Solar Battery Charger For Your Cordless Power Tools by DIY Hacks and How Tos

Solar Battery Charger For Your Cordless Power Tools
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Bio: Jason Poel Smith: Inventor, Maker,

Hacker, Tinker, and occasional Mad Genius
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DIY Hacks and How Tos (/tag/type-id/categoryworkshop/keyword-diy hacks and how tos/)
Solar power is a great way to get electricity out to a remote project site. One
simple way to do this is to use a solar panel to charge the batteries of your
cordless power tools. In this project, I am going to show you several ways that
you can do that.
diyhacksandhowtos (/tag/type-id/category-workshop
/keyword-diyhacksandhowtos/)
Jason Poel Smith (/tag/type-id/category-workshop
/keyword-jason poel smith/)
solar (/tag/type-id/category-workshop/keyword-solar/)
solar panel (/tag/type-id/category-workshop
Safety Note: Any time that you use a DIY battery charger instead of a
commercial charger, you are accepting a certain amount of risk. So always use
caution. Don't over charge the battery and don't try to charge it faster than the
manufacturer recommends. There are many different kinds of batteries and they
all need to be treated differently. These instructions are designed for batteries
that are made of Nickle-Cadmium cells. I make no guarantee that these
instructions will be appropriate for other battery types such as NiMH or lithium
batteries.
/keyword-solar panel/)
power tools (/tag/type-id/category-workshop
/keyword-power tools/)
charge controller (/tag/type-id/category-workshop
/keyword-charge controller/)
555 timer (/tag/type-id/category-workshop
/keyword-555 timer/)
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30/07/2014 17:47
Step 1: Watch the Video
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Here is video walk through of the project.
Step 2: Background: Cordless Power Tool Batteries and How

