DIY Solar Power Hack: Turn a $25 DC Boost Converter into High Voltage Solar Charge Controller

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Hi friends!
This this video, we unlock the secrets of solar power with our groundbreaking tutorial! Discover how to transform a humble $25 constant current and constant voltage DC to DC boost converter into a powerful solar charge controller, capable of efficiently converting low voltages (starting as low as 10V) to high voltages (up to 120V) for your solar projects.
In this step-by-step video, we unveil an innovative method that requires no modifications to the converter itself, making it accessible to beginners and DIY enthusiasts alike. You'll learn how to harness the converter's existing capabilities to maximize efficiency and performance in solar energy applications.
From understanding the principles behind DC to DC conversion to practical demonstrations of setup and operation, this tutorial is your gateway to affordable renewable energy solutions. Whether you're looking to power small-scale solar setups or experiment with higher voltage applications, our guide provides all the essential information you need.
Join the DIY solar revolution and watch as we demystify complex electronics with straightforward instructions and real-world examples. Don't miss out on this opportunity to revolutionize your approach to solar energy.
Don't forget to subscribe and empower yourself with knowledge that can shape a sustainable future!
Welcome to The Innovati0n Lab!
Solar Booster Project:
BILL OF MATERIALS: Major components only
DC to DC Boost Converter DC 8-60V to 10-120V 15A 900W: amzn.to/3W3K9Uv
DC to DC Boost Converter DC 8-60V to 10-120V 15A 900W:
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DROK DC Boost Converter, CNC 10V-65V to 12V-120V DC to DC 12V 24V 36V 48V 12A 800W:
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EPEVER MPPT Charge Controller 20A: amzn.to/3zklMZH
EPEVER MPPT Charge Controller 40A: amzn.to/3zySGFS
EPEVER MPPT Charge Controller 80A: amzn.to/3VJ78CW
1500W DC to DC Boost Converter: amzn.to/4a0GASD
Powerful 300W Weller D650 Soldering Iron: https: amzn.to/3Rvzor4
Digital Soldering Microscope: amzn.to/3UmD0ML
Fluke Digital Multi-meter: amzn.to/3xu0hoB
Fuse Kit - Multiple values: amzn.to/3RuqxWP
Linear Voltage Regulator Assorted Kit: amzn.to/4c47smA
470uF, 63V Input Filter Capacitors: amzn.to/3KJZva5
470uF, 250V Output Filter Capacitors: amzn.to/3KKyTG1
SMD Resistor Kit - 2010 Package Size: amzn.to/45uRn78
SMD Electrolytic Capacitor Kit: amzn.to/3RpGFcb
SMD Ceramic Capacitor Kit: amzn.to/3XoJtKc
Power Inductor: amzn.to/44rjPpC
22 Gauge Copper Inductor Wire: amzn.to/3UIrwVx
12V 750W Server Power Supplies: amzn.to/3Wn5KaO
Kaiweets Smart Digital Clamp Meter: amzn.to/3UF4gro
0 to 300V, 0 to 100A, DC Digital Power Monitor: amzn.to/4djjZnd
Soldering Gun: amzn.to/4bldBKs
48V 1000W Water Heater-Test Load: amzn.to/3UKHBtS
Rotating Display: amzn.to/3UGcC1I
6 Gauge High Current Silicone Wires: amzn.to/3UGoRLJ
Big Aluminum Heat Sink: amzn.to/44mTl8K
100A Circuit Breaker: amzn.to/3y95xxS
60A Circuit Breaker: amzn.to/4doyBS6
VIDEO CHAPTERS:
Timecodes
00:40 - Introduction
O1:40 - The control Test
03:45 - The Solar Boost Concept
05:10 - Energy Transfer Model
13:15 - The Test: Low to High Voltage Solar Battery Charging
#dctodc
#solarenergy
#solarcharger
#charge controller
#dcpower
#DIYHack
#ElectronicsRevolution
#PowerUpgrade

Опубликовано:

1 окт 2024

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Комментарии : 50

@СергейПелих-ф1з 7 дней назад

А такой вариант : солнечная панель 30 volt- dc- dc повышающий 60 volt- контролер заряда mppt : Аккумулятор 12 volt.

