MCU BASED SOLAR CHARGER

MICROCONTROLLER BASED SOLAR CHARGER

N.B PATEL POLLYTECHNIC, COLLEGE

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MMIICCRROOCCOONNTTRROOLLLLEERR BBAASSEEDD SSOOLLAARR

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CREATED AT ROYAL CIRCUIT DESIGNED,

GANDHINAGAR

DIPLOMA OF ENGINEERING IN

ELECTRONICS & COMMUNICATION

SUBMITTED BY

NAME ENROLLMENT NO

BHADANI DIPESH G.

DEVDA SHRIPALSINH D.

106680311033

106680311012

NN..BB..PPAATTEELL PPOOLLYYTTEECCHHNNIICC,, PPIILLUUDDAARRAA

22001122--22001133

INTERNAL GUIDE EXTERNAL GUIDE

Mr. RITESH PATEL Mr. ALKESH SUKHADAIYA




AAFFFFIILLIIAATTEEDD TTOO

GGUUJJAARRAATT TTEECCHHNNOOLLOOGGIICCAALL UUNNIIVVEERRSSIITTYY

CCEERRTTIIFFIICCAATTEE

This is to certify that Mr. DEVDA

SHRIPAL DUNGERSINH having Enrollment No.

106680311012 of 6th Semester Diploma Course in Electronics &

Communication Engineering has satisfactorily completed AN

INDUSTRY DEFINED PROBLEM (IDP PART-1 & PART-2) project

work.

Having title: MCU BASED SOLAR CHARGER

He has undergone the process of shodh yatra, literature survey &

problem definition along with the complete solution to meet the

objectives stated in the definition.

IDP-GUIDE

(R.H.PATEL)

I/C HOD

(R.H.PATEL)

DATE OF

SUBMISSION:

EXTERNAL EXAMINER




AAFFFFIILLIIAATTEEDD TTOO

GGUUJJAARRAATT TTEECCHHNNOOLLOOGGIICCAALL UUNNIIVVEERRSSIITTYY

CCEERRTTIIFFIICCAATTEE

This is to certify that Mr. DIPESH

GORDHANBHAI BHADANI having Enrollment No.

1096680311033 of 6th Semester Diploma Course in Electronics

& Communication Engineering have satisfactorily completed AN

INDUSTRY DEFINED PROBLEM: (PART-1 & IDP PART-2) project

work.

Having title: MCU BASED SOLAR CHARGER

He has undergone the process of shod yare, literature survey &

problem definition along with the complete solution to meet the

objective stated in the definition.

IDP-GUIDE

(R.H.PATEL)

I/C HOD

(R.H.PATEL)

DATE OF

SUBMISSION:

EXTERNAL EXAMINER



CERTIFICATE

This is to certify that Bhadani Dipesh Gordhanbhai

Enrollment No. 106680311033 of Diploma Electronics & communication

He has successfully completed PROJECT WORK carried out in the

particular topic of MICROCONTROLLER BASED SOLAR CHARGER

in our company. He has prepared its journal during the academic year 2012-

2013 from Narayanbhai Bhikhabhai Patel Polytechnic, Meshana – Visnagar

Highway, Basana Education Campus, AT & PO: Piludara, Ta & Dist

Meshsana, Gujarat, India.

Place: - Gandhinagar For, Royal Circuit Design

Date: - 25-04-2013

Propritpr



CERTIFICATE

This is to certify that Devda Shripal Dungarsigh

Enrollment No. 106680311012 of Diploma Electronics & communication

V & VIth

semester in the Branch of Electronics Engineering. He has

successfully completed PROJECT WORK carried out in the particular

topic of MICROCONTROLLER BASED SOLAR CHARGER in our

company. He has prepared its journal during the academic year 2012-2013

from Narayanbhai Bhikhabhai Patel Polytechnic, Meshana – Visnagar

Highway, Basana Education Campus, AT & PO: Piludara, Ta & Dist

Meshsana, Gujarat, India.

Place: - Gandhinagar For, Royal Circuit Design

Date: - 25-04-2013

Propritpr



AKNOWLEGMENT

I owe a great many thanks to a great many people who helped and supported me

during the writing of this project report.

I would love to say my deepest thanks to Mr. ALKESH SUKAHDIYA; the

external guide of the project for guiding me in each difficulty that I found during the

entire period of the project.

I express my thanks to lecturer, Mr. RITESH PATEL (Head of Department

Electronics and communication engineering) the internal guide of my project. He has

taken pain to go through the entire project and make necessary correction as and when

needed.

I would also my institution and my faculty members without this project would have

been a distance reality.

I also extend my heartfelt thanks to my friends and well wishers.

DIPESH BHADANI G.

DEVDA SHRIPALSINH D.



ABSTRACT

Automatic solar charger using microcontroller is intelligent device for on/off

system with solar charger. It is also give the all status about the battery voltage. Now a

day the solar charger is very useful to store the voltage in battery. The conventional solar

charger can‘t operate the load itself, but this project can operate the load also

automatically. This project is provided with dusk to down sensor for automatic turn on

load at dusk and automatic turn off the load at down. For the observation of battery

voltage we used the LCD. It always shows the battery voltage. This project is protecting

the battery also. The battery can damage due to overcharging. So to protect the battery we

used the relay in this solar charger. Relay automatic disconnect the battery when it is fully

charged and the connect the battery when it is low.

As the sources of conventional energy deplete day by day, resorting to alternative

sources of energy like solar and wind energy has become need of the hour. Solar-powered

lighting systems are already available in rural as well as urban areas. These include solar

lanterns, solar home lighting systems, solar streetlights, solar garden lights and solar

power packs. All of them consist of four components: solar photovoltaic module,

rechargeable battery, solar charge controller and load. In the solar-powered lighting

system, the solar charge controller plays an important role as the system‘s overall success

depends mainly on it. It is considered as an indispensable link between the solar panel,

battery and load.

TABLE OF CONTANS



CHAPTER

NO.

NAME PAGE

NO. LIST OF FIG. 1-2

LIST OF TABLE 3

CHAPTER-1 INDUSTRIAL PROFILE 4-6

CHAPTER-2 INTRODUCTION TO SYSTEM 7-11

CHAPTER-3 PROTOTYPE HARDWARE &

DESIGN

12-53

3.1 Block diagram of system 14-17

3.2 Hardware tools 18-53

3.2.1 Microcontroller (AT89C2051) 18-21

3.2.2 ADC converter (ADC 0831) 22-23

3.2.3 Dusk dawn sensor (MCT2E) 24-26

3.2.4 Power sever unit (LM7805) 27-28

3.2.5 Charge control relay 29-34

3.2.6 LCD (liquid crystal display) 35-37

3.2.7 Photovoltaic panel 38-43

3.3 LCD with MCU interfacing 44

3.4 Circuit diagram 45-47

3.5 PCB layout & manufacturing 48-53

3.5.1 PCB layout 48-50

3.5.2 PCB manufacturing 51-53

CHAPTER-4 SOFTWARE DEVELOPMENT &

DESIGN

54-85

4.1 Flowchart to the system 56-57

4.2 Program code to the system 58-68

4.3 Creating circuit diagram using proteus 69-72

4.4 Flowchart of software tools 73-76

4.5 Generating code for AT89C2051 using keil

µvision

77

4.6 Program loader using proloader 78-85

CHAPTER-5 CONCLUSION 86-89

5.1 Conclusion 86

5.2 Applications 86

5.3 Limitations 86

5.4 Advantages 89

REFERANCE 90-91

LIST OF FIGURE



SR NO. FIG NO. NAME OF FIG. PAGE NO.

1 3.1 Block diagram of solar charger 14

2 3.2 Pin diagram of (AT89C2051) 18

3 3.3 Pin diagram of (ADC0831) 22

4 3.4 Pin diagram of (MCT2E) 24

5 3.5 Typical characteristic 25

6 3.6 Collector current characteristic 25

7 3.7 Pin diagram of (LM 7805) 27

8 3.8 Different type of relay 29

9 3.9 Relay location 30

10 3.10 Circuit diagram of relay 30

11 3.11 Relay operation 31

12 3.12 Relay energized 31

13 3.13 Relay de-energized 32

14 3.14 Relay operation 32

16 3.15 ON-OFF relay 33

17 3.16 OFF relay 33

18 3.17 Relay design 34

19 3.18 Manufacturing of relay 34

20 3.19 LCD 16*2 35

21 3.20 Elements of a PV system 39

22 3.21 Graph of power output 40

23 3.22 The photovoltaic effect in a solar cell 42

24 3.23 Graph of current and voltage output 43

25 3.24 LCD with MCU interfacing 44

26 3.25 Circuit diagram 45

27 3.26 PCB layout 48

28 3.27 3D front view 49

29 3.28 3D back view 50

30 3.29 Manufacturing of front side 51

31 3.30 Manufacturing of back side 51

32 4.31 Flowchart to solar charger 56

33 4.32 Proteus 69

34 4.33 Proteus step-1 70








40 4.39 Flowchart of software tools 73

41 4.40 Keil µvision 77

42 4.41 Proload 78

43 4.42 Proload step-2 79









LIST OF TABLE

SR. NO. TABEL NO. NAME OF TABEL PAGE NO.

