How to Easily Make A Solar Based Mini DC IPS at Home

How to Easily Make A Solar-Based Mini DC IPS at Home

Welcome back to our solar power guide! In addition to mastering the use of a 12V Solar Charge Controller, we're excited to show you how to create your own DIY Mini Solar DC IPS (Instant Power Supply) at home. This project will not only help you understand the principles of solar power but also provide you with a practical, off-grid power solution for emergencies or small-scale applications.

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Building a DIY Mini Solar DC IPS:

Now, let's dive into the step-by-step process of creating your very own solar-based Mini DC IPS:

Almost every solar-based system has a Battery associated with it which has to be charged from solar energy and then the energy from the battery will be used to drive the loads. There are multiple choices available for charging a lithium battery, we have also built a simple Lithium battery charging circuit previously. But to charge a battery with a solar panel, the most popular choice is the MPPT or maximum power point tracker topology because it provides much better accuracy than other methods like PWM-controlled chargers.

MPPT is an algorithm commonly used in solar chargers. The charge controller measures the output voltage from the panels and the battery voltage, then by getting these two data, it compares them to decide the best power that the panel could provide to charge the battery. Whatever the situation, whether in good or poor sunlight condition, the MPPT charge controller uses this maximum power output factor and converts this to the best charge voltage and current for the battery. Whenever the power output from the solar panel gets dropped, the battery charge current also decreases.

Thus, in poor sunlight conditions, the battery continuously gets charged according to the output of the solar panel. This is usually not the case in normal solar chargers. Because each solar panel comes with a maximum output current rating and a short circuit current rating. Whenever the solar panel cannot provide the proper current output, the voltage falls significantly and the load current does not change and crosses the short circuit current rating making the output voltage of the solar panel zero. Hence, the charging gets stopped completely in poor sunlight conditions. But MPPT allows the battery to charge even in poor sunlight conditions by controlling the battery charge current.

MPPTs are around 90-95% efficient in the conversion. However, efficiency is also dependable on the solar driver temperature, battery temperature, solar panel quality, and conversion efficiency. In this project, we will build a Solar MPPT charger for lithium batteries and check the output. You can also check out the IoT Based Solar battery monitoring Project in which we monitor some critical battery parameters of a lithium battery installed in a Solar System.

MPPT Solar Charger Circuit Diagram

The complete Solar Charge Controller Circuit can be found in the image below. You can click on it for a full-page view to get better visibility.

The circuit uses LT3652 which is a complete monolithic step-down battery charger that operates over a 4.95V to 32V input voltage range. Thus, the maximum input range is 4.95V to the 32V for both solar and adapter. The LT3652 provides a constant current/constant voltage charge characteristics. It can be programmed through current sense resistors for a maximum of 2A charge current.

On the output section, the charger employs 3.3V float voltage feedback reference, so any desired battery float voltage up to 14.4V can be programmed with a resistor divider. The LT3652 also contains a programmable safety timer using a simple capacitor. It is used for charge termination after the desired time is reached. It is useful to detect battery faults.

The LT3652 requires MPPT setup where a potentiometer can be used to set the MPPT point. When the LT3652 is powered using a solar panel, the input regulation loop is used to maintain the panel at peak output power. From where the regulation is maintained depends on the MPPT setup potentiometer.

Components Required for Building MPPT Controller

LT3652 Driver
1N5819 - 3 pcs
10k pot
10uF Capacitors - 2 pcs
Green LED
Orange LED
220k resistor
330k resistor
200k resistor
68uH Inductor
1uF capacitor
100uF capacitor - 2 pcs
Battery - 7.4V
1k resistors 2 pcs
Barrel socket

Solar Charge Controller PCB Design

For the above-discussed MMPT circuit, we designed the MPPT charger controller circuit board that is shown below.

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The design has the necessary GND copper plane as well as proper connecting vias. However, the LT3652 requires an adequate PCB heat sink. This is created using the GND copper plane and placing vias in that solder plane

Materials Needed:

12V Solar Panel
12V Solar Charge Controller with LCD Display (the one we discussed earlier)
12V Lead-Acid Battery
DC-to-AC Power Inverter (if you need AC power)
DC Loads (such as LED lights, DC fans, or USB chargers)
Connecting wires
Mounting hardware (for securing the solar panel)

Step 1: Prepare the Components

Gather all the necessary components for your Mini Solar DC IPS project. Ensure that the solar panel, charge controller, battery, and DC loads are compatible with each other.

Step 2: Mount the Solar Panel

Mount the solar panel in a location that receives ample sunlight throughout the day. Use mounting hardware to secure it in place, ensuring that it is angled correctly for maximum sun exposure.

Step 3: Connect the Components

Connect the solar panel to the charge controller, and then connect the charge controller to the battery. Make sure to follow the proper polarity and wiring diagrams provided with the components.

Step 4: Configure the Charge Controller

Use the LCD display on the charge controller to configure the settings according to your battery type and system requirements. This step is crucial for optimizing the charging process and prolonging the battery's lifespan.

Step 5: Connect DC Loads

Connect your DC loads, such as LED lights or DC fans, directly to the battery terminals or through the load terminals on the charge controller. This will allow you to power your devices directly from the solar-charged battery.

Step 6: Optional: Add a Power Inverter (for AC Power)

If you need AC power for certain devices, you can connect a DC-to-AC power inverter to the battery terminals. This will convert the DC power from the battery into AC power that can be used to power standard household appliances.

Step 7: Test and Monitor

Once everything is connected, test your Mini Solar DC IPS to ensure that it's functioning correctly. Monitor the system regularly to gauge its performance and make any necessary adjustments to maximize efficiency.