@SomethingZen0 3 месяца назад

In your previous test with the boost comverter, the issue is not that the solar panel is not outputting enough power, it's that the boost converter is asking for too much power. Try to test it again but limit the output current to a low current at first and start ramping it up. At some point the solar panel will not be able to provide enough power and the voltage at the output collapes. If the battery wants 50A, and then the boost converter will try to provide that current at the set voltage, however, if the panels cannot keep up with the power demand, the panel voltage will drop, and the output voltage of the boost converter collapses. Another thing is that the previous boost converter has a low voltage disconnect, try to set that at the Vmp of the solar panel so when the panel voltage drops below it, it will oscillate the boost converter at that voltage and keep the output steady at whatever power the panel can provide. ❤

@theinnovati0nlab782 3 месяца назад

Wonderful feedback. 👍👍 However, what you are describing has been the premise of all the video tutorials showing how to use the constant current DC-DC converters as diy battery chargers. To be clear, my point is that this is the same gospel I have been preaching for many years now.☺️ 💥💥💥 My 6-Step Battery Charing process.👇👇👇 1. Determine your battery charging voltage and current - from manufacturer specs. 2. Set the converter output voltage to the recommended charing voltage for your battery. 3. Set the output current limit to a near zero value. 4. Connect battery 5. Slowly increase charging current 6. Observe and take measurements. I have made a few videos on this. Please see the video below as I covered the 6-step process in great detail around minute 2 of the video.👇👇 ru-vid.com/video/%D0%B2%D0%B8%D0%B4%D0%B5%D0%BE-WDWJ77WWkXc.htmlsi=IStKu2X45jwmBVVa The video above uses regular power supplies, but the concept still applies. The Innovati0n Lab 💥 www.theinnovati0nlab.com

@SomethingZen0 3 месяца назад

@@theinnovati0nlab782 Yes, thank you for all the hard work you have done in researching and making videos on DC to DC converters for battery charging, your videos are very informative, and helps out people who are just starting out in this field. May I suggest making a video testing out the previous Boost Converter you reviewed using the low voltage disconnect function as a pseudo MPPT for charging batteries, the board itself is impressive in being able to output a lot of power quite efficiently and is rather inexpensive. It could be a good starting point for people wanting to charge their batteries efficiently from their solar panels, but don't have the budget for an MPPT solar charge controller. This series of yours helps people charge their batteries more efficiently rather than using a PWM solar charge controller. Thanks for the feedback and I await your next videos. ❤️

@theinnovati0nlab782 3 месяца назад

@SomethingZen0 Another wonderful feedback👍👍👍 I have actually been thinking about retesting the 1500W boost converter as a solar charge controller. However, I have already tested that concept you proposed - as an idea that someone else recommended along time ago (great idea!), but it led to nothing but some really bad oscillations (motor-boating).☺️ But you have now inspired me to do something I have been thinking about.....I may not be able to explain it really well in here, but it mostly has to do with tuning the input dynamic impedance of the converter to better match that of the solar panel......if I am successful, I will make a video about it. Stay tuned, my friend! ❤️ The Innovati0n Lab 💥 www.theinnovati0nlab.com

@VictorC173 3 месяца назад

@@theinnovati0nlab782 I have kinda successfully implemented mppt (constant input voltage) using a mosfet in linear mode. When closed (input voltage > set voltage), the mosfet would not let current pass to feedback, thus, max current at the converter output; when open (input voltage < set voltage), current would pass, through a diode, to the feedback pin, reducing the output current until the input voltage reach equilibrium.

@VictorC173 3 месяца назад

But using op amps I never managed to reach stability, always there was some screeching oscillations....

@Jarda_B 3 месяца назад

It was good video ,but GUYS PLEASE DONT DO LOW VOLTAGE HIGH CURENT SETUP ON YOUR SOLAR ARRAY, it is not beneficial in any means, avoid it if you can, you will need to spend much more on thicker wires, really only solar with that low of a voltage that I have see was 70W pannel in that case if you have 2 70W pannels you will probably not spend that much on hogh voltage battery and you can even use PWM controler becuase it would be prety efficient with around 15V from pannels to 12V battery

@theinnovati0nlab782 3 месяца назад

Thanks for the thoughtful feedback. This video is basically for those with a couple of lower voltage panels as I showed in the video. Ofcourse if you are building a high power solar array, no one would ever encourage a low voltage system as you will run the risk of high cable costs, horrible system efficiencies due to lots of copper losses and excessive heat dissipation. Your points are absolutely valid. However, the disconnect is that the target audience for this video is the small scale solar project - 200-300W diy solar project enthusiasts like myself...hahaha. In a past life, I had some professional experience with solar panel arrays designed for a 1500V DC power sub-station. Ultimately power transmission at high voltage/low current is always more feasible and the gold standard...but you have to be very knowledgeable to design such systems.

@emiliorp786 3 месяца назад

Una pregunta.¿Tengo un aerogenerador de 12v podría elevar el voltaje con este dispositivo para cargar batería de 24v?