1 3.1 Port 3 pin function (AT89c205) 20

2 3.2 Pin function of (ADC 0831) 23

3 3.3 Pin function of (LM 7805) 27

4 3.4 LCD pin function 36



CHAPTER 1

INDUSRIAL

PROFILE



ROYAL CIRCUIT DESIGN PVT. LTD.

Royal Circuit Design is situated in Gandhinagar, Gujarat state since 1993. The

Company had established in small scale basic in 1993 by Mr. Alkesh Sukhadia. He is

Diploma Electronics in Ahmadabad and I.T.I. Mechanical from Gandhinagar. He is

expert in Mechanical & Electronics Drawing. He had setup one of the best manufacturing

PRINTED CIRCUIT BOARD Unit with well equipped.

FEW WORDS ABOUT COMPANY:

The company situated Electronics Industries zone in plot No.B-150, Electronics

Estate, Sector-25, and G.I.D.C Gandhinagar in 500 sq met. Plot. Area. All facilities to

staff and all testing measuring and manufacturing equipments. The company has

mechanical workshop for fabrication of various P.C.B. (Printed Circuit Board). ROYAL

CIRCUIT DESIGN has in-house facility for producing from Schematic Diagram to best

quality Printed Circuit Board by Design Tool. Companies have facilities for proto type

through large production in PCB. They are manufacturing different types of PCB like:

1) Single Side,

2) Double Sided,

3) Flexible PCB

With Epoxy base, Aluminum base and other raw materials. Royal Circuit Design is

capable of 2 mil line and 2 mil spacing, plus fine pitch in PCB and Design with electrical

testing. With its enhanced capabilities are renewed commitments to growth through

aggressive representation. Royal Circuit Design is now, more than ever in a position to

provide its customers with extremely competitive price, delivery, quality and service.

Royal Circuit Design is fast becoming a major manufacturing facility in the PRINTED

CIRCUIT BOARD industry. Company is well equipped and well known staff in this



particular area. They cover all aspects of circuit board production including ―ARTWORK

DESIGN and LAYOUT using advanced CAD techniques.

FACILITY UNDER ONE ROOF:

1) PCB DESIGNING FROM SECHEMATIC DIAGRAM BY LATEST TOOL

―CIRCUIT MAKER‖.

2) GERBER PLOTTING FACILITIES

3) MANUFACTURING OF VARIOUS TYPE PRINTED CIRCUIT BOARD BY

CNC DRILLING, PHOTO PLOTTING, DRYFILM PROCESS, QUALITY

CONTROL, HEAT & RUN PROCESS, SCREEN PRINTING, COPPER,

PLATTING, TIN PLATTING,

4) ELECTRONICS TRAINING CENTRE

Company has lot of satisfied valuable customers in private and Government sector

in all over India. Company‘s quality of work approved by ISHRO, PRL, PLASMA

RESEARCH and other Central Government Electronics division.

Royal Circuit Design is also member of GEZIA (GANDHINAGAR

ELECTRONICS ZONE INDUSTRIES ASSOCIATION) and connected with EQDC

(Electronics & Quality Development Centre) Gandhinagar.



CHAPTER

2 INTRODUCTION

TO

SYSTEM



AIM: -

Detail study of solar charger by using of Micro-controller.

OBJECTIVES: -

The objective of this project is to design and implement the microcontroller based

Proportional-integral (PI) control in a battery charger. This battery charger is design to be

powered by a solar panel which produces DC output voltage and being control using

pulse width modulation (PWM) technique to obtain maximum charging efficiency at

fastest time.

Solar power can be used to charge 12 V sealed lead acid battery using fast charging

method consist of constant current and constant voltage mode.

Fast charging method needs a precise termination technique to ensure the battery is

not being overcharge that can lead to battery damages. A wrong charging algorithm will

result in getting less life and capacity than what the battery can offer.

INTODUCTION TO SOLAR CHARGER:-

As the sources of conventional energy deplete day by day, resorting to alternative

sources of energy like solar and wind energy has become need of the hour.

Solar-powered lighting systems are already available in rural as well as urban areas.

Include solar lanterns, solar home lighting systems, solar streetlights, solar garden lights

and solar power packs. All of them consist of four components: solar photovoltaic

module, rechargeable battery, solar charge controller and load. In the solar-

powered lighting system, the solar charge controller plays an important role as the

system‘s overall success depends mainly on it.



It is considered as an indispensable link between the solar panel, battery and load.

the microcontroller plays important role for this automatic system ,microcontroller can

turn on/off the load at dusk to down. it also protect the battery from the overcharging

.battery can damage due to overcharging.

Microcontroller disconnects the battery automatically from the charging system.

Due to disconnect the battery from the solar system is the safe way to protect the battery

from the charging.

This report outlines the design and performance of a solar electric charge controller

and portable power supply, an extremely portable device which recharges electronic

devices. Along with a solar panel, this device employs microprocessor-based control

which continuously monitors the power output of the solar panel to deliver the maximum

electric power to the batteries. This is called Maximum Power Point Tracking, and it

enables the most efficient battery recharge. Our product also contains internal

rechargeable batteries (at 12 Volts). The solar panel actually charges these internal

batteries, and these batteries are used to recharge any external electronic devices which

are attached.

CURRENT WORLD IN ENERGY CRISSIS



The use of petroleum as an energy source will cease to be economically viable. But

petroleum and energy are not synonymous; there are alternative sources of energy

available to us, and it is probable that the transition from using petroleum to using

alternative sources will be a smooth and nearly painless one. And since some of these

alternative fuels are renewable, there is absolutely no need to worry about energy until

our sun ceases to shine.

In words, the "energy shortage" is a crock.

THE SOLUSION OF ENERGY CRISIS

The Use renewable energy such as (solar, wind, water, hydro, tidal and wave,

geothermal, ocean thermal, biomass and biofuel.

The solution is to produce more energy. How that energy is produced is a matter of

personal opinion. Every source has pros and cons, advantages and disadvantages, and

whose weigh differently on different people.



ENERGY CRISIS:

THE SOLUTION TO ENERGY CRISIS IS SHIFTING FROM NON-

RENEWABLE SOURCES TO RENEWABLE SOURCES OF ENERGY. ONE OF THE

RENEWABLE SOURCES IS 'BIOMASS'. WE CAN GROW ENERGY CROPS AND

USE THE BIOMASS TO LIQUID FUEL (BTL) WHICH COULD PROVE TO BE

PROMISING ALTERNATIVE. For example: Jatropha curcas, Euphorbia lathyris

Either find new ways to produce energy, or use less energy. Or a bit of both.

1. Use renewable energies such as solar energy, wind energy and things

2. Stop wasting energy in cars, and lights!



CHAPTER

3 PROTOTYPE

HARDWARE

&

DESIGN



PROTOTYPE HARDWARE & DESIN

3.1:- BLOCK DIAGRAM OF SYSTEM

3.2:- HARDWARE TOOLS

3.3:- LCD WITH MCU INTERFACING

3.4:- CIRCUIT DIAGRAM

3.5:- PCB LAYOUT AND MENIFECTURING



3.1 BLOCK DIAGRAM OF SYSTEM

Fig. 3.1 BLOCK DIAGRAM OF SOLAR CHARGER



Block Diagram contains different blocks like:

Solar panel

Analog to digital converter

Microcontroller

Battery

Relay

Load control

Inverter

16*2 LCD display

MAJOR COMPONANT IN DETAILS

RECHARGEABLE BATTERY:

It is for the storage of energy received from the panel.

The solar energy is converted into electrical energy and stored in a 12V lead-acid

battery.

The ampere-hour capacity ranges from 5Ah-100Ah.

MICROCONTROLLER:

Microcontroller AT89c2051 is the heart of the circuit.

It is a low-voltage,high-performance,8-bit microcontroller that features 2kb of

flash, 128bytes of RAM,15 input/output lines, two 16-bittimers/counters, a five-

vector two-level interrupt architecture, a full-duplex serial port, a precision analog

comparator.

