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

[GridWorks Green Solar]

Just an early attempt at a printed circuit board lay out all wires that jump another wire go to the bottom layer of the circuit board traces.

Next attempt will be to get the 555timer, optic couplers and floating power supplies area accurate and spaced.

Accurate drawings and parts list soon, this is just a doodle but considering actual physical parts lay out and size.
Need to add the additional support components around the FETs.

First draft. 50K potentiometers belong on the optic couplers input not the gate triggers, fix it next go around.

On a second thought testing two 25K potentiometers in that location has never been tested yet

More soon

 

[GridWorks Green Solar]

Currently working on parts list and diagrams/printed circuit board for the two FET inverter. Just a couple more days to complete the drawings.

The LC for a 555 timer to turn the square wave into sine is 288 uH choke with a 10 uF (works) to 24 uF capacitor (calculated). Have photo examples of the 1000watt and larger 2,000 watt chokes in several previous post.

Going to use my 60Hz 555 timer dual output optic driver circuit to drive a four N channel FET single DC input inverter of my own take of the project power board, If I can get the 555timer to work via a 12VDC floating power source it may not even need the optic couplers.

Planning to use an online PCB card maker initial order of 20 - 30 circuit boards. 6 1/2" wide by 2 3/4" tall.

Another pre draft of the printed circuit board layout

More later

 

[GridWorks Green Solar]

How about the correct parts list for the new two FET inverter.

Brain cells were abused in the production of this list, alot of forward thinking and cost reduction thoughts went into this choice of parts.

Money goes into the output FETs for serious power production P FET is tough as nails and the 40N65 FET has a proven track record.

Ask questions if you need assistance, one more day on the main circuit drawing.

Best wishes

Added DC input capacitors to the list.

2nd electrical audit says dual 10-15 Amp fast blow glass fuse are needed on the two FET inverter output, add to parts list.

 

[GridWorks Green Solar]

Main drawing now passes first audit, Need to redraw at least one more time before it is published caught missing input capacitors on the parts list during audit.

Killed two or three birds with one stone by just organizing part location and direction. After rotating things a bit the whole inverter became more simple this will help in making a circuit board also.

More soon

 

[GridWorks Green Solar]

Here it is moved potentiometers around and simplify a few things, Official circuit design of the new two FET inverter.

800 ohm resistors are optional protection for the optic couplers from too high of a setting, set all potentiometers for increasing value in the clockwise direction, (Start all potentiometers at a minimum setting) ( First test dual 9 VDC on inputs nothing can be damaged and you can see/adjust everything.) Passing the dual 21VDC bench test or higher means the unit will likley tolerate 140VDC dual solar input, This a early release of Version 1.0 of the new two FET inverter, expect refinement and a nice circuit board soon to mount the components in kit form, Two FET inverter will be compact and versatile.

Use a 25 watt standard light bulb or equivalent as minimum load on the inverter 24/7. Stability issue.

Expect more improvements highest output so far 650 watts 120 VAC 60Hz 550 watts was long-term tested.

Enjoy and ask questions if needed.after connecting the capacitors to higher voltage you must follow discharge procedures before servicing the unit!

I am going to improve the circuit diagram and audit it again, If I have a mistake the time to catch it is now.

Have plenty of alligator clip jumpers available will do a physical recreation of the optocoupler to FET output per the Official design on the second test inverter to complete the audit and report back to everyone Have plenty of new parts to test.

More soon

 

[GridWorks Green Solar]

Off to a good start with Micad for printed circuit board production (PCB) and gerber file handling, purchased grid paper for better quality diagrams, starting a real world audit of the two FET circuit diagrams, I will update you as it progresses, if I have a bug it needs to be fixed now.

Audit of P channel has began, N channel is exactly like the previous circuit diagram the one with the two bulbs, I am going to be meticulously testing everything

Old dog is going to learn a new trick, Online videos can teach you new skills, Interest in electronics hobby has declined overall in recent years.

More soon

 

[GridWorks Green Solar]

Found mistakes in the diagram on the two, 12VDC floating power supplies, The 10 Mfd 200volt capacitors belongs accross each 12VDC zener diode, once the second inverter preforms on the bench test properly I will issue a new drawings.

Sorry but it will be corrected soon, Glad to have the one and only working example to compare everthing to.

Best wishes, Sorry more soon.

Picture diagram:

Quick fix to show the correct capacitor placement in the plus and minus 12VDC power supplies, New best diagrams ever after successfully testing.

Give me a day or two to properly fix and audit everything.

 

[GridWorks Green Solar]

Still need to complete a full physical audit on live parts, this Diagram is based on the actual working two FET inverter and contains fixes and improvements.

The two 12VDC floating power supplies were wrong on the previous Diagram, improvement made in the 555 output to the diodes.