They are Charged
(http://cdn.instructables.com/F63/PFLM/HXG6N8H9/F63PFLMHXG6N8H9.LARGE.jpg)
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There are many different styles of cordless power tool batteries and many
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30/07/2014 17:47
different styles of chargers.
Solar
Battery Charger For Your Cordless Power Tools
Most cordless tool battery packs are made up of several smaller batteries that
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are all wired together in series. In the most basic models, the charger will
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(/id/Solar-Battery-Charger-For-Your-Cordless-Power-Tool/?download=pdf)
connect
directly
to the end terminals of the battery pack at two exposed pins.
The
charger
then
applies a small direct current and slowly
charges the battery
11 Steps
pack over several hours.
In more advanced
models, the battery pack may have a number of internal
(http://cdn.instructables.com/FTK/3S37/HXG6NXNN/FTK3S37HXG6NXNN.LARGE.jpg)
sensors. For example a Craftsman 19.2V battery has a thermal fuse and an
internal temperature sensor. To accommodate these sensors, the battery has
two additional terminals (a total of four). The charger connects to the battery
through the thermal fuse. If the temperature of the batteries ever goes above the
maximum safety threshold, the thermal fuse will disconnect the battery from the
charger. The temperature sensor allows the charger to actively monitor the
temperature of the batteries while they are charging. This lets the charger
automatically adjust the current to maximize the charge rate without overheating
the batteries.
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If you want to use a DIY charger to charge the battery, your primary concern
should be safety. The safest way to charge a battery is to do it slowly. This will
sacrifice some efficiency but it will guarantee that you will not destroy the battery.
Step 3: Materials
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30/07/2014 17:47
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(http://cdn.instructables.com/FE0/3YP0/HXG6O4DT/FE03YP0HXG6O4DT.LARGE.jpg)
Materials:
Cordless Power Tools and Batteries
Solar Panel
Wires/Connector Cables (rated high enough for the maximum output of the solar
panel)
Charge Controller
Multimeter
Wire Cutters
Wire Strippers
Soldering Iron
DIY Charge Controllers Materials:
555 Timer IC
7805 5V Voltage Regulator
5V Relay (with a coil that is rated for less than 100mA)
2 x 0.1 Microfarad Capacitor
0.47 Microfarad Capacitor
2 x 10 kohm Resistors
68 kohm Resistor
33 kohm Resistor
2 x Diodes (rated for at least 1 amp)
Step 4: Identify the Terminals of the Battery
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30/07/2014 17:47
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(http://cdn.instructables.com/F45/4ZBI/HXG6OUWD/F454ZBIHXG6OUWD.LARGE.jpg)
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The first thing that you need to do is identify and label each of the terminals on
the battery. If your battery has two terminals then you can easily use a
multimeter to identify which one is positive and which one is negative.
If the battery has more than two terminals, then there are several things that you
need to check. Start by noting the position of the terminals on the power tool. A
power tool will usually connect directly to the positive and negative terminals of
the battery. You can then use a multimeter to measure the voltage of the
corresponding terminals on the battery to determine which one is positive and
which one is negative. Any additional terminals will probably be a thermal fuse
or a temperature sensor.
A thermal fuse is usually connected to the positive terminal of the battery. So if
you measure its voltage with a multimeter it will have the same voltage as the
positive terminal of the battery (or slightly less). The thermal fuse also connects
to the positive output of the charger. Once you have identified the thermal fuse,
any remaining pin will be the temperature sensor.
If you want to double check yourself to make sure that you have correctly
30/07/2014 17:47
identified the terminals, you can carefully remove the cover of the battery pack
Solar
Battery
Foris Your
Cordless
PoweranyTools
and check
to see Charger
where each wire
connected.
Do not disconnect
wires, orby DIY Hacks and How Tos
move any of the sensors!
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(/id/Solar-Battery-Charger-For-Your-Cordless-Power-Tool/?download=pdf)
After
identifying
each terminals you can label them with tape, a permanent
marker
or
by
scratching
a note into the side of the plastic
housing.
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Step 5: Select an Appropriate Solar Panel
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(http://cdn.instructables.com/F5A/KDOP/HXG6OW8Z/F5AKDOPHXG6OW8Z.LARGE.jpg)
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The next thing that you need to do is select a solar panel that is well suited to
charge your battery. The panel needs to have an open-circuit voltage (Voltage
measured with no load) that it higher than the voltage of the battery when it is
fully charged. You can find the open-circuit voltage of the panel by connecting
your multimeter directly to the panel when in bright sunlight. To find the fully
charged voltage
of the battery, simple charge it with the commercial charger and
(http://cdn.instructables.com/FJA/OQCX/HXG6TSAY/FJAOQCXHXG6TSAY.LARGE.jpg)
then use a multimeter to measure the voltage between the positive and negative
terminals. This will typically be higher than the rated voltage that is listed on the
side of the battery. For example, a 12V battery may measure 14V when fully
charged.
The other thing that you need to be concerned about is the charge rate. To be
safe, I recommend using a panel that will charge the battery more slowly than
the original charger that came with the battery. The easiest way to determine
this is to compare their wattage ratings.
Here is a simple example. My "12.0 Volt" drill battery came with a charger that
lists its output as 15V DC at 200mA. This means that its wattage rating is 3
watts (15V x 0.2A = 3W). So you would want to find a solar panel that is rated
for less than 3 watts. I chose a 12 volt panel that was rated for 1.5 watts.
30/07/2014 17:47
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Step 6: Charge Controllers
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It is possible to charge the battery by connecting the output of the solar panel
directly to the terminals of the battery. However, if you are not carefully
monitoring the voltage of the battery, then you run the risk of over charging it.
This is why you usually want to use a charge controller.
A charge controller (http://en.wikipedia.org/wiki/Charge_controller) is any circuit
that limits (http://cdn.instructables.com/F5W/YFBX/HXG6PCL9/F5WYFBXHXG6PCL9.LARGE.jpg)
the current that is sent to the battery in order to prevent over charging.
You can purchase a commercial charge controller (http://www.harborfreight.com
/7-amp-solar-charge-regulator-96728.html) at most stores that sell solar
equipment or you can build your own.
In a previous project, I showed how you can use an Arduino as a charge
controller. Because the Arduino has multiple inputs, you can use it to monitor
and control the charging of multiple batteries. Check out the link to see how I did
it. http://www.instructables.com/id/Arduino-Controlled-Solar-Fountain/
(http://www.instructables.com/id/Arduino-Controlled-Solar-Fountain/)
You can also make a charge controller with a simple 555 timer IC. These chips
have an internal comparator that toggles the output on and off depend on the
30/07/2014 17:47
input voltages. This can be used to connect and disconnect the battery with a
Solar
Battery
Charger
ForisYour
Cordless
Power
Tools
low power
relay. This
control circuit
discussed
in more detail
in the next
step. by DIY Hacks and How Tos
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If you plan on leaving the battery connected to the solar panel overnight, then
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want to(/id/Solar-Battery-Charger-For-Your-Cordless-Power-Tool/?download=pdf)
make sure that either the panel or the charge controller has a
blocking
diode.
This is a diode that is placed between
panel and the battery
11the
Steps
to prevent the battery from discharging through the panel when it is dark. A
schottky diode gives the best performance for this.
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Step 7: 555 Control Circuit Design
8 de 14
(http://cdn.instructables.com/FB0/QHT4/HXDPDEDB/FB0QHT4HXDPDEDB.LARGE.jpg)
Here is one simple example of how to make a DIY charge controller.