SOLAR PANEL:

Solar panel is used for the conversion of energy directly into electricity. It is com

-posed of photo voltaic cell, which convert solar energy into electrical energy.

Higher-wattage panels can be used with some modifications to the controller unit.



ANALOG TO DIGITAL CONVETER:

The ADC0831 is an 8-bit successive approximation analogue-to-digital converter

with a serial I/O and very low conversion time of typically 32microsecound.

The differential analogues voltage input allows increase of the common-mode

rejection and offsetting of the analogue zero input voltage.

DUSK-TO-DAWN SENSOR :

Normally, in a solar-photovoltaic-based installation-for example, solar streetlight

-the load is switched on at dusk (evening) and switched off at dawn (morning).

During daytime, the load is disconnected from the battery and the battery rechar-

-ged with current from the solar panel.

RELAY:

Relay connected the solar panel to the battery through diode D1.

Under normal conditions, it allows the charging current from the panel to flow

into the battery.

When the battery is at full charge, the charging current consumption of the solar

controller low, normally closed contacts of the relay are used and the relay is

normally in de-energized state.

LOAD CONTOL:

One terminal of the load is connected to the battery through fuse F1 and another

terminal of the load to n-channel power MOSFET T3.

MOSFETs are voltage-driven devices that required virtually no drive current.

The load current should be limited to 10A.

One additional MOSFET is connected in parallel for more than 10A load current.

INVERTER:

Inverter is a direct current (DC) to alternate current (AC) converted.



16*2 LCD DISPLAY:

The system status and battery voltage are displayed on an LCD based on

HD44780 controller.

The backlight feature of the LCD makes it readable even in low light conditions.

The LCD is used here in4-bitmoad to save the microcontroller‘s port pins.

Usually the 8-bit mode of interfacing with a microcontroller required eleven pins,

but in 4-bit mode the LCD can be interfaced to the microcontroller using only

seven pins.

FEATURE OF SOLAR CHARGER

1. Automatic dusk-to-dawn operation of the load

2. Built-in digital voltmeter (0V-20Vrange)

3. Parallel- or shunt-type regulation

4. Overcharge protection

5. System status display on LCD

6. Deep-discharge protection

7. Low battery lock

8. Charging current changes to ‗pulsed‘ at full charge

9. Low current consumption

10. Highly efficient design based on microcontroller

11. Suitable for 10-40W solar panels for 10A load



3.2 HARDWARE TOOLS

LIST OF HARDWARE

List of hardware tools which is used in my project are as below

1. Microcontroller (AT89C2051)

2. 1Analog to digital converter ( ADC0831)

3. Opt coupler (MCT2E)

4. LM7805

5. Relay (12V,1C/O)

6. LCD (16*2)

7. Solar panel (10-40W)

3.2.1 MICROCANTROLAR (AT89C2051)

Fig 3.2 PIN DIAGRAM OF(AT89C2051)



The AT89c2051 is a low-voltage, high-performance CMOS 8-bit microcontroller

with 2K bytes of Flash programmable and erasable read-only memory (PEROM).

The device is manufactured using Atmel‘s high-density nonvolatile memory

technology and is compatible with the industry-standard MCS-51 instruction set

and pin out. The on-chip Flash allows the program memory to be reprogrammed

in-system or by a conventional nonvolatile memory programmer.

By combining a versatile 8-bit CPU with in-system programmable Flash on a

Monolithic chip, the Atmel AT89C2051 is a powerful microcontroller which

Provides a highly-flexible and cost-effective solution to many embedded control

applications.

PIN DISCRIPATION:

VCC: Supply voltage.

GND: Ground.

Port 1 (P1.0 TO P1.7):

The port 1 is an 8-bit bi-directional I/O port. Port pins p1.2 to p1.7 provides internal

pull-UPS. P1.0 and p1.1 required external pull-UPS, p1.0 and p1.1 also serve as the

positive input (AIN1) and the negative input (AIN1), respectively, of the on-chip

precision analog comparator. The port 1 output buffers can sink 20mA and can drive LED

display directly. When is are written to port 1 pins, they can be used as input. When pins

p1.2 to p1.7 are used as input and are externally pulled low, they will source current (IIL)

because of the internal pull-UPS.

Port-1 also receives coad data during flash programming and verification.



Port 2(P3.0 TO P3.7):

port 3 pins p3.0 to p3.5, p3.5 are seven bi-directional I/O pins with internal pull-

UPS p3.6 is hard-wired as an input to the output of the on-chip comparator and is not

accessible as a general-purpose I/O pin. The port 3 output buffers can sink 20mA. When

is are written to port 3 pins they are pulled high by the internal pull-UPS and can be used

as input. As input, port 3 pins that are externally being pulled low will source current (IIL)

because of the pull-UPS.

Port 3 also serves the functions of various special features of the AT89C2051 as

listed below

PORT PIN Alternate functions

P3.0 RXD(serial input port)

P3.1 TXD(serial output port)

P3.2 ____

INT0 (external interrupt)

P3.3 ____

INT1(external interrupt)

P3.4 T0(timer 0 external input)

P3.5 T1(timer 1 external output)

TABEL 3.1 PORT 3 PIN FONCTION

RST:

Reset input All I/O pins are reset to is as soon as RST goes high. Holding the RST

pin high for two machine cycles while the oscillator is running resets the device.

Each machine cycle takes 12 oscillator or clock cycle.

XTAL1:

input to the inverting oscillator amplifier and input to the internal clock operating

circuit.



XTAL2:

output from the inverting oscillator amplifier

FEATURES

Compatible with MCS -51 products

2Kbyte of reprogrammable flash memory –endurance:1,000 write/Erase cycles.

2.7V to 6V operating range

Fully static operation range

Two-level program memory lock

128*8-bit internal RAM

15 programmable I/O lines

Two 16-bit timer/counters

Six interrupt sources

Programmable serial UART channel

Direct LED drive outputs

On-chip analog comparator

Low-power idle and power –down modes

Green(pb/halide-free) packaging option



3.2.2 ANALOG TO DIGITAL CONVATER (ADC0831)

What is ADC

An analog-to-digital converter (abbreviated ADC, A/D or A to D) is a device

that converts a continuous physical quantity (usually voltage) to a digital number that

represents the quantity's amplitude.

Fig 3.3 PIN DIAGRAM OF(ADC 0831)

8-bit resolution

Easy microcontroller interface or stand-alone operation

Operates ratio metrically or with 5-V reference

Single channel or multiplexed twin channels with single-ended or differential

input option



Input range 0 to 5V with single 5-Vsupply

Input and outputs are compatible with TTL and MOS

Conversion time of 32microsecound at CLK=250 KHZ

Designed to be interchangeable with national semiconductor ADC0831

Pin Number Description

1 CS - Chip Select (Active Low)

2 Vin+ - Analog Voltage Input +

3 Vin- - Analog Voltage Input -

4 GND – Ground

5 Vref - Voltage Reference

6 DO - Data Out

7 CLK – Clock

8 Vcc - Positive Supply

Fig. 3.2 pin function of ADC0831



3.2.3 DUSK DAWN SENSOR (MCT2E)

Fig 3.4 PIN DIAGRAM OF MCT2E

Operation of MCT2E opt coupler IC?

Normally, in a solar-photovoltaic-based installation—for example, solar home

lighting system, solar lantern or solar streetlight—the load (the light) is switched on at

dusk (evening) and switched off at dawn (morning). During daytime, the load is

disconnected from the battery and the battery is recharged with current from the solar

panel. The microcontroller needs to know the presence of the solar panel voltage to

decide whether the load is to be connected to or disconnected from the battery, or whether

the battery should be in charging mode or discharging mode. A simple sensor circuit is

built using a potential divider formed around resistors R8 and R9, zener diode ZD1 and

transistor T1 for the presence of panel voltage.

This is the block diagram of optocoupler. The optocoupler is basically combine form

of diode and transistor. When the light strike on photo diode, the electron –hall pairs are

generated . due to this the optocoupler will be set and send the signal to controller to

deactivate load.

Similarly the reverse process is done at night time. At night time optocoupler send

signal to controller for active the load.



Fig.3.5 TYPICAL CHARACTERISTICS

Fig.3.6 Collector current characteristic



This is the typical characteristics of optocoupler .the graph is collector current Vs

input diode forward current. The input diode forward current is increases with increase in

collector current.

FEATURES:

Current transfer ratio (CTR min 50% at IF =10mA Vce=10V)

High isolation voltage be



3.2.4 POWER SEVERS UNIT LM7805:-

LM7805 is 3 terminal positive power regulators IC. Which gives +5V DC output.

