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Documentos de Cultura
ANewSolar/WindChargeControllerBasedonthe555Chip
ANew&ImprovedChargeControllerBasedonthe555
Chip
Asimplechargecontrollerforsolarandwindsystems
UPDATEThis555basedsolarchargecontrollerprojecthaswonfirstplaceintheUtility
Categoryofthe555DesignContest!!!!!Scrolltothebottomofthepageformore
informationonthecontest.
SeveralyearsagoIbeganbuilding
myownwindturbinesandsolar
panelstoprovidepoweronmy
remote,offgridproperty.Acharge
controllerisanessentialpartofany
windorsolarsystemtoensurethe
batteriesaren'toverorunder
charged.Thechargecontroller
monitorsthebatteryvoltageand
switchesthebatteriesoffcharge
whentheyarefullycharged,and
switchesthembackonchargewhen
theyreachapresetlevelof
discharge.Thisisanewand
improvedchargecontrollerdesign
basedonthe555chip.
WhenIoriginallypostedmyhomebuiltwindturbine,solarpanelandchargecontroller
designsontheweb,theybecamewildlypopular.Lotsofpeopleallovertheworldhavebuilt
theirownversions.Igetfloodedwithemailseverydayfrompeoplewithcommentsor
questions.Averylargepercentageoftheemailsconcernproblemspeoplearehaving
buildingtheoriginalchargecontrollerdesign.Whilethedesigniscertainlymoreadvanced
thansomemiddleschoollessonplansinshopclass,it'scertainlydoableforanyreasonably
skilledperson.
Theoriginalchargecontrollerdesignisstillworkingafteryearsoffielduse.Lotsofpeopleall
overtheworldhavebuiltcopiesofit.Theoriginalstoryofthedevelopmentofthischarge
controllercanbefoundonmywindturbinepage.
Problemis,peoplewithlesselectronicsexperiencehadtroublebuildingitandgettingitto
work.Thecircuitwasrathercomplexandconfusingforelectronicsbeginners.Somepeople
infarflungpartsoftheworldwerehavingproblemsfindingallthenecessaryparts.Thedaily
floodofemailsrequestinghelpwithbuildingthechargecontrollerhavepromptedmeto
redesignit.
SoIsetmyselfthegoalofgreatlysimplifyingmysolar/windchargecontrollercircuit.Iwanted
togetitdowntoonlyoneICifpossible,andreducethenumberofothercomponentsas
muchaspossible.Ialsowantedtomakesureitonlycontainedeasytofindcomponentsthat
shouldbeobtainableprettymuchanywhereintheworld.Thatwaymaybemorepeople
wouldbeabletobuilditwithoutrunningintoproblems.
OneofmyfriendssuggestedIswitchtousingoneofthepopularmicrocontrollerchipsand
replacealltheanalogcircuitrywithonechip.Thatwouldcertainlygetthepartscountway
down.However,Iwasworriedthatthemicrocontrollerswouldbetooexpensiveordifficultto
obtaininsomepartsoftheworld,andtoodifficultfornontechnicalpeopletoprogram.I
decidedtostickwithanalogcircuitryfornow,thoughthemicrocontrolleroptionisapossibility
forthefuture.
http://mdpub.com/555Controller/
1/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
Hereistheschematicofmyoriginal
chargecontrollercircuit.Theheartof
thechargecontrollercircuitconsists
ofavoltagedivider,twocomparators,
andanSRflipflop.Myoriginalidea
wastoredesignitusingtheLM339
QuadComparatorIC.I'dneedtwoof
thecomparatorsforthiscircuit,and
couldmakeanSRflipflopusingthe
othertwoleftovercomparatorson
thechip.Iplayedaroundwiththis
ideaforawhile,andevenbread
boardedafewtestcircuits.Iwas
havingsometroublegettingittowork
rightthough.SoIshelvedtheproject
forawhileandworkedonother
things.
