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

[GridWorks Green Solar]

Here is what works project system with three sets of 9 12VDC solar panels series 180VDC, 5amps + 5amps + 5 amps= 15Amps to run 120VAC mini split and more, Four FETs power board 40N65 and 15Amp ISO transformer output transformer, system allows you to add a secondary ISO transformer for 24/7 550+ watts backup secondary power and additional stability/ higher voltage for solar input.

The new two FET inverter is in beta testing 550 watts continuous output, 650 watts is currently the maximum I have seen to date. 700 watts and the FETs failed shorted source to drain, output good sine wave 120VAC 60Hz. Useful power.
Two strings of 7 standard 12VDC solar panels 140VDC, not tested yet parallel in additional groups of seven panels for more watts/amps power.

Can not wait to build the new circuit boards. More soon

 

[GridWorks Green Solar]

Running a Hybrid solar/grid home, water heater, dishwasher and night time usage on everything is grid, Looking for a $40 electric bill even with a 29% increase in the past four years the end result is good.

Right now on the project system running mini-split summer/ Quartz tube heaters in winter for comfort, running house lights and fans circuit,3 security cameras, two computer monitors, two stick computers and a mini-fridge.
Mini-fridge and electric bug zapper are on a dedicated two wire system (No ISO transformer test more than one year) also runs several modern battery rechargers for green lawn equipment.

Second much older solar/grid system runs full size side by side fridge (commanded by 15Amp smart switcher in the kitchen) Runs all living room electronics and clothes washer.
First Picture, most of my neighbors get a two or $300 electric bill.

Clothes drying is clothes line or grid powered dryer.

Old systems has 3 to 4 hours battery backup before I have to break out the gas powered inverter generator. Old system can run the new system but I currently keep the systems separated for cleaner test results and to simplify operation.

More soon

 

[GridWorks Green Solar]

Guess what I am working on?

New two FET kit inverter, hope to be testing by tomorrow noon.

Sent me 11 boards ordered 10, some of the hole could be one size larger, having fun with this first build.

30watt soldering iron seems to be working OK for assembly.
Best wishes

 

[GridWorks Green Solar]

Getting close, Four more capacitors , two optic couplers,1 resistor.

This is the 1,000 watt LC pure sine choke the 2,000 watt is a bit bigger.

New 40N65 MOSFETs are here 650Volt rating and 80amps, This build will be mostly new parts and Bench tested components, several first time events will occur tomorrow, solar panel testing will come later, tomorrow is about basic functionality and best sinewave output possible.

Already bench testing diodes and othe critical connections. So far so good.

 

[GridWorks Green Solar]

Big capacitors installed, Had to re learn optic couplers, pins straightened out for LED input and will be soldered directly to the board, will bridge in the C/E output with soldered in with small jumper wires. Only 4 connections to a 6pin chip,

Taking a break, finishing in the morning and directly to first inverter test dual 9VDC and 12VDC for the 555 timer. Will be looking for sine wave and output voltage from the FETs.

See several improvements that will improve the circuit board build, FET drill holes and conductors drill holes need to be larger, large cap drill holes need better spacing, version 1.2 in the works

More soon

 

[GridWorks Green Solar]

Was up till 3AM last night working the cad program larger drill holes for FETs, input/output wires and large capacitors.
You will want a copy of the gerber/Drill files when I get it right.

Up since 8AM finished installing parts on the two FET inverter circuit board, 555 timer ran first time although the quality of square wave and cycle drift are not good enough yet.

Unfortunately the first dual 9VDC input test is a fail no output from either FET, Don't worry I will figure it out, Just takes step by step testing.

More soon, taking a break right now.

 

[GridWorks Green Solar]

Moving slow this morning, located the problem area closing optic couplers output does not trigger the FET gate on N or P channels, going to decouple the output of the optic couplers an see if I can get my 60Hz signal to the optic couplers output.

P channel has a 60Hz output to optic coupler output, no wiring changes yet but coming, not sure the floating 12VDC power supplies are working, slow step by step testing needed to fix issues.

Now have adjustable 60Hz signal on both optic coupler outputs N channel (Opto 1) needed the input reversed on the chip LED input, reversed the direction of the chip and resoldered in place. Pin one is positive and pin 2 is negative for the LED.