The LM7805 monolithic 3-terminal positive voltage regulators employ internal

current-limiting, thermal shutdown and safe-area compensation, making them

essentially indestructible.

In addition to use as fixed voltage regulators, these devices can be used with

external components to obtain adjustable output voltages and currents.

Pin no.1 is a input pin, Pin no.2 is ground and Pin no 3 is output pin.

Fig.3.7 PIN DIAGRAM OF LM7805

Pin No Function Name

1 Input voltage (5V-18V) Input

2 Ground (0V) Ground

3 Regulated output; 5V (4.8V-5.2V) Output

Fig. 3.3 PIN FUNCTION OF LM7805



DISADVANTAGES

The input voltage must always be higher than the output voltage by some

minimum amount (typically 2 volts).

This can make these devices unsuitable for powering some devices from certain

types of power sources (for example, powering a circuit that requires 5 volts using 6-volt

batteries will not work using a 7805).

Even in larger packages, 78xx integrated circuits cannot supply as much power as

many designs which use discrete components, and are generally inappropriate for

applications requiring more than a few amperes of current

Maximum Rating of the LM7805 are follows:

DC input voltage 35v

Maximum junction temperature 150oc

Storage temperature range -65oc to +150

oc

Lead temperature range 300oc

ESD susceptibility 2KV



3.2.5 CHARGE CANTROL RELAY:

What is relay

electrical device such that current flowing through it in one circuit can switch on

and off a current in a second circuit relay.

Relays are used throughout the automobile. Relays which come in assorted sizes,

ratings, and applications, are used as remote control switches. A typical vehicle can have

20 relays or more.

Fig. 3.8 DIFFERENT TYPE RELAY

RELAY LOCATIONS:

Relays are located throughout the entire vehicle relay blocks, both large and small,

are located in the engine compartment behind the left or under the dash by themselves.

are common location. Relays are often grouped or with other components like fuses or

placed



Fig. 3.9 RELAY LOCATION

Relays are remote control electrical switches that are controlled by another switch,

such as a horn switch or a computer as in a power train control module relay allow a

small current flow circuit to control a higher current circuit. Several designs of relays are

in use, today 3-pin, 4-pin, 5-pin, and 6-pin sign switch or dual switches.

Fig. 3.10 CIRCUIT DIAGRAM OF RELAY



RELAYS OPERATION:

All relays operate using the some basic principal. Our example will use a

commonly used 4-pin relay. Relay have two circuits: a control circuit (shown in green)

and load circuit (shown in red) the control has a small control coli while the load circuit

has a switch. The coil controls the operation of the switch.

Fig. 3.11 RELAY OPERATION

RELAY ENERGIZED:

Current flowing through the control circuit coil (pin 1 and 3) creates a small

magnetic field which causes the switch to close, pins 2 and 4. The switch, which is part of

the load circuit, is used to control an electrical circuit that many connect to its current

now flows through pins 2 and 4 shown in red, when the relay in energized.

Fig. 3.12 RELAY ENERGIZED



RELAY DE-ENERGIZED (OFF):

When current stops flowing through the control circuit, pin1 and 3, the relay

becomes the DE-energized without the magnetic filed. The switch opens and current is

prevented from flowing through pins2 and 4. The relay is now off.

Fig. 3.13 RELAY DE-ENERGIZED

RELAY OPERATION:

When no voltage is applied to pin 1, then there is no current flow through the coil.

No current means no magnetic field is developed and the switch is open. When voltage is

supplied to the pin 1, current flows through the coil creates the magnetic field needed to

close the switch allowing the continuity between the pin 2 and 4.

Fig. 3.14 RELAY OPERATION



RELAY DESINE:

Relays are either open or normally closed. Notice the position of the switch in the

two relay shows bellow. Normally the open switch has a switch that remains open until

energized (ON) while closed relays are closed until energized. Relays are always shown

in the de-energized position (no current flows through the control circuit-OFF). Normally

open relays are the most common in vehicle; however other can be used in automatic

application.

Fig. 3.15 ON-OFF RELAY

NORMALLY CLOSED REALYS:

The operation of normal closed relays is the same to that of a normal open relay,

except backward. In other words, when relay control coil is not energized, the relay

switch control are closed, completing the circuit through pin 2 and 4. When control coil is

energized, the relay switch control open, which breaks the circuit open and no continuity

exist between pin 2 and 4.

Fig.3.16 OFF RELAY



ACTUSL RELAY DESIGNE:

Current flows through the control coil, which is wrapped around an iron core. The

iron core intensifies the magnetic field. The magnetic field attracts the upper contact arm

and pulls it down, closing the contact and allowing power from the power source to go to

the load.

Fig. 3.17 RELAY DESIGNE

Fig. 3.19 MENYFECTURING OF RELAY



3.1.6 LCD (LIQUID CRISTEL DISPLAY)

Fig. 3.19 LCD 16*2

A liquid crystal display is a thin, flat electronic visual display that uses the light

modulating properties of liquid crystals. They do not emit light directly. They are used in

wide range of application including: computer monitor, television, instrument panels,

aircraft cockpit display, etc.

LCDs have displaced cathode ray tube (CRT) display in most applications. They

are usually more compact, light weight, portable, less expensive, more reliable and easier

on the eyes.

LCDs with a small number of segments, such as those used in digital watches and

pocket calculators, have individual electrical contacts for each segment.

Liquid crystal display (LCD) is a passive display technology. This manse they do

not emit light, instead, they use the ambient light in the environment.



The most common LCDs connected to the 8051 are 16*2 and 20*2 display. This

means 16 characters per line by 2 lines.

The 2 line x 16 character LCD modules are available from a wide range of

manufacturers and should all be compatible with the HD44780.

LCD PINS:

Table 3.4 LCD PIN FUNCTION

Pin

No Function Name

1 Ground (0V) Ground

2 Supply voltage; 5V (4.7V – 5.3V) Vcc

3 Contrast adjustment; through a variable resistor

VEE

4 Selects command register when low; and data register when

high

Register Select

5 Low to write to the register; High to read from the register Read/write

6 Sends data to data pins when a high to low pulse is given Enable

7

8-bit data pins

DB0

8 DB1

9 DB2

10 DB3

11 DB4

12 DB5

13 DB6

14 DB7

15 Backlight VCC (5V) Led+

16 Backlight Ground (0V) Led-



To initialize LCD

Step 1:- initialize port 2 as output port

Step 2:- set control lines i.e. RS=0 and RW=0

Step 3:- send LCD init value

I.e. 0x38 for 8-bit mode OR 0x28 for 4-bit mode

Step 4:- generate Hi-Low pulse on Enable pin of LCD

Step 5:- send LCD clear value i.e. 0x01

Step 6:- send LCD display on value i.e. 0x0f

Step 7:- send LCD cursor Home i.e. 0x02

FEATURES

5*8 dots with courser

Built in controller (KS 0066 or equivalent)

+5v power supply (Also available for +3v

B/L to be driven by pin15, pin 16 or A.K (LED)

N.V. optional for +3v power supply



3.2.7 PHOTOVOLTAIC PANEL

What are Solar Cells?

Solar cells are devices which convert solar energy directly into electricity, either

directly via the photovoltaic effect, or indirectly by first converting the solar

energy to heat or chemical energy.

The most common form of solar cells are based on the photovoltaic (PV) effect in

which light falling on a two layer semi-conductor device produces a photo voltage

or potential difference between the layers. This voltage is capable of driving a

current through an external circuit and thereby producing useful work.

PV PANELS:-

As single PV cells have a working voltage of about 0.5 V, they are usually

connected together in series (positive to negative) to provide larger voltages. Panels are

made in a wide range of sizes for different purposes. They generally fall into one of three

basic categories:

Low voltage/low power panels are made by connecting between 3 and 12 small

segments of amorphous silicon PV with a total area of a few square centimeters

for voltages between 1.5 and 6 V and outputs of a few milliwatts. Although each

of these panels is very small, the total production is large. They are used mainly in

watches, clocks and calculators, cameras and devices for sensing light and dark,

such as night lights.

Small panels of 1 - 10 watts and 3 - 12 V, with areas from 100cm2 to1000cm2

are made by either cutting 100cm2 single or polycrystalline cells into pieces and

joining them in series , or by using amorphous silicon panels. The main uses are

for radios, toys, small pumps, electric fences and trickle charging of batteries.