OneotherprojectIasworkingon
wasaPWMmotorspeedcontroller
forthepumpIusewithmy
recirculatingsluiceboxthatIusefor
goldprospecting.Thespeed
controllerusesa555timerchip.
Whilelookingatadiagramofthe
internalstructureofthe555chip,I
wasstruckbyhowcloselyit
resemblesmyoriginalcharge
controllercircuit.SuddenlyIrealizedI
couldredesignthechargecontroller
circuitusingthe555chipandgreatly
simplifythecircuitandreducethe
partcount.
http://mdpub.com/555Controller/
2/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
Comparethetwodiagramsonthe
lefttoseethesimilaritiesbetween
myoriginalchargecontrollercircuit
andtheinnardsoftheNE555timer
chip.Thecoloredboxesrepresent
similarsections.The555timercould
replace7componentsintheoriginal
circuit,andreducethetotal
complexityofthecircuitawholelot.
Thisisaverynontraditionaland"off
label"useofthe555chip,sinceI'm
notusingitasatimeratall.I'mco
optingit'sinternalorgansfora
completelydifferentusethanitwas
originallydesignedfor.
Isettowork.Inonlyaveryshort
time,Ihadaworkingprototype
circuitbreadboarded.Itworkedright
thefirsttry,whichisrareforme.I
almostalwaysmakesomesortof
boneheadmistakewiringthingsup.
http://mdpub.com/555Controller/
3/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
Hereisaschematicofthenew
chargecontrollercircuit.Clickonit
foralarger,clearerversion.
Iwascarefultouseonlyeasytofind
parts.TheNE555isprobablythe
mostpopularICinhistory.Billionsof
themaremadeeveryyear.Itshould
beeasytofindjustaboutanywhere
intheworld.Ialsoswitchedtoa5
Voltregulatorfromthe8Volt
regulatortheearlierversionused.
Peoplewerecomplainingthey
couldn'tfindit.Thetransistorisa
2N2222,NTE123,2N3904,orothersimilargeneralpurposesmallNPNtransistor.The
MOSFETisanIRF540orsimilarpowerMOSFET.IjusthappentohaveabunchofIRF540s
onhand,leftoverfromotherprojects.SoIusedoneofthemratherthanbuyingsomething
else.Usewhateveryoucanfind.
Alltheresistorsare1/8watt.1/4wattorhigherresistorscanbesubstitutedifyoudon'thave
1/8Wattresistors.Thetwotrimpots,R1andR2,shouldideallybemultiturnunits,but
ordinarysingleturnunitscanbesubstituted,withaslightlossofprecisioninthetuning.I
used10KtrimpotsbecauseIalreadyhadthemonhand.Anyvaluebetween10Kand100K
oughttoworkjustfine.10%toleranceisplentygoodenoughonallthepassivecomponents.
Thereisnoneedforanyprecisionpartsinthiscircuit.
UPDATE
IhavemodifiedtheaboveschematicbyaddingoptionalresistorsR8*andR9*.These330
Ohmresistorsarenotrequiredtomakethecircuitwork,butwillhelpprotectagainst
accidentalshortcircuitsifthetrimpotsareatthelimitsoftravelandthepushbuttonsare
pressed,orifbothpushbuttonsarepressedatthesametime.Mydesignherewas
deliberatelyminimalistandIomittedthesesafetyresistorsthatwereusedonmyearlier,
morecomplexdesigns.However,aftermakingthisdesignpublic,Idecideditwouldprobably
beagoodideatoaddthembackinsoastopreventaccidents.
TherelayisageneralpurposeSPDTautomotiverelayratedat
40amps.Itshouldbeveryeasytofind.Getonefromanauto
partsstore,orsalvageonefromajunkedcarinascrapyard.I
haveincludedapinoutfortherelayforeaseofconnection.40
Ampsmayseemlikeoverkill,butitallowsforexpansioninthe
future.Youmaystartwithonlyonesmallsolarpanel,thenadd
afewmorelater,possiblyawindturbine,andabiggerbattery
bank.Eventuallythechargecontrollerwillneedtoswitchsomeseriouscurrent.Whynotbuild
inthecapabilityfromdayone?Allotherpartsarespecifiedbelow.
