controller 40 amperi

Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by nisol: 2:06pm On Jul 01, 2014

Objectives:Considering the high cost of commercially available MPPT based solar charge controllers,I decided to build one for myself at a much lower cost and secondly, to have customizable features.

Methodology:Solar charge controllers are majorly DC buck converters.There are several methods of achieving MPPT based charge controllers.

These briefly are:Perturb and observe, Incremental conductance, Current Sweep Method, Constant voltage.The first four methods involve storing the PV (photovoltaic) array Voc (Open circuit voltage) /currentagainst the controller output voltage Vout/current with varying pulse widths applied to the buck converter.The stored points are then compared and that with the maximum power transfer value is then used toswitch the semiconductors in the controller for a fixed interval after which the process is repeated.

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by nisol: 2:08pm On Jul 01, 2014

The method chosen by me is number five the constant voltage method.

Each manufacturers PV array has what is known as an IV curve i.e. a curveshowing the maximum current that can be supplied at a particular voltagefrom the panel. At some point along this curve is the maximum power transfer point.The point showing maximum current at maximum voltagethis point is known as the knee of the IV curve.

This is shown below.


An approximate maximum transfer point can then be obtained by switching at a constant ratioof Vout/Voc.

My PV modules are Joy Solar panels each rated 200W, 24V DC.They are connected three in series to give Voc (an open circuit voltage)of maximum 90V at peak irradiance. These series strings are then run in parallelI experimented with different pulse widths ranging from 0.6 to 1 of Vocand finally settled for 0.8

This was the point I achieved a maximum power transfer.


BLOCK DIAGRAM of SYSTEM DESIGN


PCB artwork from top in clockwise direction

1. Top silkscreen2. Double sided copper pcb3. Top side layout4. Bottom side layout


PCB board after etching of artwork


PCB After adding components


Microprocessor Control part simulation in PROTEUS


Screenshot of my desktop showing my design in PCB artist

Top layer tracks are in red, bottom layer tracks in brown


Highside mosfet approx. 32khz,12v peak-peak drive signal on Oscilloscope set to differential mode


Fully assembled and installed.

Some changes had to be made, number of toroids in output inductor was increased from two to threeto reduce system losses due to heat

input/output terminals were melting at above 20A so I removed them and soldered wires directly to the board

initial backlit blue background LCD replaced with more passive green background LCD


Controller at night timerelays disconnect the controller from the PV array


Some useful design tools

1. InductorRing program from Vladmir Denisenko (search google)


2. Power stage designer tool from Texas Instruments

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by mrnestyy1985: 8:32pm On Jul 02, 2014

Hi bro, nice information. But i was expecting you were building it from scratch not prebuild. Anyway do inbox me ur contact, we could work on something together

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by nisol: 3:10am On Jul 03, 2014

@mrnestyy1985:

It was built from scratch by me. The design is not exactly rocket science.The issue of being prebuilt or not was discussed in the previous version of this post before the recent loss of data on nairaland.

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by ucheezeigbo: 2:42pm On Jul 03, 2014

Hi engr @nisol. This is a great design and full of innovations. I work for a solar based marketing company as an engineer and am happy to learn how the components I sell are really made. My number is 07030098944 and email is [email protected]. I would like to meet you and learn more from you. Give me a look in sometime, please.

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by usisky(m): 11:14am On Sep 21, 2014

Hi Mr. nisol. Really nice design you've done. I really appreciate your input, especially you presentation.

A while ago, I did some research into the workings of the MPPT technique. I read a lot of application notes, notably from manufacturers like Microchip, Atmel and Intersil. But I never really got round to doing any work related to it largely because of other engagements. But with what you have done and presented here, you have just helped sparked my interest in that again. Though, I am interested in SMPS technology in general.

Out of curiosity, I would like to ask: Have you done any work on offline SMPS designs before?

Thank you much much!!

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by nisol: 11:16pm On Sep 25, 2014

@usisky

Once you control the the on/off duration of semiconductor switches in ato influence the output of a power circuit, you have an SMPS (switch mode power supply).

This project involves SMPS technology in two places.

(1) the DC-DC stepdown (48V -12v/5v) flyback converter(2) buck converter switched at 40khz.

In the not to distant future I will post more detailed SMPS designs.

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by usisky(m): 11:12am On Sep 26, 2014

@nisol

Peace and thanks for your response.

Yes! I understand that it is "switch mode" technology too. I was just curious to know if you've done designs on "offline" SMPS. I am very much interested in that, hence, my asking.

Your contribution has been immense. I hope some day we'll get to do some designs together.

Thanks Sir.

Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller. (version 1) by dknagare: 4:45am On Nov 15, 2014

Dear Sir,

how can I get software and PCB file

Regards

Obiective: Avnd n vedere costul ridicat al disponibile comercial controlere de ncrcare solar MPPT bazeaz, Am decis s construiasc o pentru mine, la un cost mult mai mic i n al doilea rnd, pentru a avea caracteristici personalizabile.

Metodologie: Controlere de ncrcare solare sunt majorly convertoare DC Buck. Exist mai multe metode de realizare a controlere MPPT taxa pe baz.

Acestea sunt pe scurt: Perturba i s respecte, conductan incremental, metoda Sweep actual, tensiune constant. Primele patru metode implica stocarea PV (fotovoltaice) matrice Voc (tensiune deschis circuitului) / curent mpotriva tensiunii de ieire controler Vout / curent cu diferite latimi de impulsuri aplicate la convertorul dolar. Punctele stocate sunt apoi comparate i care cu valoarea maxim de transfer de putere este apoi utilizat pentru a comuta semiconductori din controlerul pentru un interval fix dup care procesul se repet.