Large panels, ranging from 10 to 60 watts, and generally either 6 or 12 volts,

with areas of 1000cm2 to 5000cm2 are usually made by connecting from 10 to 36

full-sized cells in series. They are used either separately for small pumps and



caravan power (lights and refrigeration) or in arrays to provide power for houses,

communications pumping and remote area power supplies (RAPS).

Arrays and Systems

If an application requires more power than can be provided by a single panel, larger

systems can be made by linking a number of panels together. However, an added

complexity arises in that the power is often required to be in greater quantities and

voltage, and at a time and level of uniformity than can be provided directly from the

panels. In these cases, PV systems are used, comprised of the following parts.

1. a PV panel array, ranging from two to many hundreds of panels;

2. a control panel, to regulate the power from the panels;

3. a power storage system, generally comprising of a number of specially designed

batteries.

4. An inverter, for converting the DC to AC power (e.g. 240 V AC).

5. backup power supplies such as diesel startup generators (optional)

framework and housing for the system trackers and sensors (optional).

Fig.3.20 Elements of a PV System



Arrays generally run the panels in series/parallel with each other, so that the

output voltage is limited to between 12 and 50 volts, but with higher amperage (current).

This is both for safety and to minimize power losses. Panels currently cost about $3 - 6

per Watt. That is, a 50 Watt panel presently costs about $200. Eight years ago, this same

standard panel would have cost about $500 at a cost of about $8 - 10 per Watt.

Arrays of panels are being increasingly used in building construction where they

serve the dual purpose of providing a wall or roof as well as providing electric power for

the building. Eventually as the prices of solar cells fall, building integrated solar cells may

become a major new source of electric power.

The daily energy output from PV panels will vary depending on the orientation,

location, daily weather and season. On average, in summer, a panel will produce about

five times its rated power output in watt hours per day, and in winter about two times that

amount. For example, in summer a 50 watt panel will produce an average of 250 watt-

hours of energy, and in winter about 100 watt-hours. These figures are indicative only,

and professional assistance should be sought for more precise calculations.

Trackers are used to keep PV panels directly facing the sun, thereby increasing the

output from the panels. Trackers can nearly double the output of an array (see figure 7).

Careful analysis is required to determine whether the increased cost and mechanical

complexity of using a tracker is cost effective in particular circumstances. A variety of

trackers, which will take about 10 panels, are manufactured in Australia.

Fig. 3.21 Graph of power output.



Energy storage is often necessary when power is required when the sun is not

shining either at night or in cloudy periods - or in quantities greater than can be supplied

directly from the array. Specially designed "deep-cycle" lead acid batteries are generally

used. Unlike normal batteries, they can discharge about half of their stored energy several

thousand times before they deteriorate. Each battery is usually 2 V, and the total battery

bank usually has many batteries in series and parallel to give the required power rating.

Battery banks need to be individually sized to suit the particular applications, depending

on total daily solar radiation, total load, peak load and the number of days storage

required. As a rule of thumb, battery storage costs about $250 per kWh of energy stored

for domestic sized systems.

How do Solar Cells Work?

To understand the operation of a PV cell, we need to consider both the nature of

the material and the nature of sunlight. Solar cells consist of two types of material, often

p-type silicon and n-type silicon. Light of certain wavelengths is able to ionise the atoms

in the silicon and the internal field produced by the junction separates some of the

positive charges ("holes") from the negative charges (electrons) within the photovoltaic

device.

The holes are swept into the positive or p-layer and the electrons are swept into

the negative or n-layer. Although these opposite charges are attracted to each other, most

of them can only recombine by passing through an external circuit outside the material

because of the internal potential energy barrier. Therefore if a circuit is made (see figure

3) power can be produced from the cells under illumination, since the free electrons have

to pass through the load to recombine with the positive holes.



Fig.3.22 The Photovoltaic Effect in a Solar Cell

The amount of power available from a PV device is determined by;

The type and area of the material;

The intensity of the sunlight; and

The wavelength of the sunlight.

Single crystal silicon solar cells, for example cannot currently convert more than

25% of the solar energy into electricity, because the radiation in the infrared region of the

electromagnetic spectrum does not have enough energy to separate the positive and

negative charges in the material.

Polycrystalline silicon solar cells have an efficiency of less than 20% at this time

and amorphous silicon cells, are presently about 10% efficient, due to higher internal

energy losses than single crystal silicon.



A typical single crystal silicon PV cell of 100 cm2 will produce about 1.5 watts of

power at 0.5 volts DC and 3 amps under full summer sunlight (1000Wm-2

). The power

output of the cell is almost directly proportional to the intensity of the sunlight. (For

example, if the intensity of the sunlight is halved the power will also be halved).

Fig.3.23 Graph of current and voltage output.

An important feature of PV cells is that the voltage of the cell does not depend on

its size, and remains fairly constant with changing light intensity. However, the current in

a device is almost directly proportional to light intensity and size. When people want to

compare different sized cells, they record the current density, or amps per square

centimeter of cell area.

The power output of a solar cell can be increased quite effectively by using a

tracking mechanism to keep the PV device directly facing the sun, or by concentrating the

sunlight using lenses or mirrors. However, there are limits to this process, due to the

complexity of the mechanisms, and the need to cool the cells.



3.3 LCD WITH MCU INTERFACING

CIRCUIT DIAGRAM OF LCD WITH MCU

Fig. 3.24 LCD with MCU interfacing



3.4 CIRCUIT DIAGRAM

Fig. 3.25 circuit diagram



CRICUIT DISCRIPTION

Basically, there are two methods of controlling the charging current: series

regulation and parallel (shunt) regulation. A series regulator is inserted between the solar

panel and the battery. The series type of regulation ‗wastes‘ a lot of energy while

charging the battery as the control circuitry is always active and series regulator requires

the input voltage to be 3-4 volts higher than the output voltage. The current and voltage

output of a solar panel is governed by the angle of incidence of light, which keeps

varying.

Parallel regulation is preferred in solar field. In parallel regulation, the control

circuitry allows the charging current (even in mA) to flow into the battery and stop

charging once the battery is fully charged. At this stage, the charging current is wasted by

converting into heat (current is passed through low-value, high-wattage resistor); this part

of the regulation dissipates a lot of heat.

After power-on, the microcontroller reads the battery voltage with the help of the

ADC and displays the values on the LCD. It monitors the input signal from the dusk-to-

dawn sensor and activates the load or charging relay RL1 accordingly. The digital

voltmeter works up to 20V.

As Vref of the ADC is connected to VCC (5V), the input voltage to the ADC

cannot exceed +5V. A potential divider is used at pin 2 of the ADC (IC2) using resistors

R5, R6 and R7 to scale down the voltage from 0V-20V to 0V-05V. The ADC output is

multiplied four times and displayed on the LCD as battery voltage. When the solar panel

voltage is present, the dusk-to-dawn sensor provides a signal to the microcontroller,

which then displays ‗charging‘ message on the LCD. During charging, the battery voltage

is continuously monitored. When the voltage reaches 14.0V, the microcontroller

interrupts the charging current by energising the relay, which is connected to MOSFET

BS170 (T2), and starts a5-minute timer. During this stage, the LCD shows ―battery full.‖



After five minutes, the relay reconnects the panel to the battery. This way, the

charging current is pulsed at the intervals of five minutes and the cycle repeats until the

panel voltage is present. When the panel voltage falls below the zener diode (ZD1)

voltage of the dusk-to-dawn sensor, the microcontroller senses this and activates the load

by switching on MOSFET T3 via optocoupler IC3 and ―load on‖ message is displayed.

In this mode, the microcontroller monitors for low battery. When the battery voltage

drops below 10 volts, the microcontroller turns off the load by switching off MOSFET T3

and ―battery low—load off‖ message is displayed.

Normally, when the load is switched off, the battery voltage tends to rise back and

the load oscillates between ‗on‘ and ‗off‘ states. To avoid this, the microcontroller

employs a hysteresis control by entering into a ‗lock‘ mode during low battery state and

comes out of the lock mode when the dusk-to-dawn sensor receives the panel voltage (the

next morning). During lock mode, the microcontroller keeps converting the ADC value

and displays the battery voltage on the LCD.



3.5 PCB LAYOUT AND MENIFACTURING

3.5.1 PCB LAYOUT

Fig.3.26 PCB layout



PCB 3D VIEW IN FRONT SIDE

Fig.3.27 3D front view



PCB 3D VIEW IN BACK SIDE

Fig.3.28 3D back view



3.5.2 PCB MENIFACTURING

PCB LAYOUT OF FANT SIDE

Fig.3.29 manufacturing of fant side



How to Make a PCB manufacturing

Lamination:

"Multi layer" printed circuit boards have trace layers inside the board. One way to

make a 4-layer PCB is to use a two-sided copper-clad laminate, etch the circuitry on both

sides, then laminate to the top and bottom prepreg and copper foil. Lamination is done by

placing the stack of materials in a press and applying pressure and heat for a period of

time.

