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.
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:08pm On Jul 01, 2014
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.
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:10pm On Jul 01, 2014
BLOCK DIAGRAM of SYSTEM DESIGN
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:11pm On Jul 01, 2014
PCB artwork from top in clockwise direction
1. Top silkscreen2. Double sided copper pcb3. Top side layout4.
Bottom side layout
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:12pm On Jul 01, 2014
PCB board after etching of artwork
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:12pm On Jul 01, 2014
PCB After adding components
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:13pm On Jul 01, 2014
Microprocessor Control part simulation in PROTEUS
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:14pm On Jul 01, 2014
Screenshot of my desktop showing my design in PCB artist
Top layer tracks are in red, bottom layer tracks in brown
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:14pm On Jul 01, 2014
Highside mosfet approx. 32khz,12v peak-peak drive signal on
Oscilloscope set to differential mode
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:16pm On Jul 01, 2014
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
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:16pm On Jul 01, 2014
Controller at night timerelays disconnect the controller from
the PV array
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:18pm On Jul 01, 2014
Some useful design tools
1. InductorRing program from Vladmir Denisenko (search
google)
Re: Design And Build Of A 48v 40a Mppt Solar Charge Controller.
(version 1) by nisol: 2:18pm On Jul 01, 2014
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.
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:08 La unu iulie 2014
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.
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 02:10 La unu iulie 2014
Schema bloc de SYSTEM DESIGN
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:11 La unu iulie 2014
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
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 02:12 La unu iulie 2014
PCB bord dup gravare de art
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 02:12 La unu iulie 2014
PCB Dup adugarea componente
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 02:13 La unu iulie 2014
Microprocesor de control parte simulare la PROTEUS
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:14 La unu iulie 2014
Screenshot de desktop-ul meu arat designul meu n PCB artist
Piese strat de top sunt, piese roii strat de fund n maro
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:14 La unu iulie 2014
Highside aprox MOSFET. 32kHz, 12v vrf-vrf semnal unitate pe
osciloscop setat la modul diferenial
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:16 La unu iulie 2014
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
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:16 La unu iulie 2014
Regulator pe timp de noapte relee deconectai regulatorul de
matrice PV
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:18 La unu iulie 2014
Unele instrumente de proiectare utile
Programul 1. InductorRing de la Vladimir Denisenko (cutare
Google)
Re: proiecta i construi Of A 40a 48v MPPT Solar Charge
Controller. (Versiunea 1) de nisol : 14:18 La unu iulie 2014
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
Datta