Baby steps till I get it right, all corrections will be forwarded to the version 1.2 circuit board and circuit drawings.

Can manually open the FETs main output looks nice, both gate close resistors working, Main error in 12VDC to power FET gates.

More soon

 

[GridWorks Green Solar]

Something strange going on with the 555timer not getting the rock solid square wave I am use to and cycle drift is around 4 Hz instead of 1.5 HZ. Working on it.

P channel is working during latest testing and current timer configuration P FET gave me a steady 122HZ of full power
P channel just passed 21VDC test.

Almost certain both silk screen mask for 12VDC zener diode direction is reversed on the printed circuit board cut out diodes and replaced with new in the opposite direction only fixed the P channel

More soon

The N channel 6K 5watt resistor is a new bad part or bad circuit board connection, replacing part.

Both P and N channels operate now but scope says they are on the same phase of the sine, need to swap a diode or something

Have seen full power on both channels but something wrong with stereo output, this will be the third time I have run into problem, good news for me the previous second time around Diagram is correct and working.

Just need to recreate diagram to solve the current timing issue.

Tomorrow I will painstakingly mimic the diagram for the optic couplers also good news should only require a couple small adjustments to mimic operation

More tomorrow

 

[GridWorks Green Solar]

Last look, mostly working need another day, Pictures: P FET working, N FET working, overview 98% completed.

Dual 27 volt test, failed sync test.

Swapping out the capacitor gave me a better square wave but right now stuck at 122HZ instead of 60Hz.

More tomorrow

 

[GridWorks Green Solar]

Massive improvement in the circuit board, nothing like building a kit to figure out the needed improvements.

Tomorrow's changes will also be rolled into this circuit board design.

Improvements better holes for FETs and wires, capacitors, corrected silk screen to show corrected zener diodes, opto coupler are now six pin instead of four, and improvement in the optic couplers.

Serious take a look at the front view, over four hours of work recently

More tomorrow

 

[GridWorks Green Solar]

Working on the same problem for a day and a half without improvement.

Have cloned the Working version of the optic couplers, 50K potentiometers and 12VDC power supply LED outputs but still have a timing issue.

Going to shift over to making the 555 timer produce good square wave 60Hz signal and add a small heatsink to the N FET, Hopefully the solution will present itself in the process.

More soon

 

[GridWorks Green Solar]

Was explaining to my better half the problem when I accidentally turned the frequency knob instead of the optic coupler adjustment knob and presto stereo output

Still need to get the 555timer down to 60Hz but here it is working correctly at120Hz.

Electrically moved one of the 1amp diodes to the opposite side input of the P channel optic coupler LED and the original silk screen of both 12VDC zener diodes is backwards, Corrected Diagrams and Gerber files incoming.


After I get it working to my expectations new gerber/drill files and parts list, Diagram update will be offered to all.

More testing ahead, time to up the voltage again, FIXED&FIXED Timer running smoothly 59 - 60.4Hz added a 20.5K ohm resistors to the potentiometer instantly went to 60.4 Hz last picture 59.8 Hz, Unit responding nicely to upping the voltage currently at dual 45VDC (passed!) and starting to over drive the oscilloscope.

HOME RUN !
Total success with the new circuit board two FET inverter, success in reproduction of the two FET inverter.

 

[GridWorks Green Solar]

New Gerber and drill files Version 1.2

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

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

github.com

Tons of fixes and improvements over 6 hours on the Cad program.

Look under main branch for primetwofetv12.zip view raw or down load file.

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

1 P channel Mosfet IXTK40P50P
1 N channel Mosfet FGA40N65
2 Zener diodes 12VDC 5 watt Zener Diodes 1N5349
1 555 timer through hole 8 pin
2 15Amp diodes STTH1502DI or four 10Amp diodes 200+ volts rated 10A10
2 Flyback diodes 10 amp 200+ volt rated 10A10
3 1Amp diodes 1N4007
20K resistor may be needed for 60Hz potentiometer additional for low hertz.
1 5.7K resistor
2 15K: New data says 40K gate close for N channel and 30K for P channel
3 50K good qulity potenteometers
2 2A154k small green ceramic capacitors
2 optic couplers 4N33M LED input with Darlington 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 2100 HT V/H
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

Best wishes

 

[GridWorks Green Solar]

Ordered 5 more of the deluxe V1.2 boards in purple

Board and parts list placed in the public domain by the PCB manufacturer.

