Introduction: Solar LED Rechargeable Emergency Light

Picture of 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

Picture of 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

Picture of 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

Picture of 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

Picture of Deep Discharge Warning Circuit

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

Step 5: Installing Electronics

Picture of 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.

Picture of Preparing the Cabinet.
  • Install the mains chord.
  • Drill holes switches and DC female jack.

Step 7: Wiring

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

Step 8: Assembling

Picture of Assembling

Assemble the light.

Step 9: Preparing the Solar Panel

Picture of 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

Picture of 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.

Comments

DavidS697 (author)2017-05-28

What I really like is your great effort to reuse some old things in new ways, not even new - in modern ways. I think you have some great sense of doing what is right and getting things done. I admire you.

Thank you so much..

RobnAus (author)2016-10-12

A great way to re purpose an older lantern! I am going to build one similar for some 18650's I have. Thanks for sharing

Thanks for watching

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