Drilling:

Holes through a PCB are typically drilled with small-diameter drill bits made of

solid coated tungsten carbide. Coated tungsten carbide is recommended since many board

materials are very abrasive and drilling must be high RPM and high feed to be cost

effective. Drill bits must also remain sharp so as not to mar or tear the traces. Drilling

with high-speed-steel is simply not feasible since the drill bits will dull quickly and thus

tear the copper and ruin the boards. The drilling is performed by automated drilling

machines with placement controlled by a drill tape or drill file.

It is also possible with controlled-depth drilling, laser drilling, or by pre-drilling the

individual sheets of the PCB before lamination, to produce holes that connect only some

of the copper layers, rather than passing through the entire board.

Test:

Unpopulated boards may be subjected to a bare-board test where each circuit

connection (as defined in a netlist) is verified as correct on the finished board. For high-

volume production, a bed of nails tester, a fixture or a rigid needle adapter is used to

make contact with copper lands or holes on one or both sides of the board to facilitate

testing. A computer will instruct the electrical test unit to apply a small voltage to each

contact point on the bed-of-nails as required, and verify that such voltage appears at other

appropriate contact points.

http://en.wikipedia.org/wiki/Drill_bit

http://en.wikipedia.org/wiki/Tungsten_carbide

http://en.wikipedia.org/wiki/Automation

http://en.wikipedia.org/wiki/Milling_machine



http://en.wikipedia.org/wiki/Bed_of_nails_tester

http://en.wikipedia.org/wiki/Rigid_needle_adapter



Protection and packaging :

PCBs intended for extreme environments often have a conformal coating, which is

applied by dipping or spraying after the components have been soldered. The coat

prevents corrosion and leakage currents or shorting due to condensation. The earliest

conformal coats were wax; modern conformal coats are usually dips of dilute solutions of

silicone rubber, polyurethane, acrylic, or epoxy. Another technique for applying a

conformal coating is for plastic to be sputtered onto the PCB in a vacuum chamber. The

chief disadvantage of conformal coatings is that servicing of the board is rendered

extremely difficult.[25]

Copper thickness :

Copper thickness of PCBs can be specified in units of length, but is often specified

as weight of copper per square foot, in ounces, which is easier to measure. Each ounce of

copper is approximately 1.4 mils (0.0014 inch) or 35 μm of thickness.

The printed circuit board industry defines heavy copper as layers

exceeding 3 ounces of copper, or approximately 0.0042 inches (4.2 mils, 105 μm) thick.

PCB designers and fabricators often use heavy copper when design and manufacturing

circuit boards in order to increase current-carrying capacity as well as resistance to

thermal strains. Heavy copper plated vias transfer heat to external heat sinks.

Safety certification (US) :

Safety Standard UL 796 covers component safety requirements for printed

wiring boards for use as components in devices or appliances. Testing analyzes

characteristics such as flammability, maximum operating temperature, electrical tracking,

heat deflection, and direct support of live electrical parts.

http://en.wikipedia.org/wiki/Conformal_coating

http://en.wikipedia.org/wiki/Wax

http://en.wikipedia.org/wiki/Sputter_deposition

http://en.wikipedia.org/wiki/Printed_circuit_board#cite_note-26

http://en.wikipedia.org/wiki/Unit_of_length

http://en.wikipedia.org/wiki/Square_foot

http://en.wikipedia.org/wiki/Ounce

http://en.wikipedia.org/wiki/Operating_temperature



CHAPTER

4 SOFTWARE

DEVELOPMENT

&

DESIGN



SOFTAWARE DEVELOPMENT & DESIGN

4.1:- FLOWCHART TO THE SYSTEM

4.2:- PROGRAM CODE TO THE SYSTEM

4.3:- CREATING CIRCUIT DIAGRAM USING PROTEUS

4.4:- FLOWCHART OF SOTWARE TOOLS

4.5:- GENERATING CODE FOR AT89C2051 USING KEIL µVISION



4.1 FLOWCHART TO SYSTEM:

Fig. 4.31 FLOW CHART TO SOLAR CHARGER



The flow chart shown in figure.17. Flow chart is starting from the get battery voltage

at starting time. When solar charger is started, the first step is the microcontroller send

battery voltage detail to LCD. It is done with the help of A/D convertor. Now dusk to

down sensor sense the temperature and decide it is dusk or down. So we have two cases.

1. Dusk, 2. Down

1 .DUSK (evening):-

If dusk, than temperature of atmosphere is a decrease. At night time optocoupler

send the signal to microcontroller to active the load. During the load active time, battery

is discharge

The microcontroller is automatically disconnecting the load from battery. This is

done with help of relay. Relay is worked as switch in the circuit. During this all operation,

LCD will continuously display battery voltage. Like low battery.

2. DOWN (morning):-

If down, than temperature of atmosphere is increases. At day time optocoupler send

the signal to microcontroller to deactivate the load. During the load deactivate, battery is

charged through the solar panel. When the battery is fully charged LCD will show the

message ―BATTERY FULL‖. At this time microcontroller disconnect the battery from

the solar panel.



4.2 PROGRAM CODE TO SYSTEM

$MOD51; LCD 4-BIT MODE CONNECTIONS

RS EQU P1.7 ; LCD REGISTER SELECT LINE

EN EQU P1.6 ; LCD ENABLE LINE

DB4 EQU P1.5 ;

DB5 EQU P1.4 ;

DB6 EQU P1.3 ;

DB7 EQU P1.2 ; ADC0831 CONNECTIONS

CS EQU P3.0

CLK EQU P3.1

DO EQU P3.2 ; INPUT & OUTPUT

DYI EQU P3.4 ; SOLAR PANEL VOLTAGE SENSOR

CHG_RL EQU P3.5 ; CHARGING CONTROL RELAY

LD_RL EQU P3.7 ; LOAD CONTROL RELAY DSEG

ORG 0020H

VAL1: DS 1

VAL2: DS 1

VAL3: DS 1

ADC_VAL: DS 1

BUF: DS 1

CNT1: DS 1

CNT2: DS 1

IMG: DS 1

FLAGS: DS 1

OCF BIT FLAGS.0 ; OVER CHARGE FLAG

LBF BIT FLAGS.1 ; LOW BATT FLAG

CSEG

ORG 0000H

JMP MAIN

ORG 000BH ; Timer Interrupt0

JMP COUNTDOWN

MAIN: MOV SP, #50H

MOV P3, #0FFH



MOV P1,#0FFH

CLR CHG_RL

CLR LD_RL

LCALL PWR_DELAY

LCALL INIT

SETB CLK

SETB DO

SETB CS

SETB DYI

MOV VAL1, #00H

MOV VAL2, #00H

MOV VAL3, #00H

MOV FLAGS, #00H

LOADCHAR: MOV BUF, #40H

LCALL CMD

MOV DPTR, #RCHARG

REP:

CLR A

MOVC A,@A+DPTR

JZ SCREEN1

MOV BUF, A

LCALL DAT

INC DPTR

SJMP REP

SCREEN1: MOV BUF, #80H

MOV DPTR, #MSG1

HERE: CLR A

MOVC A,@A+DPTR

JZ NEXT

MOV BUF,A

LCALL DAT

INC DPTR

SJMP HERE

NEXT: MOV BUF, #0C0H

LCALL CMD



MOV DPTR, #MSG2

HERE1: CLR A

MOVC A,@A+DPTR

JZ OVER

MOV BUF, A

LCALL DAT

INC DPTR

SJMP HERE1

OVER: LCALL ONE_SEC_DELAY

LCALL ONE_SEC_DELAY

LCALL CLEAR

MOV BUF, #0C0H

LCALL CMD

MOV DPTR, #MSG7

HERE2: CLR A

MOVC A,@A+DPTR

JZ CONVERT

MOV BUF, A

LCALL DAT

INC DPTR

SJMP HERE2

CONVERT: LCALL DELAY

CLR CS ; INITIATE CONVERSION

SETB CLK

CLR CLK ; FIRST CLOCK

SETB CLK

CLR CLK ; SECOND CLOCK

MOV A, #00H ; CLEAR A

MOV R5, #08H ; 8 CLOCK PULSES

AGAIN: MOV C, DO

RLC A

SETB CLK

CLR CLK

DJNZ R5, AGAIN

SETB CS

MOV ADC_VAL, A



MOV B, #79D

MUL AB ; PRODUCT IN AB

MOV R1, B ; HIGH BYTE IN B

MOV R2, A ; LOW BYTE IN A

LCALL HEX2BCD

MOV VAL1, R7

MOV VAL2, R6

MOV VAL3, R5

LCALL SENDVAL2LCD

CHECK: JNB LBF, CHECK2 ; SEE IF ANY FLAGS ARE SET,

I , e LOW BATT FLAG OR BATTFULL FLAG

JB DYI, CONVERT

CHECK2: JNB OCF, PROCEED

JB DYI, NIGHT

SJMP CONVERT

PROCEED: JB DYI, NIGHT

CLR LD_RL ; OFF LOAD

CLR LBF ; CLEAR LOW BATT FLAG

MOV A, VAL2 ; SEE IF BATT.IS FULL

XRL A, #04H

JZ FULLCHG

CLR CHG_RL ; CONNECT BATT. TO PANEL

MOV DPTR, #MSG4 ; DISPLAY CHARGING MSG

MOV IMG, #00H

LCALL SENDSTAT2LCD

LJMP CONVERT

FULLCHG: SETB OCF ; SET OVERCHARGE FLAG

SETB CHG_RL ; DISCONNECT BATT.FROM PANEL

MOV TH0, #03CH ; START 5 MIN TIMER HERE

MOV TL0, #0B0H ; DISCONNECT BATT FROM PANEL

MOV CNT1, #200D

MOV CNT2, #30D

SETB ET0

SETB TR0

SETB EA

MOV DPTR, #MSG5 ; DISPLAY BATT.FULL MSG



MOV IMG, #01H

LCALL SENDSTAT2LCD

LJMP CONVERT

NIGHT: CLR CHG_RL ; RECONNECT BATT. TO PANEL

CLR TR0 ; STOP TIMER0 INCASE ITS RUNNING

CLR OCF ; CLEAR OVER CHARGE FLAG

SETB LD_RL ; CONNECT LOAD TO BATT.

MOV A, VAL1

XRL A, #00H

JZ LOWBAT

MOV DPTR, #MSG3 ; DISPLAY LOAD ON MSG

MOV IMG, #02H

LCALL SENDSTAT2LCD

LJMP CONVERT

LOWBAT: SETB LBF

CLR LD_RL ; DISCONNECT LOAD FROM BATT.

MOV DPTR, #MSG6 ; DISPLAY LOAD OFF MSG

MOV IMG, #03H

LCALL SENDSTAT2LCD

LJMP CONVERT

SENDVAL2LCD: MOV BUF, #0C7H

LCALL CMD

MOV A, VAL1

ORL A, #30H

MOV BUF, A

LCALL DAT

MOV A, VAL2

ORL A, #30H

MOV BUF, A

LCALL DAT

MOV BUF, #'.'

LCALL DAT

MOV A, VAL3

ORL A, #30H

MOV BUF, A

LCALL DAT



RET

SENDSTAT2LCD:

MOV BUF, #080H

LCALL CMD

HERE3: CLR A

MOVC A,@A+DPTR

JZ PICT

MOV BUF, A

LCALL DAT

INC DPTR

SJMP HERE3

PICT: MOV BUF, #0CEH

LCALL CMD

MOV BUF, IMG

LCALL DAT

BACK:

RET

;********************************

; TIMER0 ISR (5 MINUTES TIMER)

;********************************

COUNTDOWN: CLR TR0

MOV TH0, #03CH

MOV TL0, #0B0H

SETB TR0

DJNZ CNT1, BACK2

MOV CNT1, #200D

DJNZ CNT2, BACK2

CLR TR0 ; OFF 5 MIN TIMER

CLR ET0

CLR OCF ; CLEAR OVER CHARGE FLAG

CLR CHG_RL ; RE-CONNECT BATT TO PANEL

BACK2: RETI

Hex2BCD: MOV R3, #00D

MOV R4, #00D

MOV R5, #00D

MOV R6, #00D



MOV R7, #00D

ACALL H2B

RET

H2B: MOV B, #10D

MOV A, R2

DIV AB

MOV R3, B ;

MOV B, #10 ; R7, R6, R5, R4, R3

DIV AB

MOV R4, B

MOV R5, A

CJNE R1, #00H, HIGH_BYTE ; CHECK FOR HIGH BYTE

SJMP ENDD

HIGH_BYTE: MOV A, #6

ADD A, R3

MOV B, #10

DIV AB

MOV R3, B

ADD A, #5

ADD A, R4

MOV B, #10

DIV AB

MOV R4, B

ADD A, #2

ADD A, R5

MOV B, #10

DIV AB

MOV R5, B

CJNE R6, #00D, ADD_IT

SJMP CONTINUE

ADD_IT: ADD A, R6

CONTINUE: MOV R6, A

DJNZ R1, HIGH_BYTE

MOV B, #10D

MOV A, R6

DIV AB



MOV R6, B

MOV R7, A

ENDD: RET

ONE_SEC_DELAY: MOV R0, #10D ; One second delay routine

RZ3: MOV R1, #100D

RZ1: MOV R2, #250D

RZ2: NOP

NOP

DJNZ R2, RZ2

DJNZ R1, RZ1

DJNZ R0, RZ3

RET

PWR_DELAY:; 15 mSec DELAY FOR LCD TO INTIALIZE AFTER POWER-ON

MOV R4, #100D

H2: MOV R3, #250D

H1: DJNZ R3, H1

DJNZ R4, H2

RET;******LCD SUBROUTINES********

CMD: PUSH ACC ; SAVE ACCUMULATOR

SETB EN

CLR RS ; SELECT SEND COMMAND

MOV A, BUF ; PUT DATA BYTE IN ACC

MOV C, ACC.4 ; LOAD HIGH NIBBLE ON DATA BUS

MOV DB4, C ; ONE BIT AT A TIME USING...

MOV C, ACC.5 ; BIT MOVE OPERATOINS

MOV DB5, C

MOV C, ACC.6

MOV DB6, C

MOV C, ACC.7

MOV DB7, C

CLR EN

NOP

SETB EN ; PULSE THE ENABLE LINE

MOV C, ACC.0 ; SIMILARLY, LOAD LOW NIBBLE

MOV DB4, C

MOV C, ACC.1



MOV DB5, C

MOV C, ACC.2

MOV DB6, C

MOV C, ACC.3

MOV DB7, C

CLR EN

NOP


LCALL MSDELAY

POP ACC

RET; ******LCD SUBROUTINES*******

DAT: PUSH ACC ; SAVE ACCUMULATOR

SETB EN

SETB RS ; SELECT SEND DATA

MOV A, BUF ; PUT DATA BYTE IN ACC

MOV C, ACC.4 ; LOAD HIGH NIBBLE ON DATA BUS

MOV DB4, C ; ONE BIT AT A TIME USING...