New best diagram in a couple days.

More soon

 

[GridWorks Green Solar]

One vision of how to use Two FET inverter set it up for best solar power production and leave the 60Hz signal on 24/7 or timer for day sun up hours, use one or more voltage controlled relays to (ON/Reset) 120VAC and cut the loads 100VAC and below put a delay in the loop so it does not act like a blinker, Charge battery systems and more daily

Regulated 12VDC from solar can also power the 60Hz signal and cooling fan

Multiple systems could charge night time equipment and run daytime work loads. My setup easily rechargers green lawn mower lithium ion batteries in two hours in full sunlight conditions.

Best wishes, more soon

Real working Version 1.0 board, silk screen mask for zener diodes was reversed, opto couplers needed special attention for polarity and 6 to 4 pin conversion, electrically moved 1 Amp diode to opposite side of optical coupler input, my advice just get the Version 1.2 circuit board

 

[GridWorks Green Solar]

Best Diagram to date results of a triple audit, wanted to do it while everthing was still fresh in my mind from the optic coupler battle that I just won.

Version 1.2 tested good.Take a good close look at each picture. New optic driver approach to turn sun into 60Hz 120VAC power. Not done working on this expect big improvements

Having issues getting a clear picture.

Last picture lamp and level one heater was on for hours from dual 140VDC input new two FET inverter from solar input only.

Best wishes to all

 

[GridWorks Green Solar]

Waiting on 15Amp diodes and the new V1.2 circuit boards, Will in the next couple of weeks do extreme solar testing at dual 140VDC and 160VDC, Expect to set new output records for the new two FET inverters.

Thinking about investing in new mono-silcone solar 12VDC panels, 14 panels 7 panels 140VDC in series for each input.

More soon

Check out photos in previous post.

 

[GridWorks Green Solar]

Information: Solder in small parts first, than the diodes,Potentiometers, Pure sine choke,FETs and in/out copper wires.

Test first with dual 9VDC and 12VDC for 60Hz timer also small fan later on when you start loading the inverter, basic operation can be assessed with an oscilloscope and volt/ohm meter.
(Be aware of the quality of the 12VDC you are sending to the 555 timer, No negative earth grounded battery power or you need a transformer based 12VDC power supply to use grid power).

9VDC testing is 100% safe to you and all your new parts, changes can be safely made till you get basic operation.

Passing 21VDC test tells you dual 12VDC floating power supplies are running (standard 25 watt bulb will glow) and unit is likly good for dual 140VDC to 160VDC solar input. Each 7-8 solar panels in series needs a proper 5AMP fast blow glass fuse and holder, Caution mains voltage during sun up conditions

Unit needs a 25 watt standard light bulb for the base output 120VAC load or equivalent.
(I will soon address this stability issue again) using the primary of an ISO transformer is working good for base load but I am not happy with the through put of the ISO transformer (Daily run ISO loads (House lights) and directly connected 2 wire loads (Mini-fridge) off the same 4 FET 40N65 power board) looking for improvement in the two FET inverters sinewave output.

Adjust for best sinewave no spikes just beyond where the FETs start up, More raw power is available if don't care about the quality of the sinewave, Still advise to keep spikes to a minimum, Spikes are a sign that phases are starting to short (also any loss of output power when increasing the setting means the inverter is about to short), Just nano seconds of both FETs being on at the same time will blow both P and N MOSFETs shorting them source to drain.

Expect improvements

 

[GridWorks Green Solar]

PCB manufacturer is asking me for a build of materials file BOM parts file to link in with the Gerber and drill CAD files.

So far I have not been able to find a valid part number for this 2,000 watt 60Hz torridal choke or for the smaller 1,000 watt version pictured many times in previous post.

Asking your help on this, do not own Mili Henry tester and really don't want to purchase one for $60+ or higher cost.

Best photo 2,000 watt version, could unwind one and measure things if it will help.

Need advice Thanks

 

[Sunny Day]

PCB manufacturer is asking me for a build of materials file BOM parts file to link in with the Gerber and drill CAD files.

So far I have not been able to find a valid part number for this 2,000 watt 60Hz torridal choke or for the smaller 1,000 watt version pictured many times in previous post.