MostofthepartscanbepurchasedatyourlocalRadioShack,orpurchasedonlineat
Newark/Element14.Therestofthepartscanbefoundatautopartsstores.Youmightfind
theonlinesupplierstobemuchcheaper,especiallyifyouplanonbuildingseveralunitsand
needmultiplesofeachpart.YoucouldalsotrylookingfordealsonpartsonAmazon.com.I
buymyautomotiverelaysonEbay.Evenwithshippingitischeaperthantheautopartsstore,
andtheyaredeliveredrighttomymailbox.
IC178055VoltpositiveVoltage
Regulator
R3,R4,R51KOhm1/8Watt10%
IC2NE555TimerChip
R6330Ohm1/8Watt10%
PB1,PB2NOMomentaryContactPush
http://mdpub.com/555Controller/
R7100Ohm1/8Watt10%
4/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
Buttons
LED1GreenLED
LED2YellowLED
Q12N2222OrSimilarNPNTransistor
Q2IRF540OrSimilarPowerMOSFET
RLY140AmpSPDTAutomotiveRelay
D11N4001orsimilar
C10.33uF35V10%
C20.1uF35V10%
R1,R210KMultiTurnTrimPots
R8*R9*Optional330Ohm1/2WResistors
(seetext)
OnceIhadtheprototypeworkingon
thebreadboard,Ibuiltanotheruniton
apieceofRadioShackProtoboard
foruseinthefield.Itcametogetherin
onlyacoupleofhours,andagain,
workedthefirsttime(Imustbeliving
rightlately).Thismorerugged
versionwillgetmountedinaboxand
givenathoroughtestinginthefield.
NotethatonthisboardIhavechosen
tousethe78L05versionofthe5Volt
regulator.ItisinatinyTO92
package,thesamesizeasthe
2N2222transistor.Itisthesmall,
blackrectangleontheupperleft
corneroftheboard.Itsavesalotofboardspace.Itcanonlyhandle100mA,butthatis
plentyenoughtopowerthiscircuit.Ifyoucan'tfindthelittle78L05,youcanusethefullsize
TO220versionofthe7805,whichismuchmorecommon.Therewillbenopenaltyother
thanusingupalittlemoreboardrealestate.Ijusthappenedtohaveafewofthe78L05sleft
overfromanotherproject.
Onceyouhavethecircuitbuilt,itistimetotuneorcalibrateit.Iuse11.9Vand14.9Vasmy
lowandhighsetpointsforthecontroller.Thesearethepointswhereitswitchesfromsending
powertothebatteriestodumpingpowerintoadummyload,andviceversa(adummyloadis
onlyneededifyouareusingawindturbine,ifusingonlysolarpanels,thedummyloadline
canbeleftopen).
ProbablythebestwaytotunethecircuitistoattachavariableDCpowersupplytothe
batteryterminals.Setthepowersupplyto11.9V.MeasurethevoltageatTestPoint1.Adjust
R1untilthevoltageatthetestpointisascloseto1.667Vasyoucangetit.Nowsetyour
variablepowersupplyto14.9VandmeasurethevoltageatTestPoint2.AdjustR2untilthe
voltageatthetestpointisascloseto3.333Vasyoucangetit.
Testtheoperationofthechargecontrollerbyrunningtheinputvoltageupanddownbetween
about11.7and15.1Volts.Youshouldheartherelaypullinatabout14.9Voltsandopenat
about11.9Volts.Inbetweenthetwosetpointsthecontrollershouldstayinwhicheverstateit
isin.TheChargeandDumpbuttonscanbeusedtochangethestateofthecontrollerwhen
theinputVoltageisbetweenthetwosetpoints.
