Why does my homemade charge controller switch rapidly between charge and dump?

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Discussion Overview

The discussion revolves around a homemade charge controller circuit using a 555 timer to manage the charging of a 12 V battery from a solar panel. Participants explore the issue of the circuit rapidly switching between charging and dumping modes, seeking to understand the underlying causes and potential solutions.

Discussion Character

  • Technical explanation
  • Debate/contested

Main Points Raised

  • One participant describes the circuit's operation and the observed rapid switching behavior when the battery voltage is low and the solar panel output is high.
  • Another participant questions the pinout of the 555 timer, suggesting a potential issue with pin 5 and recommending verification against the datasheet.
  • A different participant advises checking the battery voltage with the solar panel directly attached, mentioning that a sulfated battery could show a voltage higher than the dump setpoint.
  • A later reply indicates that using a different battery resolved the issue, implying that the original battery was likely sulfated.
  • Another participant confirms the suggestion about pin 5, noting that adding capacitance could improve noise immunity and referencing the 555 datasheet for additional recommendations.
  • There is a mention of "smart" analog battery charger ICs as alternatives, but the homemade solution is deemed acceptable for a hobby application.

Areas of Agreement / Disagreement

Participants express differing views on the cause of the rapid switching, with some attributing it to battery condition and others to potential circuit design issues. The discussion does not reach a consensus on the primary cause of the problem.

Contextual Notes

There are limitations regarding the assumptions about battery condition and the specific circuit design, as well as the potential impact of noise on the 555 timer's performance.

Who May Find This Useful

Individuals interested in DIY electronics, solar energy applications, or battery management systems may find this discussion relevant.

damosuz
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I have built the following circuit which uses the comparators inside a 555 timer to control the charge of a 12 V battery from a solar panel. The circuit is adjusted (via pots R1 and R2) so that when the battery voltage gets under 12 V, the relay connects the solar panel to the battery so it charges while when the battery voltage gets over 14 V, the relay connects the solar panel to a dummy resistor so it dumps energy.

When I try the circuit with the panel outputing 15 V and the battery at 10 V, the relay swithes very fast between charge and dump. Does anyone know why?

Thank you for your help.

555ChargeController2.jpg
 
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The 555 pinout looks a bit odd to me. Where is pin 5? Have you checked that pinout against the 555 datasheet?
 
I tried with a different battery and it seems to be working. The battery I was using must have been sulfated!

Thank you.
 
Great.

Berkeman's suggestion about pin 5 was right on. 555 wants a capacitor there to smooth its internal reference .

Some capacitance from node R1-R2-R8 to common would help noise immunity.

555 datasheet suggests robust capacitance across supply near the chip for it draws considerable current during switching. The cmos versions are less rambunctious.

Nice job!
There exist "smart" analog battery charger IC's made for this job, but for a one-off hobby application yours looks fine.

http://www.ti.com/lit/an/slua115/slua115.pdf
 
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