Solar LED Rechargeable Emergency Light

This is a 48 Led solar / AC rechargeable emergency light. Fully recharged battery works 9 hrs with 24 led's and 4.5 hrs with 48 led's. A SPDT switch is used to select 24 and 48 led's. Deep discharge warning before 10 minutes of actual deep discharge is incorporated. Generally many emergency lights deep discharge cut-off stops suddenly. We don't know when it stops. That is why I made my circuit to beep at low voltage for 10 mins so that we can aware before stopping suddenly. We have to switch OFF manually after beeping within 10 mins. I used Solar panel for charging which is renewable energy.

Step 1: Parts Needed

• Emergency Light cabinet
• 6v 4.5ah rechargeable battery
• 12v white LED strip
• 12v 1amp transformer
• LM2596 DC stepdown module
• XL6009 DC stepup module
• Mains chord
• 12v solar panel
• ON/OFF rocker switch * 1
• 3pin SPDT switch * 1
• Green LED * 1
• DC jack male and female
• PCB plastic spacers * 6
• 1k resistor * 1
• 4007 diodes * 6
• 5402 diode * 1
• 1000mfd 25v * 1
• 5v buzzer * 1
• BC547 transissors * 2
• 33k resistors * 2
• 47k pot * 1
• Wires

Step 2: Preparing the LED Panel

• Attach the LED strip to the mirror.
• Solder the wires to LED strip as shown in pictures.
• 1st and 4th strips are one set and 2nd and 3rd are one set.

Step 3: Setting the Voltages

• Solder a diode at step-down output in forward bias.
• Set the voltage 7.2v after the diode.
• Set the step-up voltage between 12v-14.2v.

Step 4: Deep Discharge Warning Circuit

Assemble the circuit. Adjust 47k preset so that buzzer beeps at 5.3v.

Step 5: Installing Electronics

• Place the electronics on base plate and make markings for the holes.
• Drill the holes and assemble the electronics.

Step 6: Preparing the Cabinet.

• Install the mains chord.
• Drill holes switches and DC female jack.

Step 7: Wiring

• Make diode bridge rectifier.
• solder 1 diode to SPDT switch.
• Start wiring all components as shown in pictures.

Step 8: Assembling

Assemble the light.

Step 9: Preparing the Solar Panel

Solder 5402 diode to +ve terminal in forward bias to protect the solar panel. Solder DC male jack to it.

Step 10: Testing

• Plug the AC and check for charging.
• Connect Solar panel and check.

Current consumption and battery backup time:

• 700ma for 48 LED's @ 12.4v and backup for 4.5 to 5hrs.
• 350ma for 24 LED's @ 12.4v and backup for 9 to 10hrs.
• 1.2amp for 48 LED's @ 14v and backup for 2 to 2.5hrs.
• 600ma for 24 LED's @ 14v and backup for 4 to 5hrs.