BeforeyouwritetomeandtellmethatmylowersetpointistoolowandIamover
dischargingmybatteries,considerthatthebatteryvoltageisn'tnormallygoingtogetthatlow
exceptunderload.Iftheloadwereremoved,thevoltagewouldrecoverovertimebackupto
wellover12V.Sothebatteriesaren'tasdeeplydischargedasyoumightthinkatfirstglance.
http://mdpub.com/555Controller/
5/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
OnceIhadthecircuitworking,I
mounteditinsideasemi
weatherproofenclosure.Therelayis
ontheleftside.Iusedabarrierstrip
tomakewiringeverythingtogether
easier.Iusedheavygagewireforall
thehighcurrentconnections.This
thingwasdesignedtoswitchupto
40Ampsafterall.Ialsoincludeda
fuseinlinewiththesolar/windinput
line.
Clickontheimageforalargerview.
Hereisanotherviewwiththelidin
place.Iusedthisenclosurebecause
Ihappenedtoalreadyhaveiton
hand,notbecauseitisthebestone
forthejob.Forpermanentoutdoor
useIwouldprefertouseamore
ruggedandweatherproofenclosure
likeIdidformyoriginalcharge
controllerdesign.However,Ilikethe
factthatIcanseetheLEDsthrough
thetranslucentlidandtellwhich
statethechargecontrollerisinata
glance,andIdidn'thavetodrillany
extraholesintheboxfortheLEDs.
Thisboxwillworkforfieldtesting
purposes.
Clickontheimageforalargerview.
Hereisasideviewoftheunit
showingthefeedthroughbarrier
stripwithalltheconnectionstothe
outside.Thereareconnectionsfor
thepositivesideofthebattery(s),the
positiveinputfromasolarpanelor
windturbine,thepositivesideofan
optionaldummyload,andthree
groundconnections.
Whenhookingupthecharge
controller,thebatteryshouldbe
connectedfirst.Thatwaythe
electronicswillhaveastablesource
ofpower.Ifasolarpanelorwind
turbineisconnectedfirst,the
controllerisliabletowildlyoscillatebetweenstates.
Ishouldexplainaboutdummyloads.ThetypeofwindturbinesIbuildhavenorealprovision
forbrakingorfurlinginhighwinds.Itisonlythepresenceofaconstantloadonthemthat
http://mdpub.com/555Controller/
6/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
preventsthemfromoverrevinginhighwinds.Sowhenthechargecontrollersensesthatthe
batteriesarefullychargedandswitchesthemoutofthecircuit,itswitchesinadummyload
(justabigexternalbankofhighwattageresistors)tosoakupthepoweroutputofthewind
turbineandkeepitunderload.Ifyouareusingacommerciallymadewindturbinewithbuiltin
overrevprotection,orusingonlysolarpanels,thenthedummyloadisn'tnecessaryandyou
canleavethedummylineunconnected.Youcanlearnmoreaboutdummyloadsonmywind
turbinepage.
Hereisanothersideviewshowing
thechargeanddumpbuttons.The
chargecontrollerwillautomatically
switchbetweenchargeanddump
whenthebatteryvoltagereachesthe
lowandhighsetpoints.Betweenthe
setpointsthecontrollerwillremainin
whicheverstateitisin.Thesebuttons
allowmetomanuallytogglethe
chargecontrollerbetweenthetwo
states.
Hereisaphotoofthefirstrealfield
testofthenewchargecontroller
design.Itseemedtobeworking
goodinmybenchtests,butIwanted
tomakesureitworkedrightunder
realworldconditions.SoIsetupone
ofmyhomemade60Wattsolar
panelsoutsidemyworkshopand
usedittochargeupadeepcycle
batteryusingthenewcharge
controller.Itworkedgreat.The
chargecontrollerletpowerruninto
thebatteryuntilitwasfullycharged
andthenswitchedtodumpingpower
soasnottooverchargethebattery.
Perfect!
Clickonthephotoforalargerversion.
http://mdpub.com/555Controller/
7/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
Hereisacloserphotoofthesetup.
Thebatteryisa36AHdeepcycle
unitoftenusedinpersonalmobility
scootersandmotorizedwheelchairs.
