a charged battery
for a few seconds.

Photos

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/wp-content/uploads/2014/04/100-Bench-Setup.jpg)

(http://www.electroschematics.com

/wp-content/uploads/2014/04/100-Protoboard.jpg)

For the future

6A, 6V SSS based solar charge control
SolarSearch
charge control
4 million with synchronous recti�er
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 MPPT buck converter solar charge control
Selection guide for the various solar charge controls
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Fix for Akismet Error
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Related Tutorials

6A, 12V Relay Based Solar Charge Control

(http://www.electroschematics.com/10186/12v-relay-solar-
charge-control/)
6A, 12V SSS Based Solar Charge Control
(http://www.electroschematics.com/10218/sss-solar-charge-
control/)
6A, 6V SSS Based Solar Charge Control
(http://www.electroschematics.com/10327/6v-sss-based-solar-
charge-control/)
Solar Based Multipurpose Charger Circuit
(http://www.electroschematics.com/4809/solar-based-
multipurpose-charger/)

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