Just need a second working example to start the process, Notice the open spaces this thing could shrink down to almost nothing with modern parts, going with classic parts and 6 inches in the long direction for easy FET mounting options.

Bench testing every day, unit running smooth

Diagram is the best so far, basically the result of two ongoing audits, Can not proceed properly till it runs a second time on new/tested parts, Making progress on all fronts.

Pressure washed all the solar panels today,Nice

Last picture is the new diagram configuration running on the two FET inverter. Audit successfully completed all fixes and updates working.


Whew ! Newest configuration works great and first time.

Last diagram most updated version of the new two FET inverter. Sorry for mistakes here is the one you really want.

More soon

 

[GridWorks Green Solar]

See previous post, Circuit passed audit and live testing.

Three days in a row the Project system has run the Mini-split plus house lights,fans circuit,mini fridge, two computer monitors and two stick computers 8:30 AM to 5:30 PM no glitches or errors except lights dim a moment when mini fridge starts.

No battery grid backed secondary operation works 99% of the time.

Many use options available ️

More later

 

[GridWorks Green Solar]

Slow start on PCB cad program, but going to double down on the effort starting tomorrow.

Although I have been able to label (silk screen) text and place some parts on a circuit board much more study is needed to build the two FET inverter board I have in mind.

More later

 

[GridWorks Green Solar]

Starting to make progress on the PCB, will not take too long to finish.

More soon

 

[GridWorks Green Solar]

See any improvements?

Back/bottom layer traces are there but not very visible.

Getting very close now, program shows no errors

More soon

Enough spare new parts to build one tomorrow if I had the PCB, a couple more days and the gerber files will be ready for export, hope to get bright red green and blue/purple new power boards

Small,light weight, low cost power boards.

Just caught a mistake N FET 40N65 is missing two support components and the 100 ohm resistor does not belong on this side, must get everything right before going to make duplicate circuit boards.

Updated photos, last is latest

DRC test passes with 5 silk screen warnings, making Gerber export files

More soon

 

[GridWorks Green Solar]

Making progress, Will likely order circuit boards tomorrow

Zero errors on the files fixed everything.one more audit on the circuit board.

New pictures,test pins removed,passed audit, Whew hot off the press New two FET inverter.


Fixed all through holes, ready to order now

More soon

 

[GridWorks Green Solar]

10 green circuit boards ordered, $35 for the product and $23 shipping, So about $6 each for the two FET inverter board
Uploaded about 12 .gbr files in a zip file but order did not pass because the drill file was missing, I should make a YT video now that I figured out how it is done.

Zip file available to anyone who wants it contains. Grb files and drill files nessassary to make/reproduce this Version 1.0 circuit two FET inverter board, may post on git hub in a few days.



Excited to say the least, More soon

 

[Mil]

Thanks for ALL your work,
-will more 85 mfd 450v improve work ,ie motor start
-do you plan to use ISO on outside
Best

 

[GridWorks Green Solar]

Thanks for ALL your work,
-will more 85 mfd 450v improve work ,ie motor start
-do you plan to use ISO on outside
Best

Yes 85 MFD is the minimum, I will leave to the user to manage capacitor size for motor starts Warning capacitor charge/discharge warnings must apply
One Meg ohm resistors will bleed down capacitors over time.

Just missing two 15Amp diodes to build one as soon as the new circuit boards arrive,
ISO transformer working just OK but additional improvements are needed to increase through put, it ran the small heater off the ISO transformer just fine.

Thank you for the starting information, still feel with improvement in the opto couplers drivers running the ISO transformers will be less of an issue in the future.

Right now a car battery could run the 555 60Hz signal for a month or more, 14 standard 12VDC solar panels will give you nice day time energy, charge battery systems for night time power and more
Epoxy dip a working circuit board minus the heat sinks for ultimate weather proofing and out door durability.

More soon

 

[GridWorks Green Solar]

Link to get new two FET inverter circuit board build files Gerber/Drill files in a zip file format.

Three dots file for download. Twofet.zip.

Two-FET-Inverter/Twofet.zip at main · Matt9876453/Two-FET-Inverter

Circuit board build files from Micad 6.0 Zip file containing Gerber/Drill files for PCB production. - Matt9876453/Two-FET-Inverter

github.com

Two new FET working parts list May 8th 2024 Grid Works.

1 P channel Mosfet IXTK40P50P
1 N channel Mosfet 40N65
2 12 Volt zener diodes 5Watt
1 555 timer
2 15Amp diodes or 4 10Amp diodes
2 Flyback diodes 10 amp 200 volt rated
3 1Amp diodes
1 5.7K resistor
2 15K : New data says 40K gate close resistor for N channel 30K for P channel
3 50K good qulity potenteometers
2 2A154k small green ceramic capacitors
2 optic couplers led input with Darrlington C/E output
3 820 ohm resistors
1 12VDC power supply must be isolated from earth ground/grid power
1 Inverter case with fan or heat sinks with fan
Each 140-160 VDC solar array needs 5Amp glass fast blow fuse and holder.
2 12K 5Watt resistors, Parts changes less heat and better stability
2 10MFD 200volt capacitors
1 225J630 filter capacitor
1 60hz 2,000 watt choke
2 85 Mfd capacitors 450Volt
2 800ohm resistors
2 10-15 amp glass fast blow fuse and holders for Inverter output 120 VAC 60Hz.
END

More soon

 

[GridWorks Green Solar]

Big steps forward in both projects,Have been updating (any pictures with a zero or one view count are likely new).