@Jarda_B 3 месяца назад

@@emiliorp786 Yes that is actually a reasonable aplication of this, just make sure to set your voltage to max charge voltage, and dont overshoot it (for example if you use lead-acid its going to be 28V max bacuse full charg of one cell is 2v if you have different chemistry you calculate it same way take max charge for one cell and multiply it by number of cells)

@emiliorp786 3 месяца назад

@@Jarda_B gracias por la información

@hyconiek22 3 месяца назад

Interesting test! I'm just wondering if your panels can't deliver more than 8 amps and this converter doesn't have MPPT built in so if your budget allows I'd like to see your review of the WZ10020L converter

@theinnovati0nlab782 3 месяца назад

Thanks for the great feedback. But this was exactly the reason why I added a control test whenever I do this. Did you watch the control test? How many amps did you see coming in from the panels, and how many amps was being delivered to the battery system? I will search for the WZ10020L converter. I would love to review it in a future video. The Innovati0n Lab 💥 www.theinnovati0nlab.com

@hyconiek22 3 месяца назад

@@theinnovati0nlab782 yes, I saw your verification test but it did not show whether the panels can output more than 8 amperes, hence my consideration

@hyconiek22 2 месяца назад

One more thing interests me, a system of mosfets switching 115v from this converter to 230v alternating current.

@theinnovati0nlab782 2 месяца назад

Wonderful. 👍👍

@b.g.bvoice1142 3 месяца назад

I think if you modified it a little by upgrading the Wire Guage in the converter and with beefier masfets, I think that would work, oh, and decrease the current while the battery almost reached full point

@theinnovati0nlab782 3 месяца назад

Great idea!👍👍 I love the way you are thinking. That's the type of mindset we need in our community. Stay tuned! The Innovati0n Lab 💥 www.theinnovati0nlab.com

@richardbumanglag9610 3 месяца назад

This days there are already mppt step up available in the matket. I have one. Im using to charge my ebike battery 72v

@theinnovati0nlab782 3 месяца назад

Of course! That is amazing, though. Please share the specs if you don't mind.👍👍👍 The Innovati0n Lab💥 www.theinnovati0nlab.com

@maukaman Месяц назад

Yes I have one I bought from Ali a while back. It seems to work pretty well from the couple of tests I’ve done so far. It is limited to

@maukaman Месяц назад

@@theinnovati0nlab782I will check the specs on the one I have and share them later

@MrFiveStarzz Месяц назад

Good day Sr. Nice video do you know of any DC to DC boost converter that can boost 3V or 6V to 12V or higher at 15 to 20 amps?

@theinnovati0nlab782 Месяц назад

Thanks for the feedback. I don't know any that fits your specs. However, you should be able to find one, but operating down to 3V may be a challenge. The Innovati0n Lab 💥 www.theinnovati0nlab.com

@emmanuelokonko3155 2 месяца назад

Can a test be set up for Fuel- less Generator 7kW maximum power using 1.5kW dc or ac motor.

@theinnovati0nlab782 2 месяца назад

I am not sure what you have in mind. Could your please elaborate? Thanks. The Innovati0n Lab 💥 www.theinnovati0nlab.com

@madmangaming5621 2 месяца назад

We have made a better booster 12 v to 240v

@theinnovati0nlab782 2 месяца назад

Ok. Congratulations.

@anonhollmuller4032 2 месяца назад

who made?

@angusmcgil 3 месяца назад

ive done extensive testing to see if can boost 12 volt of 72 volt for charging ,but due to limitions iof the device it can only output less than an 1amp

@angusmcgil 3 месяца назад

12 volts unfortunatly is to low for best boost conditions ,a 24 volt to 36 volt input minimum is requiredf for any decent current output

@theinnovati0nlab782 3 месяца назад

Hmmmm, what converter are you using? Also, what is the power rating of your solar panel? The Innovati0n Lab 💥 www.theinnovati0nlab.com

@angusmcgil 3 месяца назад

@@theinnovati0nlab782 its the 600watt 15 amp model with the lcd screen i was running it off a 12 volt 19 amp power supply it over leaded with an output of 84 volts just on 2amp

@angusmcgil 3 месяца назад

im possitive that i should have got the 30 or 40 amp version and next time ill get higher voltage and higer current for the input to reduce the boost load,ideally id want an output of 84 volt at 10 amps

@SalmanKhan-wd4sp Месяц назад

Can you make 12vdc to 450vdc boost converter

@theinnovati0nlab782 Месяц назад

Yes. But it will require a power tranformer design and special high voltage components.

@joels7605 3 месяца назад

This channel is excellent. A solar boost converter is particularly useful right now with the price of copper being sky-high.

