New no battery pure sine wave solar power system with smart switchers.

[GridWorks Green Solar]

I have this,just do`nt know that to do
-https://www.next.gr/oscillators/Multiple-waveform-generator-circuit-diagram-l59906.html
View attachment 198364
-https://www.instructables.com/Grid-Tie-Inverter-V4-1/
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-https://makingcircuits.com/blog/h-bridge-inverter-circuit-using-ic/
DC for all
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Going to stay focused on the build with the B1 & B2 input power source, I see a path to big power output naturally, also the test you requested shows a square wave before the LC circuit off the FETs expect the square wave out to nicely convert to pure sine especially since I have a nice ISO transformer already to experiment, expect transformer output sine wave to be rounded nicely.

Best wishes

 

[GridWorks Green Solar]

With a 50% duty cycle on the alternating solar arrays the in between voltage spikes will build up in the capacitors for an extra punch of output energy.

The effect should be awesome!
Also this voltage boost will excite the full sun panels MPPT effect for more energy.

I fully expect this to work after some trial and error approach testing, cannot wait to see this push a motor or quartz tube heater.

More soon

 

[GridWorks Green Solar]

With diodes before each capacitors I can prevent backfeed or back flow (Safty feature) and the extra energy is captured by the capacitors behind the diode ready for the inverter to use.

Instead of the main energy flow passing through 4 Simiconductors 40N65 causing 180 volts to become 120VAC in the new Inverter it will be time sliced down to one Mosfet at time, this will be more direct and efficient likely causing a lower input DC voltage from the solar panels, Likely to need 150VDC to get 120VAC output from the new inverter.
With the first high voltage test with solar 180VDC will try just to see what I get for the output.

More soon, added to previous post

 

[GridWorks Green Solar]

Parts have arrived OK will get started in the morning, P channel and N channel MOSFETs verified. Just got to keep it under 100 DC volts and 15 amps.

First go around low battery voltage and small loads, larger FETs more volt/amps to be ordered soon.

Best friend from high school has passed away will need to go out of town in about two weeks.

 

[GridWorks Green Solar]

Just ordered two super P channel Mosfets 500VDC 40amp $20 each
IXTK40P50P From Digi-Key.

IRFP460 N Channel 500 volts 20amp quantity 5.

Found out the hard way P Channel Mosfets are rare and costly. Powerful N Channel MOSFETs are cheap in comparison. Ordering higher voltage and amperage Mosfets now.

More soon

 

[GridWorks Green Solar]

Parts pulled only missing two capacitors C1 & C2 to start, 555 timer will be glued to 3D printed base stand and adjusted for 60Hz square wave, Parts board will be reconfigured for dual DC power inputs with boost capacitors, LC output circuit will be reconfigured for pure sine output to the ISO transformer.

Mosfets mounted to heat sink and have passed initial testing. Some resistors in series other parallel for more watts, audit is good so far.

More kick butt parts coming soon. Getting excited now

So far so good, More soon

When I make this into a kit it will all fit on the circuit board and the FETs will be on the ends ready for inverter case mounting.

Have seen a similar inverter with a PNP transistor driving a bunch of MOSFETs for more amps.

 

[GridWorks Green Solar]

Wow was have nothing but trouble out of N channel Mosfet would start in on and did not respond correctly to gate trigger.

Solar array drawing shows a different orientation for the B2 solar panel (A plus and minus must meet at the grounded connection) I now have proper manual control of both FETs (First base)

Using 9VDC batteries to simulate solar panels.

Hope the main circuit drawing has no more errors, must admit it makes a lot more sense with the plus on the top and negative on the bottom.

It's been a productive day. When I get it working I will provide a much better schematic of this inverter.

I have multiple YT videos on making the 555 timer do 60Hz square wave and FET trigger, I smell success just around the corner, plenty of new parts to work with.

Hard to believe that was accidental if you look closely the negative symbol is in the wrong place, someone did not want you to build a working inverter.

So far the FETs are wrong for the operating voltage, B2 power source is inverted and I still see a few more hurdles before this circuit works as it should.

More soon

 

[GridWorks Green Solar]

Watched many YT videos last night before going to bed for the best/simple way to use the three modes available on the 555 timer for 60Hz/50Hz signal.

This configuration is rare and locks in a mandatory 50% duty cycle also the best looking square wave on the oscilloscope to date.

Dead simple I really hope it works, also will make this system a one of a kind.

Dual DC inputs with boost capacitors 50% duty cycle will directly charge high voltage boost, proven LC output circuit and output ISO transformer will provide really clean pure sine power.

More soon.

Best wishes

 

[GridWorks Green Solar]

Spent a few moments with metal cutting snips and cut out my two DC inputs from the solar arrays, also the LC output filter circuit for pure sine. Diodes/fuses will be added to the DC input capacitors.

I will add to this post my steps forward in progress today.

555 timer epoxy glued to the 3D printed stand wires have been soldered on and pass initial electronic testing.

N Channel MOSFETs have arrived IRFP460 20AMP 500VDC only need one for the new inverter, guess you know why I ordered 5 of them.