This charge controller is built around a 555 timer IC. This chip has two inputs
(pins 2 and 6). It compares these input voltages to a set of reference voltages
that are based on the supply voltage. If the voltage at pin 2 drops below the 1/3
of the supply voltage, then the output at pin 3 goes HIGH. If the voltage at pin 6
goes above 2/3 of the supply voltage, then the output at pin 3 goes LOW.
By using the 7805 voltage regulator, we can fix the supply voltage to 5 volts. So
1/3 of the supply voltage will always be 1.66V and 2/3 of the supply voltage will
always be 3.33V.
The input voltages at pin 2 and 6 are dependent on the voltage of the battery.
Each input has a voltage divider (http://en.wikipedia.org/wiki/Voltage_divider)
that is made of two resistors. The ratio of the two resistors determines what
percentage of the battery voltage is sent to the input pins. In this example the
pin 2 voltage divider uses a 68 kohm resistor and a 10 kohm resistor. This
means that the voltage at pin 2 will always be 12.8% of the battery's voltage.
Similarly, the voltage divider at pin 6 uses a 33 kohm resistor and a 10 kohm
resistor. This means that the voltage at pin 6 will always be 23.2% of the
battery's voltage. This is only approximate because all resistors will vary a little
from the indicated value.
When the battery's voltage goes above 14.4 volts, the output of the 555 goes
LOW and activates the relay. This disconnects the battery from the solar panel.
When the battery's voltage drops below 13 volts, the output of the 555 will go
HIGH and deactivate the relay. This resets the system for another charging
cycle. In the case of cordless power tool batteries, this will happen when you
disconnect the battery. But in a typical solar system, the battery stays connected
and the voltage will drop as the power is used.
If your battery has a different operating voltage, you can change the voltage
setting of the charge controller by using different values for the resistors. The 33
kohm resistor can be replaced using the formula R = (3 x Vcutoff) - 10 (in
kohm's). The 68 kohm resistor can be replaced using the formula R = (6 x
Vreset) - 10 (in kohms).
30/07/2014 17:47
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Step 8: Assemble the Circuit
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(http://cdn.instructables.com/F25/ITNT/HXG6PDIP/F25ITNTHXG6PDIP.LARGE.jpg)
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First prototype the circuit on a breadboard and make adjustments as needed.

Then once it is working, solder the components onto a breadboard.
In this case, I needed to make some modifications to the board. The pins on the
relay where positioned in such a way that there was no place that I could mount
it on the board where the pins could be isolated from each other. So I mounted it
(http://cdn.instructables.com/FOV/DZS5/HXG6PEF0/FOVDZS5HXG6PEF0.LARGE.jpg)
in the middle
of a set of columns. Then I used a knife to cut the conductors in
the middle. This separated the two halves and let me access the pins
independently.
I also used a Dremel to trim the edges of the circuit board. This let me easily fit
the board in a small plastic project enclosure.
Step 9: Cut Slots in the Project Enclosure
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(http://cdn.instructables.com/F6C/ZWO1/HXG6PEXI/F6CZWO1HXG6PEXI.LARGE.jpg)
The circuit board has four wires that connect to it. So we need to cut four slots in
the side of the project enclosure to accommodate these wires. I just used a knife
to cut two lines in the side of the housing. Then I used a pair of needle nose
pliers to break off the tab of plastic. Do this for all four locations on the top and
bottom of the housing.
Step 10: Test the System
10 de 14
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30/07/2014 17:47
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(http://cdn.instructables.com/FMH/S0DM/HXG6PFMC/FMHS0DMHXG6PFMC.LARGE.jpg)
Now you need to test the system to make sure that everything is working
properly. The easiest way to test this system is to switch the battery and the
solar panel. The battery is connected to the input of the charger where the solar
panel would normally be connected. Then the solar panel is connected to the
output of the charger where the battery would normally be. Keep the polarities of
the positive
and negative wires the same.
(http://cdn.instructables.com/F1N/QEKZ/HXG6PGEW/F1NQEKZHXG6PGEW.LARGE.jpg)
The battery supplies a stable power source for the charge controller circuit and
the solar panel acts as a variable voltage source. Start by covering up the solar
panel. You can either put something over it or turn it face down. Then slowly
uncover the panel. As more light hits the panel, its output voltage will go up.
When the voltage reaches 14.4V, you should hear a click from the relay
activating. Then slowly cover the panel. When the voltage drops to 13V, you
should hear another click from the relay turning off. If everything is working
properly, then you are done.
Step 11: Hook Up Your Finished Solar Charger
11 de 14
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30/07/2014 17:47
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Now you are ready to connect all the components together. First connect the
output of the charge controller to the battery. Then connect the solar panel to the
input of the charge controller. The relay may turn on and off a few times while
the circuit is powering up.
Now you have your own solar charger. This will let you charge your batteries
anywhere that has sunlight. This can be really useful for working with power
tools at remote project sites.
Make Comment
warpspeed (/member/warpspeed/)
20 hours ago
Reply (C0MT7JUHY7SV5KA)
Wrong video was displayed, the video being shown is for a water to wine trick.
fix.
(/member Please
/warpspeed/)
DIY Hacks and How Tos (/member/DIY+Hacks+and+How+Tos/) (author)

