Solar Powered Lead-Acid
Battery Charger
National Semiconductor
RD-165
Applications Design Center - FD and RK
November 2008
1.0 Design Specifications
Inputs Output #1
VinMin=6.0V Vout1=12.4V
VinMax=10V Iout1=0.09A
2.0 Design Description
The lead-acid solar charger reference design not only shows
how to efficiently convert solar energy into a charge current
for lead acid batteries, but it incorporates additional circuitry
to compensate for temperature and sunlight variances. A
lead-acid solar charger is well-suited for applications such as
automotive where a constant charge is needed to maintain an
idle battery.
A solar cell’s output current decreases with the reduction in
sunlight (solar Irradiance), and the voltage of solar cells de-
creases with increases in temperature. National’s lead-acid
solar charger uses an 18-cell (3W) solar panel as the input
source. The design comprises two stages:
• The first stage monitors the solar panel voltages, and a
SEPIC design using (LM5001 controller) provides the output
voltage which tracks the input (solar panel voltage over the
temperature range). A simple, cost-effective thermal monitor
circuit that uses a string of BAT54 diodes tracks the solar
panel voltage over the temperature range of 25°C to 100°C
• The second stage takes the output of the first stage (SEPIC
converter) and boosts the SEPIC voltage to nominal 13.3V
at 25°C and 14.4V at 100°C. It also consists of a constant
current control used to charge the 12V lead-acid battery.
The charging current into the battery is also varied to ensure
that maximum power capability of the solar panel is not ex-
ceeded. This is accomplished by reducing the current that is
fed into the battery at higher temperatures. Again, a cost-ef-
fective thermal monitor circuit using a BAT 54 diode provides
feedback that adjusts the output voltage and output current
over the temperature range.
3.0 Features
1. Standard 12V Lead Acid battery (normally used
in auto’s) is charged using a "solar Powered battery charger"
design.
2. Recover from Shading
3. Dual Stage constant current regulation
4. Overvoltage protection
5. Design operates over wide temperature range ( 25°C to
100°C)
© 2008 National Semiconductor Corporation www.national.com
Solar Pow
ered Lead-Acid Battery Charger
R
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www.national.com 6
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5.0 Bill of Materials
Designator Value Footprint Parameters Manufacturer Manufacturer_PN RoHS
D1 0.24V SOT-23 Vr = 30V, Io = 0.2A, Vf =
0.24V
Diodes Inc. BAT54-7-F Y
D2d 0.24V SOT-23 Vr = 30V, Io = 0.2A, Vf =
0.24V
Diodes Inc. BAT54-7-F Y
D3D 0.24V SOT-23 Vr = 30V, Io = 0.2A, Vf =
0.24V
Diodes Inc. BAT54S-7-F Y
D4D 0.24V SOT-23 Vr = 30V, Io = 0.2A, Vf =
0.24V
Diodes Inc. BAT54S-7-F Y
bom38
FIGURE 6. Solar Powered Battery Charger - Thermal Board BOM
7 www.national.com
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Designator Value Footprint Parameters Manufacturer Manufacturer_PN RoHS
(P1) pad100
(P4) pad100
C1 1uF 1210 Ceramic, X7R, 50V, 10% MuRata GRM32RR71H105K
C2 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C3 22uF 1210 Ceramic, X5R, 16V, 10% MuRata GRM32ER61C226K
C4 0.1uF 0805 Ceramic, X7R, 50V, 10% TDK C2012X7R1H104K
C5 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C6 10uF 1210 Ceramic, X7R, 16V, 20% TDK C3225X7R1C106M
C7 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C8 1uF 0805 Ceramic, X7R, 10V, 10% TDK C2012X7R1A105K
C9 22uF 1210 Ceramic, X5R, 16V, 20% TDK C3225X5R1C226M
C10 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C11 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C12 150pF 0805 Ceramic, C0G/NP0, 25V, 5% Kemet C0805C151CJ3GAC
C13 150pF 0805 Ceramic, C0G/NP0, 25V, 5% Kemet C0805C151CJ3GAC
C14 0.015uF 0805 Ceramic, C0G/NP0, 25V, 5% TDK C2012C0G1E153J
C15 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C16 1uF 1210 Ceramic, X7R, 50V, 10% MuRata GRM32RR71H105K
C17 680pF 0805 Ceramic, X7R, 50V, 10% AVX 08055C681KAT2A Y