Ifindthattheyworkwellinsmall
scalewindandsolarpowersystems.
TheVoltmeterisshowing12.64
voltsonthebattery,whichis
essentiallyfullycharged.Thebattery
wasnearlyfullychargedwhenI
startedthistest.Ittookonlyashort
timeforthesolarpaneltotopitoff
andthechargecontrollertoswitch
overtodumping.Ahighlysuccessful
test.
TheonlyissueIhadduringthetestwasseeingwhichoftheLEDswasoninthebright
sunlight.Innormalusethoughthechargecontrollerwouldbemountedinashelteredand
shadyspotoutofthedirectsunlight.
Clickonthephotoforalargerversion.
X
NetworkAccessMessage:Thepagecannotbe
displayed
Explanation:Thereisaproblemwiththepageyouaretryingtoreach
anditcannotbedisplayed.
Trythefollowing:
Refreshpage:SearchforthepageagainbyclickingtheRefresh
button.ThetimeoutmayhaveoccurredduetoInternetcongestion.
Checkspelling:CheckthatyoutypedtheWebpageaddress
correctly.Theaddressmayhavebeenmistyped.
Accessfromalink:Ifthereisalinktothepageyouarelooking
for,tryaccessingthepagefromthatlink.
HereisabriefvideoIshot
duringthetestrun.Itshows
howthechargecontroller
automaticallyswitchesover
fromchargingtodumpingwhen
theuppersetpointisreached.
Ifyouarestillnotabletoviewtherequestedpage,trycontactingyour
administratororHelpdesk.
TechnicalInformation(forsupportpersonnel)
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UniformResourceLocator(URL).(12202)
IPAddress:173.194.117.78
Date:12/2/201411:54:30AM[GMT]
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Multiplesolarpanelsand/orwind
turbinescanbeconnectedtothis
unit.Allthepowersourcescanbe
connectedinparallelandfedintothe
singleinputconnection.Each
individualsolarpanelorwindturbine
needstohaveitsownblockingdiode
though.Hereisadiagramofa
typicalsystemwithawindturbine
andtwosolarpanelsfeedingthe
chargecontroller.TypicallyanAC
inverterisincludedinthesystemto
powerACloads.Clickontheimage
foralargerversion.
Peoplewritemeandaskwhytheyneedachargecontrollerandbatteries?Whynotjust
http://mdpub.com/555Controller/
8/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
connectthesolarpanelorwindturbinedirectlytotheinverterandbedonewithit?Well,the
answeristhatthesundoesn'talwaysshineandthewinddoesn'talwaysblow,butpeople
wantpoweranytime.Thebatteriesstorepowerwhenitisavailable,forusewhenitis
needed.
Imaydevelopaprintedcircuitboardforthisproject,iftimepermitsandthereissufficient
interest.I'llpostfurtherupdatesonthisprojectasitprogresses.
UPDATE
MyfriendJasonMarkhamhas
createdaPCBoardlayoutforthis
projectalmostassoonasIpostedit.
ClickthePCBtogotohiswebsite.
UPDATE
Peoplearewritingmeandaskingifthischargecontrollercanbeusedwith24Voltsystems,
andwhatchangeswouldbenecessary.Thecircuitshouldworkfinefor24Voltsystems.The
relaywillneedtobereplacedwithoneratedfor24Vcoilvoltage,andthepotswillhavetobe
recalibratedfornewhighandlowsetpointsforthehigherbatteryvoltage.The7805voltage
regulatorisratedforupto35Voltsinputvoltage,sonootherchangesinthecircuitshouldbe
necessary.
UPDATE
Inanefforttocreateacompact,neat
andportablesolarpowersystem,I
havemountedthechargecontroller
ontopofabatterybox.Ihavealso
mountedanACinverteronthebox.
Thisisamuchlargerandhigher
capacitybatterythanIwasusingin
myearlytestsofthecharge
controller.Theinverterandcharge
controlleraremountedonthebattery
boxwithindustrialstrength,sticky
backVelcro.