Asking your help on this, do not own Mili Henry tester and really don't want to purchase one for $60+ or higher cost.

Best photo 2,000 watt version, could unwind one and measure things if it will help.

Need advice Thanks

You will get a lot more attention on that question, and hopefully a few useful answers, if you also post it as a new thread somewhere in the busier parts of the forum. There is only a subset of forum members following this thread, whereas new threads get more visibility sometimes.

 

[GridWorks Green Solar]

You will get a lot more attention on that question, and hopefully a few useful answers, if you also post it as a new thread somewhere in the busier parts of the forum. There is only a subset of forum members following this thread, whereas new threads get more visibility sometimes.

Thank You for the advice, The electrical engineer at the PCB manufacturer is very excited about this one of a kind inverter.

Small compact design, was able to join the FET Drains together of opposing P and N MOSFETs efficiently with 15Amp diodes for bold/clean 120 VAC 60/50Hz output, The simple 555 timer configuration to optic couplers for FET triggers is also unique.

Sorry electronics is a dry subject but this small power board can make a real difference. Under $200 for the inverter and around $80 each for 12VDC standard solar panels, I recommended the output ISO transformer for safety but have also proven you don't really have to use one to get the benefits.

Best thing since sliced bread that fits in the palm of your hand, Picture:

First build V1.0, Version 1.2 and 1.4 will look much nicer, yes have invested days in improvements V1.4 is nearly complete. Second Picture new look V1.4

Best wishes

 

[GridWorks Green Solar]

Newest version 1.4 of the PCB build files look for (besttwofetv1.4.zip) under the main branch, View raw or down load zip file.

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

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

github.com

More later

 

[GridWorks Green Solar]

Will have the V1.2 circuit boards in the next two days, also waiting on 15Amp diodes that have heat sink option.

My plan is to totally rebuild the big two FET inverter with the new circuit board, FETs will be mounted to the inverter case and full testing at dual 160VDC and 140VDC solar inputs.

Expecting long term testing of 5+ hours of continuous loads.

More soon

 

[GridWorks Green Solar]

Have found a part number that may work for the two FET inverter 60Hz pure sine choke J.W. Miller. 2100HT (V/H) 21Amp max. has a different foot print than the original/ still looking.

Range 1uH to 1,000 uH to the best of my knowledge you need a 288uH choke for 60Hz.

Optocouplers now have a part number in the main parts list 4N33M.

Also the 12VDC Zener 5watt Diodes 1N5349 part number.

1amp diodes 1N4007

STTH1502DI 15Amp diodes with heat sink option.

10amp diodes all can be 10A10 have a 1,000 volt rating and should work nicely.

Most complete parts list to date.

New circuit boards arrive tomorrow

More soon

 

[GridWorks Green Solar]

Completely removed everything but the capacitors on the large Two-FET-Inverter case in preparation for the version 1.2 circuit board and case mounted P and N MOSFETs. The FETs test good and will be reused for the new build.

The small ceramic capacitors are key to stable 60Hz square wave signal from the 555 and stable operation of the optic couplers LED input
Wish to share getting it correctly running with version v1.0 circuit board, did not have the correct capacitors and the square wave was trashy and cycle drift was bad, replaced capacitors with correct parts and sinewave and drift were fixed but unit was running at 122Hz, adding 20.5K resistor to the potentiometer almost automatically pulled the cycle frequency down to 60.4 Hz and the inverter runs stable.

If you are not getting a clean square wave or 60Hz signal is not stable within 2Hz replacing the capacitors is your first step.
Like the foundation of a home if the base signal isn't correct the inverter simply won't work as you expect.

I am excited at the prospects of the never tested before dual 160VDC input voltage, I already know the two FET inverter can handle 180 VDC input with a 150VAC 60hz output!
140VDC dual input produces 120VAC output but 80% load pulled the output voltage down to 100VAC 60Hz.

Can't wait to test dual 160VDC and test larger loads, Like I said excited at the prospects of running larger loads at a more normal 115 VAC output voltage.

Tomorrow is also going to be interesting with new circuit boards V1.2. If you download and make the V1.4 board you can leap frog the inventer in having the best highest amps output Two-FET-Inverter on the planet, the traces are maxed out for current flow. Look at the picture.

Best wishes