Reply (CZQL9A3HY8IOCVR)
2 minutes ago
warpspeed
Sorry. It should
(/member
be fix. Thanks for letting me know.
repworth (/member/repworth/)
Its a miracle though!
warpspeed
9 hours ago
Reply (CCM409BHY8IKCFX)
(/member
/repworth/)
parth_bhat (/member/parth_bhat/)
2 days ago
Reply (CIGA8VGHY5NOYPS)
hi,
(/member
can
/parth_bhat/)
12 de 14
you please please help me to find out my resistors value?
i have a black and decker cordless drill machine whose battery voltage is 14.4v
and when fully charged 15.5v and its adapter's voltage is 17v @ 200mA
i am going to use this project for automatic charging. instead of solar pannel ill be
using the original dc charger.
30/07/2014 17:47
Please can you help me to find the voltage divider's resistor's value?
SolarRegards
Battery Charger For Your Cordless Power Tools
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parth temkar
artchie (/member/artchie/)
11 Steps
parth_bhat 20 hours ago
Reply (C9NIXHXHY7SZJWD)
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use 1k ohm's
(/member
/artchie/)

Reply (CYEMTJDHY734LVY)
parth_bhat
yesterday
If yo are using the original charger, you shouldn't need a charge

(/member
controller. But if you want one just use the formulas at the bottom
of
step 7.
"The 33 kohm resistor can be replaced using the formula R = (3 x
Vcutoff) - 10 (in kohm's). The 68 kohm resistor can be replaced using
the formula R = (6 x Vreset) - 10 (in kohms)"
dfietkau (/member/dfietkau/)
parth_bhat
yesterday
Reply (CHAZ7K0HY7345DJ)
Doesn't Ohm's law for direct current fit here ?

(/member
/dfietkau/) i.e.:
U = R * I; R = U / I; R = 17V / 0.2 A = 85 .
Otherwise you might have to manually measure it step by step.
carlos66ba (/member/carlos66ba/)
2 days ago
Reply (C7JZHRTHY48DUEC)
Clever non orthodox use for the 555 circuit. Clever.

(/member
/carlos66ba/)
tutdude98 (/member/tutdude98/)
(/member
/tutdude98/)
3 days ago
Reply (C5MTL6FHY3Z9HSW)
Ive put led instead of relay and i set to reset at 10v and cutoff at 12.6v but it
reset at 9.3v and it doesnt cutoff
anybody know why?
(http://cdn.instructables.com/FHS/SLBH/HY3Z9HSV
/FHSSLBHHY3Z9HSV.LARGE.jpg)

Reply (CE0JHVCHY3ZABGS)
tutdude98
2 days ago
Sorry, I can't
(/member
really see any of the parts from that picture
deba168 (/member/deba168/)
3 days ago
Reply (CBKOMAOHY3Z84GN)
Can I use a MOSFET instead of relay??

(/member
/deba168/)
13 de 14

deba168
As long as it is rated for a high enough current it should be fine. I just used
30/07/2014 17:47

a relay because it
work for almost
Solar BatterywillCharger
For
any
application.
(/member
Reply (CN18X0XHY3ZAA3A)
2 days ago
Your Cordless Power Tools
Vote!
(/id/Solar-Battery-Charger-For-Your-Cordless-Power-Tool/) 11 Steps
3 days ago
brmarcum (/member/brmarcum/)
Reply (CT4DUNTHY21X5FE)
I was just looking for a solar charger solution. This is perfect, thank you.
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(/member
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Danger is my middle name (/member/Danger+is+my+middle+name/)

Reply (CZB0TY4HY12D4V1)
5 days ago
This is awesome, I just got a cordless

to try this!
(/member
drill, I'll have
/Danger+is+my+middle+name/)
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30/07/2014 17:47

Solar Battery Charger For Your Cordless Power Tools by DIY Hacks and How Tos

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Solar Battery Charger For Your Cordless Power Tools by DIY Hacks and How Tos

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Solar Battery Charger For Your Cordless Power Tools

About This Instructable

DIY Hacks and How Tos

Bio: Jason Poel Smith: Inventor, Maker,