Hereisanotherviewofthesetup.As
youcansee,Ihavealsoincludeda
cigarettelighterstyleplugfor
powering12VDCloads.Itisa
completesolarpowersysteminone
small(butheavy)package.AllIhave
todoisconnectasolarpanelortwo
toit.Ican'twaittotryitoutonmy
nextcampingtrip.I'llhaveplentyof
powerinthewilderness.
http://mdpub.com/555Controller/
9/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
Ihavefinallydecidedtoditchmyold
batterybank,whichIhadbeen
luggingaroundonmywilderness
outingsforyears.Itwasabankof14
smaller12VAGMbatteries.Igotthe
batteriesessentiallyforfree,soI
wiredtheminparallel,putthemina
plasticbin,andusedthemwithmy
portablesolar/windpowersystem.
Thesetupwasveryheavyand
unwieldy.IkepttellingmyselfI'dget
ridofitandgowithonebigbattery
oncethelittlebatteriesstarteddying.
Theyhungonforyearsandyears.I
musthavebeentreatingthemright.
Finallytheystartedloosingcapacityanddyingoffonebyone.SoIwentoutandboughtone
bigbatterytoreplacethemall.Itisaboutthesamesizeandweightasacarbattery,butitisa
deepcycledesign,perfectforsolar/windsystems.IthasaboutthesameAHcapacityasthe
oldbankof14,butismuchsmallerandquiteabitlighter.Itonlysetmebackabout$200.Ifit
lastsasmanyyearsastheoldbank,I'llbeveryhappy.MybackwillalsobehappythatIdon't
havetolifttheoldbankof14batteriesanymore.
UPDATE
This555
basedsolar
charge
controller
projecthas
wonfirst
placeinthe
Utility
Categoryof
the555
http://mdpub.com/555Controller/
10/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
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Design
Contest!!!!!
Yahooooo!
Foranyone
interested,
hereisa
Youtube
videoof
Chris
Gammell
andJeri
Ellsworth
announcing
the555
contest
winners.
Thebit
wherethey
talkthis
projectat
aboutthe
47minute
mark.
Trythefollowing:
Refreshpage:SearchforthepageagainbyclickingtheRefresh
button.ThetimeoutmayhaveoccurredduetoInternetcongestion.
Checkspelling:CheckthatyoutypedtheWebpageaddress
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Accessfromalink:Ifthereisalinktothepageyouarelooking
for,tryaccessingthepagefromthatlink.
Ifyouarestillnotabletoviewtherequestedpage,trycontactingyour
administratororHelpdesk.
TechnicalInformation(forsupportpersonnel)
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Date:12/2/201411:54:30AM[GMT]
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Justtoclearuponedetailmentionedinthevideo,thisprojectwasnotactuallycreatedtobe
acontestentry.Ihadalreadyhadmy"EurekaMoment"aboutusingthe555toreplacea
wholebunchofpartsintheoriginaldesign,andwasbuildingtheprototypebeforeIeven
heardaboutthe555Contest.Itjustturnedouttobegreataccidentaltiming.Hearingabout
thecontestdidspurmetoquicklyfinishtheprototypeandgetthiswebpageupinatimely
mannerthough.
ManythankstoJeri,Chris,theotherjudges,andthesponsorsofthecontest.
UPDATE
Somethingreallycoolhappenedtoday.
IgotanemailfromChrisHackettfrom
theScienceChannelTVshowStuck
WithHackett.Heusedmy555Based
ChargeControllerDesigninoneofhis
buildsinaYoutubevideo.Hebuilta
bikepoweredgeneratorforrecharging
batteriesandneededacharge
controller.Hewasinspiredtobuildhis
generatorbythepoweroutagesafter
SuperstormSandy.Ihaveembedded
thevideohere.
http://mdpub.com/555Controller/
11/12
02/12/2014
ANewSolar/WindChargeControllerBasedonthe555Chip
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http://mdpub.com/555Controller/
12/12