Current output of a solar panel when connected to battery and load

batteriesbuckcurrentsolar cell

I am trying to build a microgrid (final year project) where a 100-250 W 48V solar array will charge a 24V battery bank and a couple of 24V loads (40W lights, 60W fan).

Batteries used (7 of this in series) :
http://industrial.panasonic.com/www-cgi/jvcr13pz.cgi?E+BA+3+ACA4001+NCR18650+7+WW

I will be using a buck converter to step down the voltage of the array to that of the battery.

Assuming the power of the solar array is 200W, 200/48 = 4A~
After step up by the buck converter, it should be around 8A?

Now I am trying to figure out what will happen if only the battery is connected across it. Will it only draw as required (what happens to the solar panel's excess current?) or will the 8A of the solar panel's output be forced into the battery? (and maybe spoiling it).

Also, if the battery is near fully charged, how do I know that? Is it by checking the voltage level? Do I have to turn off the mosfet switch then (cut the connection between the array and battery)?
I will be using a microcontroller to regulate PV supply using the buck converter.

Best Answer

First of all you need to be very careful when designing with Lithium-ion batteries. If you exceed their specified charge or discharge rates they can leak or explode, and nobody wants that! You definitely need a charge controller. This will regulate the battery charging to safe levels, and follow a recommended charge profile, which is typically to charge first at a constant current until the cells reach a certain voltage, and then to top off at a constant voltage. This is called "CCCV" charging. You also need something to limit the discharge rate of the batteries. This can be a very simple circuit, but for safety you need something. Your buck converter can supply both the load and the charger. Any excess capacity of the solar panels will just not be used. The panel output voltage will probably rise above 48V at lower loads. For 7 cells, a linear charge controller is not good as at low battery voltages the power dissipated will cause overheating. You probably need a switcher there too, either buck or SEPIC. If you can design a pcb for this, so much the better. I appreciate that your school would probably not really appreciate it if you went and bought this on Amazon!