C18 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C19 22uF 1210 Ceramic, X5R, 10V, 20% TDK C3225X5R1A226M
C20 0.01uF 0805 Ceramic, X7R, 50V, 5% AVX 08055C103JAT2A Y
C21 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C22 0.047uF 0805 Ceramic, X7R, 100V, 10% TDK C2012X7R2A473K Y
C23 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C24 10uF 1210 Ceramic, X7R, 16V, 20% TDK C3225X7R1C106M
C25 0.1uF 0805 Ceramic, X7R, 25V, 10% TDK C2012X7R1E104K Y
C26 1uF 0805 Ceramic, X7R, 16V, 10% TDK C2012X7R1C105K
C27 22uF 1210 Ceramic, X5R, 16V, 20% TDK C3225X5R1C226M
D1 0.79V SMA Vr = 100V, Io = 1A, Vf =
0.79V
Diodes Inc. B1100-13 N
D2 0.24V SOT-23 Vr = 30V, Io = 0.2A, Vf =
0.24V
Diodes Inc. BAT54S-7-F Y
D3 0.24V SOT-23 Vr = 30V, Io = 0.2A, Vf =
0.24V
Diodes Inc. BAT54C-7-F Y
D4 0.79V SMA Vr = 100V, Io = 1A, Vf =
0.79V
Diodes Inc. B1100-13 N
D5 0.24V SOD-323 Vr = V, Io = A, Vf = V
D6 0.24V SOT-23 Vr = 30V, Io = 0.2A, Vf =
0.24V
Diodes Inc. BAT54S-7-F Y
D7 SOD-123 Centeral Semi CMHZ4678
other4
FIGURE 7. Solar Powered Battery Charger BOM - Main Board Sh1 of Sh3
www.national.com 8
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65
Designator Value Footprint Parameters Manufacturer Manufacturer_PN RoHS
L1 100uH PF055X_CO
UPLED
Pulse
Engineering
PF0552.104NL Y
L1_Alt 100uH Coilcraft MSD1260.104
L2 100uH PF055X_CO
UPLED
Pulse
Engineering
PF0552.104NL Y
L2_Alt 100uH Coilcraft MSD1260.104
M1 60V SOT-23 0.26A, 0.81nC, rDS(on)
@4.5V=3
ON
Semiconductor
2N7002ET1G Y
M2 60V SOT-23 0.26A, 0.81nC, rDS(on)
@4.5V=3
ON
Semiconductor
2N7002ET1G Y
Q3 30V SOT-23 4.5A, 6.35nC, rDS(on)
@4.5V=0.08
Vishay-Siliconix SI2316BDS Y
Q4 30V SOT-23 4.5A, 6.35nC, rDS(on)
@4.5V=0.08
Vishay-Siliconix SI2316BDS Y
R1 10k 0805 5%, 0.125W Panasonic ERJ-6GEYJ103V
R2 5.1k 0805L 5%, 0.125W Vishay-Dale CRCW08055k10JNEA Y
R3 10k 0805 5%, 0.125W Vishay-Dale CRCW080510k0JNEA Y
R5 100k 0805 1%, 0.125W Panasonic ERJ-6ENF1003V
R6 22.6k 0805 1%, 0.125W Vishay-Dale CRCW080522k6FKEA Y
R7 15.8k 0805 1%, 0.125W Panasonic ERJ-6ENF1582V
R9 10k 0805 5%, 0.125W Vishay-Dale CRCW080510k0JNEA Y
R10 0 0805M 5%, 0.125W Vishay-Dale CRCW08050000Z0EA Y
R11 11.5k 0805L 1%, 0.125W Vishay-Dale CRCW080511k5FKEA Y
R12 10.0k 0805 1%, 0.125W Vishay-Dale CRCW080510k0FKEA Y
R13 1.74k 0805L 1%, 0.125W Vishay-Dale CRCW08051k74FKEA Y
R14 11.5k 0805 1%, 0.125W Panasonic ERJ-6ENF1152V
R15 200k 0805L 1%, 0.125W Vishay-Dale CRCW0805200kFKEA Y
R16 1.69k 0805 1%, 0.125W Vishay-Dale CRCW08051k69FKEA Y
R17 140k 0805 1%, 0.125W Vishay-Dale CRCW0805140kFKEA Y
R18 5.1k 0805L 5%, 0.125W Vishay-Dale CRCW08055k10JNEA Y
R19 34.0k 0805 1%, 0.125W Vishay-Dale CRCW080534k0FKEA Y
R20 2.43k 0805 1%, 0.125W Vishay-Dale CRCW08052k43FKEA Y
R21 10.0k 0805 1%, 0.125W Vishay-Dale CRCW080510k0FKEA Y
R22 10k 0805 5%, 0.125W Vishay-Dale CRCW080510k0JNEA Y
R23 0 0805 5%, 0.125W Vishay-Dale CRCW08050000Z0EA Y
R24 0 0805 5%, 0.125W Vishay-Dale CRCW08050000Z0EA Y
R25 100k 0805 1%, 0.125W Vishay-Dale CRCW0805100kFKEA Y
R26 1.37 0805 1%, 0.125W Yageo America 9C08052A1R37FGHFT
R27 10k 0805 5%, 0.125W Vishay-Dale CRCW080510k0JNEA Y
R28 15.8k 0805 1%, 0.125W Panasonic ERJ-6ENF1582V
R29 54.9k 0805 1%, 0.125W Vishay-Dale CRCW080554k9FKEA Y
R31 200k 0805 1%, 0.125W Vishay-Dale CRCW0805200kFKEA Y
R33 11.5k 0805 1%, 0.125W Vishay-Dale CRCW080511k5FKEA Y
R33A 3.0k 0805 5%, 0.125W Vishay-Dale CRCW08053k30JNEA Y
bom65
FIGURE 8. Solar Powered Battery Charger BOM - Main Board Sh2 of Sh3
9 www.national.com
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Designator Value Footprint Parameters Manufacturer Manufacturer_PN RoHS
R34 1.00 0805 1%, 0.125W Vishay-Dale CRCW08051R00FNEA Y
R35 1.00 0805 1%, 0.125W Vishay-Dale CRCW08051R00FNEA Y
R36 10k 0805 5%, 0.125W Vishay-Dale CRCW080510k0JNEA Y
R37 0 0805 5%, 0.125W Vishay-Dale CRCW08050000Z0EA Y
U1 MF03A National
Semiconductor
LM4041CEM3-ADJ
U2 SDC08AM National
Semiconductor
LM5001SD
U3 MF05A National
Semiconductor
LMP7701MF O
U4 SDC08AM National
Semic
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