diy solar

diy solar

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

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 πŸ˜€
 
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.πŸ˜€

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. πŸ’š
 

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New Gerber and drill files Version 1.2


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
 

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

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

New best diagram in a couple days.

More soon πŸ˜€
 

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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 πŸ˜€

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 πŸ˜€
 

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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 improvementsπŸ’š

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
 

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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.
 
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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) πŸ’šlooking 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 πŸ˜€
 
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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 😊
 

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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.
 
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.πŸ’š

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
 

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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 πŸ˜€
 
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
 

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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 πŸ˜€
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
 

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Expecting V1.2 circuit boards around 5PM, Picture new parts pull for a new Two-FET-Inverter 😊

This thing is going to look nice when I am done✨️

15amp diodes in the mail (Home made 15 amp set of diodes will be soldered in from bottom till the new diodes arrive), I am aiming for a full 15Amp from this inverter testing that may take a little time.

Little green ceramic capacitors all came from an old kitchen AM/FM radio circuit board, works good with the 555timer and optic coupler inputs.

More soon
 

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Large soldering iron made quick work of installing the 60Hz pure sine choke, placing parts on the really nice circuit board.

Nice when the hole sizes are correct ✨️

Things moving along smoothly,
Still need potentiometers and copper in/out wires, also 15 Amp diodes, looking good for testing tomorrow.

Almost 9PM done for the night second Picture.

More soon πŸ˜€
 

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Good morning Version 1.2 working first time around, 555 timer ceramic capacitor is a touch smaller than the recommended
part but the board is running fine at 84.2Hz.

Adjustment will be made shortly by adding a capacitor or more resistance on the potentiometer, If the 555timer were clocking closer to 60Hz the sinewave would look much better.

Great news you should be able to build and have working versions 1.2 and 1.4 the first time around πŸ˜€

About 4 hours so far to build the new inverter.

15amp diodes are under the board new 15amp diodes with heat sink option is on the way😎

First look at v1.2 at 24VDC dual inputs, AWESOME ❀️

Added a second ceramic capacitor to the 555 timer, last picture is 60.4Hz everything heading the right direction.

More later πŸ˜€
 

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New two FET inverter V1.2 mounted in a standard inverter case, used a dead fet next to the N channel FET to make the clamp work properly, P channel Mosfet secured nicely.

Got the spacing correct for lots of mounting options.

Very much like what is going on here ❀️

Will not be long this thing is going to be a permanent part of the overhead lights, fans and more day time power.πŸ’š
Voltage controlled relay 115VAC+ ON 100VAC and lower OFF or shed to grid/secondary, use a two sec OFF delay for lighting and fans and 5-7 minuets OFF for compressor motor starts (A small refrigerator needs the full seven minutes!) HVAC 24VAC delay on make and delay on break timers work reliably for this task. The 5 minutes time delay on the side by side fridge in the kitchen is working great unless you need ice or water through the door during the delay.
Deluxe smart 15Amp switcher displays a big red light during the delay to let you know all is normal πŸ˜€

Plenty of room inside a case that was stuffed full two days ago 😍

More soon
 

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In the next two days will work with the PCB manufacturer to make the latest Two-FET-Inverter a public domain educational project.

If I can get the BOM parts file format correctly done and build information, You may be able to order a factory assembled Two FET Inverter.

I will not advertise the company because they are offering 10% and my thoughts are why not?

If you directly upload the free V1.2 and V1.4 Gerber/Drill files when you order circuit boards I get nothing and I am very much OK with that❀️

Best wishes
 
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