Not far away from oscilloscope testing for square wave and pure sine.

First test for square wave out using 555 output with above circuit 255Hz output.

As it sits now 255Hz is the low setting, can go very high.

Wrong capacitor needs more work but pleased with the initial testing. (Second base)

Good quality square wave for alligator clip wired 555 timer, once wires are shorter and the connections soldered it should be rock solid. Think a higher K ohm potentiometer and slightly larger capacitor is in order, need to watch that video one more time.

More soon

 

[GridWorks Green Solar]

Delay while I order adjustable capacitors, technical issue getting below 200 Hz square wave, YT video says adjustable capacitor is the quick approach to the problem

Going to do the nessassary soldering to correctly bring all the parts together as one functional Inverter adding diodes, fuses,fan for heat sink. A real prototype of a two MOSFET flip inverter. Have also started down the path of making a nice circuit board for a inverter kit.

Have pulled out an antique soldering iron for making the big connections on this new inverter 1960s Bell Telephone soldering iron for people who solder things all day long, still running great.

So far added third wire to LC circuit, Added 10 amp blocking diodes to the boost capacitors electricity testing each, Additional wires added to each input capacitor.

Big soldering iron is making quick work of these important connections.

Best wishes, more soon

 

[GridWorks Green Solar]

Large Mosfets have arrived must mount the largest FETs to the heat sink and test.

The P channel 40amp FET is the largest I have ever owned.

The small ones were recommended by the diagram wrong voltage range 100 volt maximum, the two larger ones exceed the specified needs and is what I recommend if you want to produce full time 120Volts 50/60Hz or 220Volt 50/60 Hz (not tested yet).

A few bumps in the road but good progress going on with the new two FET inverter, first one being not grounded or ISO transformer isolated in testing, The second will be grounded per the diagram and I pray it works long term, could reduce the complexity/cost of turning sun into usable power.

I think this is a solid step forward I invite some young electronics guru to run with this idea, The 50% duty cycle on the alternating solar arrays will spike the voltage 50% of time if you use the correct capacitors and diodes to trap that energy for the the inverter you will have big power to turn motors/heaters and so on.

More soon

 

[GridWorks Green Solar]

Tested a capacitor from a radio parts board and got 73.2 Hz good square wave from the 555 timer, adjustable capacitors for the 60Hz win.

Second picture Another capacitor from the same parts radio, Now running 61Hz on the 555 timer very good! Small green capacitor clearly marked 2A154K and 100K potentiometer using the simple 555 configuration. Trash spots in the square wave is due to long alligator clip leads and twisted connections once I get it just right everything will be soldered and reduced to minimum lengths.

Baby steps forward.

Keep it simple is working!

More soon

 

[GridWorks Green Solar]

New Mosfets mounted to heat sink, All parts test good have full manual control of both P & N FET channels, It is another great day when I get what was paid for.

Making progress on all fronts.

More soon

 

[GridWorks Green Solar]

Early look at the new Prototype two MOSFET flip inverter, lots more to do.

Going to double glass fuse at 10Amps until I fully understand how this is going to function safety first expect final DC maximum input voltage between 150VDC and 180VDC FETs are rated 500volts 20+ Amps. If it works as expected,

Found another something I don't like about the original plan pin 3 out from the 555 timer connected to two inverted diodes and directly to the FET gates. Seems a single resistor to get the output into the best range and let it feed the Hi tech MOSFETs gates for switching.

Cleaning out my work space and getting off the dining room table with this remaining project.



See you soon

 

[GridWorks Green Solar]

Here is a drawing of what I plan to build the actual connection to earth ground will omitted on the first go around, this shows the new 555 timer configuration and complete system overview.

Full parts list soon.

Decided to build the prototype in top part of the combo inverter case, This will save me hours of work later on and if it works correctly will allow faster real world testing.

Actually a simple design. Not yet tested. Best wishes

More soon

 

[GridWorks Green Solar]

New home for the two FET inverter, much better idea, more caps, better layout. Ruff drawing passes general function audit needs fuses and Zener diode is 5.1 volt.

Adjustable capacitors due in tomorrow.
Update: Third picture adjustable capacitors are here already know from YT videos the light gray/white ones work best with the 555 timer.

Will start tomorrow with 555 timer final adjustments and soldering.
Soldering on long conductors to the different parts that need connected.

More soon

 

[GridWorks Green Solar]

Have made real forward progress with the dual DC inputs soldering, mounting parts and boost capacitors.

555 timer is not steady enough for power production floats between 58Hz and 62Hz the LC circuit needs 60Hz to work properly, going to try another method.

I am starting to doubt that the original circuit diagram was actually functional but stick around we are going to fix it properly.

Need 60Hz square wave signal to make the FETs work properly,

Going to test the 555 timer for it's ability to switch the FETs before moving on to something else.

More soon

 

[GridWorks Green Solar]

Parts list:
R4 & R5 100 ohm
R3 10K 10 watt omit resistor 555 timer needs 5VDC separate power supply
D1 & D2 1N4148 diode
D3 & D4 15 amp 200 volt
C1 & C2 200volt+ large boost capacitors, testing will show exact Mfd!