@theinnovati0nlab782 3 месяца назад

Thanks a lot for the wonderful feedback! ❤️❤️ We appreciate appreciate your inspiring comment. I fully agree with you regarding the need for solar boost converters. 👍👍👍 The Innovati0n Lab 💥 www.theinnovati0nlab.com

@HoneyBerighthere-Saysarath 3 месяца назад

Get a Preaditor 5000

@theinnovati0nlab782 3 месяца назад

Sounds great! I will look for it. 👍👍👍 The Innovati0n Lab 💥 www.theinnovati0nlab.com

@mask-u5v 3 месяца назад

Не вижу практического смысла в повышении напряжения до 120в, при таком преобразовании происходят потери и неизбежно снижается ток нагрузки. Если надо высокое напряжение для питания бытовой техники, для этого есть инвертор 12/24-220 с нормальным синусом. Мне кажется это баловство, но оно полезное в плане проектирования dc-dc преобразователей.

@theinnovati0nlab782 3 месяца назад

Thanks for sharing your opinion. The simple truth about opinions is that we all have one. The premise of this video is to show what is possible with this specific converter case - per its input and output voltage ranges/specs. My guess is that your comment came directly from taking a quick glance at the thumbnail without watching the actual video....yes? The name of my channel is 'The Innovati0n Lab'. Maybe you could read some meaning into that. My video projects are usually inspired by the Diy needs of my audience. This converter has an input voltage range of 10 to 60V and an output voltage 'RANGE' of 12 to 120V. Now, with that said, what you choose to do or not do with that information is totally up to you. Again, I tailor my videos to highlight the limits of possibilities and to inspire innovation... 'self-indulgence' or not, I will leave that for the viewer to decide. I encourage my audience to at least watch a video and then give us constructive feedback. Your feedback was composed with a hint of sarcasm and pessimism, but again, I will respect that as your opinion. Yes, most of us do DIY projects for fun and to boost our knowledge. It is very important to keep an open mind when you neither have an insight into what others are designing nor their needs for high voltage DC power. The assumption that one needs '120V'....then it must be to power a household appliance......then just use an inverter, is a very close minded way of perceiving the rapidly advancing world of power. EXAMPLES of HIGH VOLTAGE DC-DC Applications: 💥DIY EV projects 💥High voltage battery systems and chargers 💥DIY transformerless power inverters!!...etc,etc. Sorry for my tone, but these videos take lots of effort, time, and resources to make. I do not take kindly to someone glancing over a thumbnail and trivializing or disparaging my work. I hold this channel to high ethical and moral standards. Please keep your comments respectful and constructive in the future. I hope this helps. The Innovati0n Lab 💥 www.theinnovati0nlab.com

@LostSoulsMed. 3 месяца назад

Just wondering, how could MPPTs reach so much efficiency in conversion compared to typical boost and buck converters, where most of them adapt to a synchronous design to minimize loses, what makes an MPPT so special in converting energy?

@theinnovati0nlab782 3 месяца назад

Wonderful comment! 👍👍👍 It's essentially everything you just said, plus a layer of somewhat complex software control that implements maximum power point tracking using incremental conductance. Most dc to dc converters use PWM control, but there are lots of high-end expensive converters that can give you very good efficiencies - the question is affordability to most everyday diy hobbyists. The 20A MPPT solar charger shown in this video costs almost $100 with all the accessories. While most 20A off the shelf converters would cost you less than 20 bucks or less. I hope this helps. The Innovati0n Lab 💥 www.theinnovati0nlab.com

@b.g.bvoice1142 3 месяца назад

Mppt got to be changing every minute to find that sweet spot current and voltage, while buck and boost at a constant voltage ⚡️ in other works so if the v drop buck in stop while mppt follow the v drop for it to work same way

@LostSoulsMed. 3 месяца назад

@@b.g.bvoice1142 yes correct, I'm aware of it, I'm just fascinated by the efficiency of MPPTs in converting the IV from different levels, for example a maximum power point of 36v with 11 amps from the panel, that gives you approximate 400watts, How could this SCC convert that IV to the batteries charing voltage such as 14.4v , with minimal current losses in the conversion process, that even the Current efficiency of most buck or boost converters in the market has only a maximum convertion efficiency of around 90-95%. The kevel of efficiency of MPPTs that can reach 98.7% is just unbelievable.

@delicacydelight 3 месяца назад

Maybe make another; 230v?

@theinnovati0nlab782 3 месяца назад

It is possible, but not with these converters. Unless I decide to modify them, but honestly, it won't be whorth the effort. The Innovati0n Lab 💥 www.theinnovati0nlab.com

@delicacydelight 3 месяца назад

@@theinnovati0nlab782 yeah i meant 230VDC - probably someone done it already, cheers