MOV C, ACC.5 ; BIT MOVE OPERATOINS

MOV DB5, C

MOV C, ACC.6

MOV DB6, C

MOV C, ACC.7

MOV DB7, C

CLR EN

NOP


MOV C, ACC.0 ; SIMILARLY, LOAD LOW NIBBLE

MOV DB4, C

MOV C, ACC.1

MOV DB5, C

MOV C, ACC.2

MOV DB6, C

MOV C, ACC.3

MOV DB7, C

CLR EN

NOP



SETB EN ; PULSE THE ENABLE LINENOP

LCALL MSDELAY

POP ACC

RET;******LCD SUBROUTINES******

CLEAR: MOV BUF, #01H

LCALL CMD

RET;******LCD SUBROUTINES*******

DDELAY: MOV R5, #41D ; 4.1 mS DELAY

QT2: MOV R6, #50D

QT1: DJNZ R6, QT1

DJNZ R5, QT2


MSDELAY: MOV R5, #26D

QT22: MOV R6, #50D

QT11: DJNZ R6, QT11

DJNZ R5, QT22


INIT: MOV BUF, #30H ; FUNCTION SET -DATA BITS, LINES, FONTS

LCALL CMD

ACALL DDELAY ; INITIAL DELAY 4.1MSEC

MOV BUF, #30H ; FUNCTION SET - DATA BITS, LINES, FONTS

LCALL CMD


MOV BUF, #30H ; FUNCTION SET-DATA BITS, LINES, FONTS

LCALL CMD


MOV BUF, #28H ; 2 LINES 5X7, 4-BIT MODE

LCALL CMD

MOV BUF, #0CH ; DISPLAY ON

LCALL CMD

MOV BUF, #01H ; CLEAR DISPLAY, HOME CURSOR

LCALL CMD

MOV BUF, #06H ; SET ENTRY MODE

LCALL CMD ; INCREMENT CURSOR RIGHT, NO SHIFT

RET

ORG 0320H



MSG1: DB ' SOLAR CHARGE ', 00H

MSG2: DB ' DIPESH, SHRIPAL ', 00H

MSG3: DB ' LOAD ON ', 00H

MSG4: DB ' CHARGING ', 00H

MSG5: DB ' BATTERY FULL ', 00H

MSG6: DB ' BAT.LOW-LOAD OFF', 00H

MSG7: DB ' Volts: ', 00H

ORG 0400H

RCHARG: DB 04D, 31D, 17D, 31D, 17D, 31D, 17D, 31D ; CHARGING

DB 04D, 31D, 31D, 31D, 31D, 31D, 31D, 31D ; FULL

DB 31D, 31D, 14D, 04D, 04D, 14D, 31D, 31D ; LOAD

DB 04D, 31D, 17D, 17D, 17D, 17D, 17D, 31D ; LOW BATT

DB 31D, 31D, 31D, 31D, 31D, 31D, 31D, 31D

DB 31D, 31D, 31D, 31D, 31D, 31D, 31D, 31D

DB 31D, 31D, 31D, 31D, 31D, 31D, 31D, 31D

DB 031D, 31D, 31D, 31D, 31D, 31D, 31D, 31D, 00H

END



4.3 CREATING CIRCUIT DIAGRAM USING PROTEUS:-

Fig.4.32 proteus



5 STEPS:

1. Start with proteus design suit. To add component click on the P.

Fig. 4.33 PROTEUS STEPS-1

2. A dialogue box will open asking you to select you‘re your component used. Select

the appropriate device for e.g. at89s52.Then click OK. Put all the components which you

have to use to create design.




3. Make the connection as required.


4. Now edit the properties of the device as required like to load the hex file in the

microcontroller then right click on the component and select edit property. Then browse

your file from project folder then click on OK.

Fig. 4.36PROTEUS STEPS-4



Fig.4.37PROTEUS STEPS-5




4.4 FLOWCHART OF SOFTWARE TOOLS

Fig. 4.39 FLOW CHART OF SOFTWARE TOOLS



Developing an assembly language program is a four step process. the steps are as

follows:

A. To specify the source code as per the assembly language definition

B. Assembly the program to create the object code.

C. Link the program to create an executable code.

D. Test and debug the program.

Fig. shows the steps involved in developing and executing an assembly language

Program.

Description:

Step 1:

The first step is to analyze what the program is to do and how we want the

program to do it.

Then using an editor create the source file for program

Step 2:

The second step is to assemble this source file.

If the assembler indicates errors then use the editor for correcting them.

Step 3:

If the program consists of several modules, then use the linker to join them into

one large object module.

If the system needs to locate a program in order to specify its location in the

memory then use the locator.

At this stage the program is ready for loading into the memory and run.

Step 4:

If the developed program does not interact with any external hardware other than

that connected directly to the system then use debugger for running and debugging

your program.



If the program is supposed to work with the external hardware system such a

microprocessor based instrument then use emulator to run and debug the program.

Development Tools:

1) Editor :

An editor is basically software. It helps the user to create a file that contains the

assembly language statements.

The job of the editor is to store the ASCII codes for the letters and numbers in the

successive RAM locations.

When program is stored in hard disk then the file is called source file whose

extension is (.ASM)

2) Assembler :

To convert assembly language statement into corresponding Binary code.

Two types of assembler available for IBM-PC are:

(.OBJ) file contains binary code of program instruction and information about

their address.

(.LST) file contains assembly language statement, binary code and relative offset

of each instruction.

(.LST) file indicate assembly language syntax errors but not logical errors.

3) Linker :

It is program which is used for joining many object files (.OBJ) into one large

object files (.OBJ).

When a large program is being written, it is always to break it into small modules

so that each module can be separately tested and debugged.

(.EXE) file contains binary codes for all combined modules.

(.MAP) file contains address all linked file but not their absolute address.

4) Locator :

It assigned specific address of the locations where their segment off the object

code are to loaded into memory.



A locator program converts an (.EXE) file into a (.BIN) file which has physical

address.

5) Debugger :

A software tool that is used to detect the source of program or script errors by

performing step by step execution of application code and viewing the content of

code variables.

If a program is directly accessible from the microcomputer and does not need any

external hardware, then we can use debugger to run and test the program.

Debugger is basically a program which permits the user to load object code

program into the system memory, execute the program and debug it.

The debugger also permits the change in register contents, memory locations and

rerun the program.

6) Emulator :

The emulator is used to test and debug the hardware and software of an external

system such as the microprocessor based system.

Emulator is a combination of hardware and software.

An emulator consists of a multi-wire cable that connects the host system to the

external system.

Through this cable the software of the emulator allows the users the download the

object code program into RAM in the external system being developed.

Like the debugger the emulator also allows the users to load the programs to be

tested, run the, programs check and modify the contents of various register and

memory locations and also insert the breakpoints.



4.5 GENERATING CODES FOR AT89C2051 USING KEIL

µVISION:-

AT89S52 weighing system programming involves two steps.

A. First step is to write and compile the code and generate the (.HEX) file.

B. Second step is to load this (.HEX) file into microcontroller.

We are use keil-µvision software for writing the code for the microcontroller

following steps are for generate code for keil-µvision

Fig.4.40 keil µVISION



4.6 PROGRAM LODE USING PROLOADER

5 How to program the IC by programmer

Fig.4.41 prolad

Step 1: install the proload v5.4 microcontroller programmer software in your PC

You can download the hex code you have prepared, into the microcontroller using

our microcontroller programmer software. To install this software, choose the folder

―programmer setup ―in the accompanying CD(CD – NV5001-Programmer setup). You

will find file setup .exe. Now double click on setup .exe to run the installation program.

Follow the instruction on the screen. Click finish to complete the installation. To run the

program chooses ―proload v5.4‖ from the menu & Nvis technologies. Shortcut of proload

v5.4 icon also have made in desktop



Step 2:

Check the correct com port in device manager for communication.

Fig.4.42 proload step-2



Step 3:

Select the correct com port in proload v5.4 programmer

.




Step 4:

Click device option or recent devices for selecting desired microcontroller.

Fig.4.44 proload sstep-4



Step 5:

After selecting device select option follow the following root.

Device search-> AT89C51/52->select device->OK.




Step 6:

After selecting the device, click signature to detect the controller.




Step 7:

Erase facility: erase facility can be used to erase whole flash area in the selected

microcontroller.




Step 8:

After erasing, load the hex file which you have created, for this follow the following

root:

File optionopen

Fi.4.48 proload step-8



CHAPTER

5

CONCLUSION



CONCLUSTION

5.1:- CONCLUSTION

5.2:- APPLICATIONS

5.3:- LIMITATIONS

5.4:- ADVANTAGES



5.1 CONCLUSION

By using the technique of microcontroller based solar charger we can accurately

control the voltage of solar Charger. It is automatic control the load, not need to control

manually and it is reduce the damages of battery due to over charging.

5.2 APPLICATIONS:-

These include solar lanterns, solar home lighting systems, solar streetlights, solar

garden lights and solar power packs

A charge controller for a wind-electric or hydro-electric system must protect

batteries from overcharge, just a PV controller

It can also be used in automobiles to increase their battery life.

It can be also used a supplement for the inverter to control battery charging etc.

Coast guard navigation

Off-grid and grid –connected homes

Railroad signaling

Satellites and space station

Outdoor lighting‘s

Telecommunication and water pumping etc.

5.3 LIMITATIONS:-

Large initial setup is required to supply high rating solar energy supplies.

Solar panels are costlier and its bulkiness increases to have large power supplies

of dc.

Solar panels are very delicate and a slight mishandling may lead to destruction of

solar cells which are embedded in solar panels.



5.4 ADVANTAGES:-

Salient and low maintenance

Solid states with no moving parts

High-quality powers

Life times of 20 to 30 year

Flexible and reliable

Modular and expandab



REFERENCES



ALL DATASHIT.COM

FAADOOENGINEEARS.COM

WORLD MICROCANTROLLER.COM

SOLARB.COM

AMERICAN SOCIETY FOR ENGINEERING EDUCATION

KIDWIDE.ORG

WIKIPEDIA.COM

REFERANCE BOOK

Microcontroller and interfacing

By :- muhmad ali mazidi

MCU BASED SOLAR CHARGER

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Transcript of MCU BASED SOLAR CHARGER