555 timer simple configuration
1H104K capacitor, 500K potentiometer drawing shows 100K the 500K is better.

Omit part Zener diode 5.1 volt (Actually needs good 5VDC power supply for the 555 timer)
P channel Mosfet IXTK40P50P
N channel Mosfet IRFP460

You will need two FET gate isolation transformers for high voltage switching, new circuit diagram when I get it working.

Parts may change as testing continues.
First version will be limited/fused at 10Amps blocking diodes will also be 10Amps rated.

Stable 555 timer at 61Hz for testing Mosfet switching and output. Best so far drift is between 60Hz & 61Hz. Moving drift to 59Hz to 60Hz for better match LC filter circuit (Major Win here!)

Last real hurtle is the FET gate isolation transformers for another win.

Third picture raw output from the project power board before the LC circuit I have high hopes this is going to work well.
Did not lock on to 60Hz signal but clearly a square wave output MILs requested test of the project system FETs output, convinced me to build a two FET inverter that will actually do the job I will keep at it till its right. Single high quality FET switches can pass alot of energy, with the 50% duty cycle the capacitors will be fully charged when the switch closes on the next output cycle, In technical terms its known as attack and in the real world result it means this inverter will push a motor well.

The inverter is coming in at around $200 in parts and is really not that complicated to build.

This post updated when build changes are made.

Best wishes

 

[GridWorks Green Solar]

Using clear silicone caulk to glue and insulate the individual parts into the half inverter case, only thing left is to finish and install is the 555 timer, next will be an intensive session of soldering to complete the inverter.

Going to test with and without an ISO output transformer. Oscilloscope pictures of each hope to get good pure sine from each.

Basic concept already works on the test bench just need good MOSFET gate trigger and 60Hz signal for a win.

All the components glued in place, lots of soldering ahead to complete the two FET inverter.

My main target is 120VAC 15Amp 60Hz pure sine goodness.

More soon

 

[GridWorks Green Solar]

Getting close to electrical testing, Most everything is glued and mounted upside down 555 timer encased in a blob of silicone a bit ugly but it is also a prototype, passed basic wiring audit.

First test will be 9 volt on all inputs, second test 21 volt on all inputs.

Adjustment knob is for frequency 60Hz. Relocated FETs to the center of the inverter.

Safety first.

More soon

 

[billvon]

555 timer is not steady enough for power production floats between 58Hz and 62Hz the LC circuit needs 60Hz to work properly, going to try another method.

Get a 3KHz oscillator, divide by 10 and divide by 5 with 7490-type counters.

Alternatively get something like a PIC processor, almost any crystal, and divide it down to the frequency you want.

 

[GridWorks Green Solar]

Get a 3KHz oscillator, divide by 10 and divide by 5 with 7490-type counters.

Alternatively get something like a PIC processor, almost any crystal, and divide it down to the frequency you want.

Thanks may need something else with better clock, First 9 volt test the oscilloscope is watching inverter output with no iso transformer, small load on the output.
Results 11Hz output and right now it will not respond to the adjustment knob but the good news is that bold clean sine wave.

Get it up to 60Hz and it will round out nicely (Third base)

More soon

 

[GridWorks Green Solar]

21 volt test inverter worked for two seconds 25 watt bulb lit brightly and failed, no 555 timer signal anymore. New 500K potentiometer but unit went down so quickly I didn't get to test.

Figure need new 555 and better voltage regulator to fix the issue, excited it may have been two seconds but it works.

Taking a break now, more later.

Can not turn back now even though it was only a few seconds it worked, Can’t tell you how many times the project system through me a curve ball after showing me that it actually works, two steps forward and one step back.

Will soon master this inverter.

Best wishes

 

[GridWorks Green Solar]

Have restored the 555 timer by replacing it with a new one, Watched several videos on making the timer chip more stable, one recommended improvement is to add a capacitor to the Vcc + and - of the timer.

Learning about how to bias the FETs so the gate trigger functions properly.

Restoring everything back to the 9 VDC test conditions for more testing,
Don't mind a separate power 5VDC power supply for the 555 timer as long as the FET triggers work correctly.

Just encased the new 555 timer in epoxy and will slowly resume testing.

Don't think the 5.1volt zener diode and 10K 10watt resistor work at higher voltages to protect the timer the one from the 21VDC test was cooked.

Baby steps till I figure it out.

Best wishes

 

[GridWorks Green Solar]

Small step forward, oscilloscope monitoring FET gate trigger signal at the FETs, steady 60Hz, put timer on it's own battery while leaving it also connected to the inverter, Problem now lost FET output, not responding to the nice trigger signal.

Blue dotted line is center.

Removed third battery for timer attempted to run it normal no 555 output and 5.1 zener diode was running way hot to the touch, NE555 has 18 volt limit maximum I have some real nice heavy-duty 12VDC Zener diodes.

Should be no way to damage anything with 9VDC batteries, If the zener diode was damaged it was during the 21VDC test.

Working on it, more soon