Step 14: Update
I have completed the rebuild of the charge controller. It is now in a semi-weatherproof enclosure and I have also added a built in voltage meter. Both were bought cheap on Ebay. I have also added a few new features. The unit now has provisions for power inputs from multiple sources. It also has built-in fused 12V power distribution for three external loads.
The second photo shows the inside of the charge controller. I basically just transferred everything that I originally had bolted onto the plywood board in the prototype into this box. I added an automotive illuminated voltage gage and fuses for 3 external 12V loads. I used heavy gage wire to try to reduce losses due to wire resistance. Every watt counts when you are living off-grid.
The third image is the schematic for the new charge controller. It is pretty much the same as the old one above, except for the addition of the Volt meter and extra fuse blocks for the external loads. A larger, easier to read version of the schematic, and more information on the new charge controller can be found on my web site at http://www.mdpub.com/Wind_Turbine/
The fourth photo is a block diagram of the whole power system. Note that I only have one solar panel built right now. I just haven't had the time to complete the second one. Please visit my home-built solar panel page at http://www.mdpub.com/SolarPanel/ for more information on home-built solar panels.
The second photo shows the inside of the charge controller. I basically just transferred everything that I originally had bolted onto the plywood board in the prototype into this box. I added an automotive illuminated voltage gage and fuses for 3 external 12V loads. I used heavy gage wire to try to reduce losses due to wire resistance. Every watt counts when you are living off-grid.
The third image is the schematic for the new charge controller. It is pretty much the same as the old one above, except for the addition of the Volt meter and extra fuse blocks for the external loads. A larger, easier to read version of the schematic, and more information on the new charge controller can be found on my web site at http://www.mdpub.com/Wind_Turbine/
The fourth photo is a block diagram of the whole power system. Note that I only have one solar panel built right now. I just haven't had the time to complete the second one. Please visit my home-built solar panel page at http://www.mdpub.com/SolarPanel/ for more information on home-built solar panels.
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poppintool says:
Aug 10, 2009. 7:46 AMReply
I agree with cornchild! It's been impossible to find plans as thoughtfully and thoroughly laid out as these. Thanks for taking the time to share it with all of us!
cornchild says:
May 13, 2009. 3:06 PMReply
MY HAT OFF TO YOU. IN SEARCHING THE INTERNET FOR PLANS TO BUILD SUCH A DEVICE THERE ARE MANY SCAMS AND PEOPLE WHO WANT YOUR MONEY. I WISH MORE PEOPLE WOULD BE WILLING TO HELP OTHERS LIKE YOUR EXAMPLE. I HAVE FOUND THAT BATTERIES FROM ELECTRIC FORK LIFTS LAST FAR LONGER THAN NORMAL LEAD ACID AND SEALED LEAD ACID CAN BE FOUND THAT WILL LAST FOR MANY YEARS. I HAVE A 12 VOLT ONE AND IT HOLDS A CHARGE FOR 2 MONTHS OR MORE WITHOUT RECHARGING AND IT IS AT LEAST 10 YRS OLD
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