Have everything I need to build one of new circuit boards and test upon arrival.

More soon

Best wishes

 

[GridWorks Green Solar]

Assembly tip use a large soldering iron to install pure copper wires to the circuitboard. Also use big iron to quickly solder in the big FETs and diodes. Put a small gap between the circuit board and the package of the 15Amp diodes when soldering in place think thermal and electrical isolation.

Use smaller iron with 555timer and the smaller parts.

Use isolation pads on the FETs, first test use dual 9VDC inputs and 12VDC on the 555timer circuit with a meter and oscilloscope you should be able to confirm basic operation and make safe changes if necessary.

Once you pass dual 21VDC input or higher the unit will likely run smooth at 140VDC solar inputs, Fuse everything with glass fuses.

I will make an instruction sheet after the first new circuit board build and testing.

More soon

 

[GridWorks Green Solar]

New circuit boards finished and are being shipped out to me

After I test may order more colorful boards and thicker copper traces.

More later

 

[GridWorks Green Solar]

Don't fall for this solar scam, sales person tells customer to sign IPad so they can run their credit score.

After refusing the solar installation because of the $70,000.00 cost people with no solar panels on the roof years later find they are in collection and a lean has been filed on the home owners house. One lady discovered all this two years later when she went to sell the home and could not.

The company still claims with a lobby full of protesters that these customers are just suffering buyers remorse.

I can not believe the number of scams that occur every day against American consumers.

Just want you to know that solar inverters and panels simply do not cost that much. $70,000 is a whole lot of electricity and most still get an electric bill that is now 29% higher than just 4 years ago.

More soon

 

[GridWorks Green Solar]

Real world report, at 5:00 PM yesterday the project system faulted and the lights went off.

The reason for the fault is simple attempting to run the mini split and more in the late afternoon after completely loosing sun conditions.In thirty minutes the system would have switched to grid power for the night. Going to re adjust the voltage controlled relays for better protection against this loss of solar.

Suspect one or more Mosfets have shorted source to drain and need replacing, Picture is of blown 10amp glass fuse from secondary ISO DC output from the diode bridge. This is the reason I say glass fuse everything.

More soon

Short has dissappeared on main project inverter, Total carnage 2 40N65 MOSFETs shorted source to drain, one 10amp fuse in the secondary ISO transformer, restoration in progress.

 

[GridWorks Green Solar]

Main project inverter restored, now just have to put it back on the shelf.

About 3 hours so far working on it, more soon right here.

All in all a easy repair, needs a couple small adjustments on the voltage controlled relays and ready for summer

This is one of the latest Kit inverter boards that I spaced the FETs wide for better heat distribution and shortest route for main power flow, Newest 40N65 MOSFETs have a 650Volt rating, old parts were 450Volt rated.️

Voltage controlled relay #1 is now set for 100 VAC off/grid dump all extra loads (98VAC old setting) and 115VAC resets/restarts extra loads with delays. (Genius)

Project system fully functional again,

 

[GridWorks Green Solar]

Discovered a way to find shorted FETs with an analog ohm meter x1 scale without removing from the board, Found two in a row the bad components will show closer to zero than a good one.

Short will disappear the moment you remove the last bad FET. Replace the ones you cut out and presto new inverter again.️

This tip can save you hours of labor fixing inverters, simple test between source and drain and only cut out the FETs that are closest to full short.

Project system running good but it is a passing clouds day, ️

More soon

Still have two of the premium P FETs new in the bag and the better 40N65s on the way, Expect to set new record high for watts with the two FET inverter, Have been working on the circuit board for the two FET inverter for days now free to anyone who wants it, Big improvement in trace isolation less possible to cross talk, Going to test the first one before releasing the new file to github.

Circuit boards due in the 23rd, 8 better quality 40N65 MOSFETs 650Volt 80amps on the way.

Seriously the two FET inverter system only requires 15Amps 140VDC, these parts should last forever in power production.

 

[GridWorks Green Solar]

Result from 2nd audit says two FET inverter needs dual output glass fast blow fuses 10-15 Amps because either FET can fail closed and cause a problem!

Parts list is being updated.

Enjoying full operation again on the Main project system comfortable on a 90 degree Fahrenheit day, voltage controlled relay #1 back to 98VAC for shed extra loads