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) de nisol : 14:08 La unu iulie 2014

Metoda aleas de mine este numrul cinci - metoda tensiune constant.

PV matrice Fiecare productor a ceea ce este cunoscut ca o curb IV, adic o curb artnd curentul maxim care poate fi furnizat la o anumit tensiune de la panou. La un moment dat de-a lungul acestei curbe este punctul maxim de transfer de putere. Punctul maxim arat Curentul la tensiunea maxim acest punct este cunoscut ca genunchiul curbei IV.

Acest lucru este artat mai jos.


Un punct de maxim aproximativ de transfer poate fi apoi obinut prin comutarea la un raport constant de Vout / Voc.

Modulele fotovoltaice mele sunt panouri solare "Bucuria" fiecare 200W evaluat, 24V DC. Acestea sunt conectate trei n serie pentru a da Voc (o tensiune circuit deschis) de 90V maxim la iradiere vrf. Aceste siruri de serie sunt apoi executai n paralel Am experimentat cu diferite latimi de impulsuri variind 0.6-1 din Voc i, n final stabilit pentru 0,8

Acesta a fost punctul I realizat un transfer de putere maxim.


Schema bloc de SYSTEM DESIGN


Opera de arta PCB de sus n sensul acelor de ceasornic

1. silkscreen Top 2. Facei dublu PCB de cupru fee 3. aspect lateral de top 4. aspect lateral de jos


PCB bord dup gravare de art


PCB Dup adugarea componente


Microprocesor de control parte simulare la PROTEUS


Screenshot de desktop-ul meu arat designul meu n PCB artist

Piese strat de top sunt, piese roii strat de fund n maro


Highside aprox MOSFET. 32kHz, 12v vrf-vrf semnal unitate pe osciloscop setat la modul diferenial


Asamblat i instalat complet.

Unele modificri au trebuit s fie fcute, numrul de toroids n producia inductor a fost crescut de la dou la trei pentru a reduce pierderile de sistem la caldura

Terminale de intrare / ieire au fost topete la peste 20A, aa c am s le ndeprtat i fire lipite direct pe placa de

backlit iniial fundal albastru LCD inlocuit cu mai pasiv fundal LCD verde


Regulator pe timp de noapte relee deconectai regulatorul de matrice PV


Unele instrumente de proiectare utile

Programul 1. InductorRing de la Vladimir Denisenko (cutare Google)


2. Puterea instrument scenograful de la Texas Instruments

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) de mrnestyy1985 : 08:32 La 02 iulie 2014

Bun frate, informaii frumos. Dar m ateptam ai fost o cldire de la zero nu prebuild. Oricum nu m inbox de contact ur, am putea lucra la ceva mpreun

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) de nisol : 03:10 La 03 iulie 2014

@ Mrnestyy1985:

A fost construit de la zero de ctre mine. Designul nu este tocmai tiin de rachete. Problema de a fi preinstalat sau nu a fost discutat n versiunea anterioar a acestui post nainte de recenta pierderea de date pe nairaland.

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) de ucheezeigbo : 02:42 La 03 iulie 2014

Bun Engrnisol. Acesta este un design deosebit i plin de inovaii. Lucrez pentru o companie de marketing bazat solar ca un inginer i sunt fericit pentru a afla cum componentele eu vnzare sunt ntr-adevr fcute. Numrul meu este 07030098944 i de e-mail este [email protected]. A dori s v ntlneasc i s nvee mai mult de la tine. D-mi o privire n cndva, v rog.

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) prin usisky (m): 11:14 La douzeci i unu septembrie 2014

Bun Dl. Nisol. ntr-adevr design placut ce ai fcut. Apreciez de intrare, mai ales tu prezentare.

Un timp n urm, am fcut nite cercetri n modul de funcionare a tehnicii MPPT. Am citit o mulime de note de aplicare, n special de la producatori precum Microchip, Atmel i Intersil. Dar n-am ajuns ntr-adevr rund pentru a face orice lucrare se raporteaz la acesta n mare parte din cauza altor angajamente. Dar cu ceea ce ai fcut i prezentat aici, tocmai ai ajutat strnit din nou interesul meu n asta. Dei, eu sunt interesat de tehnologie SMPS, n general.

Din curiozitate, a vrea s v ntreb: V-ai fcut nici o lucrare pe deconectat SMPS planuri nainte?

Va multumesc mult mult !!

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) de nisol : 23:16 La 25 septembrie 2014

usisky

Odat ce ai controla on / off durata de switch-uri semiconductoare ntr-un de a influena ieirea unui circuit de putere, avei un SMPS (comutator de alimentare).

Acest proiect implic tehnologie SMPS n dou locuri.

(1) Stepdown DC-DC (48V -12V / 5V) convertor flyback (2) convertor dolar pornit la 40kHz.

n a nu viitorul ndeprtat, voi posta modele SMPS mai detaliate.

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) prin usisky (m): 11:12 La 26 septembrie 2014

nisol

Pace multumita pentru rspunsul dumneavoastr.

Da! Am neles c aceasta este o tehnologie "n modul n comutaie" prea. Am fost doar curios s tiu dac ai face pe modele SMPS "off-line". Sunt foarte mult interesat de faptul c, prin urmare, ntreb.

Contribuia dumneavoastr a fost imens. Sper ntr-o zi vom ajunge s facem unele desene mpreun.

Mulumesc domnule.

Re: proiecta i construi Of A 40a 48v MPPT Solar Charge Controller. (Versiunea 1) de dknagare : 04:45 La 15 noiembrie 2014

Stimate Domn,

cum pot obine software-ul i PCB fiier

Salutari

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controller 40 amperi

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maximum current

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