DESIGN AND CONSTRUCTION OF 1.

5KVA SOLAR

INVERTER

BY

DARAMOLA BOLUWATIFE ABIDEMI

FPI/SLT/22/087

SUBMITTED TO THE DEPARTMENT OF

SCIENCE LABORATORY TECHNOLOGY,

SCHOOL OF APPLIED SCIENCE,

FEDERAL POLYTECHNIC, ILE-OLUJI.

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 CHAPTER ONE

INTRODUCTION

1.1 BACKGROUND OF THE STUDY

In today's society, electricity has a significant influence on the majority of daily

activities, such as the use of energy in home and commercial operations. The British

used natural gas from coal to illuminate homes and streets around 1785 (Owen, 1996).

Electricity can be created from public supply to customers in a variety of ways,

including using energy to drive the turbine. Additionally, sources of electricity

include nuclear and solar energy.

Due to the reliance on and steady growth in the expense of fossil fuels, which have a

large detrimental impact on the environment, new energy sources have been proposed

and created in recent years. Renewable energy generation is expected to increase from

19% in 2010 to 32% in 2030, resulting in lower CO2 emissions. More than 1 billion

people lack access to basic energy services in rural areas, particularly in developing

countries, where up to 80% of the population lives (Suleiman, 2000).

In Nigeria, the power-supplying company's provision of electricity to users is

irregular, resulting in people purchasing generators for their everyday operations.

Nigeria's increasing energy demand compelled us to employ these renewable energy

resources. In recent years, efforts have intensified to promote the use of renewable

energy resources rather than polluting fossil fuels and other types. To use these

renewable energy resources, an inverter that transforms direct current (DC) power to

alternating current (AC) power is required, as the majority of renewable energy is

found in DC form (Suleiman, 2000).

These alternative and renewable energy sources could also be used as emergency

backup power. Backup power is becoming increasingly important due to today's

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reliance on electricity and the frequency of power outages. During power outages, an

emergency backup power system can give electricity to key loads or the entire house.

These systems may incorporate lighting and other devices to provide backup

resources in a crisis or when regular systems fail. They are used in several settings,

including residential dwellings, hospitals, research laboratories, and computing

systems. Generators or uninterruptible power sources can be used to power

emergency power systems. For their functions, all sorts of electronic equipment

require an electric power supply. This source can be either a generator or a battery. In

our society today, the need for a steady power supply must be over-emphasized,

because the provision of goods and services could be completely cut off without

adequate power supply.

This project focuses more on DC-to-AC power inverters, which convert a DC power

supply into an AC output with a voltage that is significantly higher than the input.

When low-voltage DC sources like batteries, solar panels, or fuel cells need to be

converted into AC power so that devices can function, inverters are utilized in a

variety of scenarios. For household, commercial, and industrial applications, power

electronic solutions like inverters that convert the direct current (obtained from

renewable energy sources: solar and wind) to alternating current are gaining

popularity. (Akpan, 2012).

1.2 PROBLEM STATEMENT

The government is often unable, or unwilling, to direct its attention to the issue of

power supply because the country is not yet economically or technologically mature

enough to support a quality power system. Additionally, due to the Power Holding

Company of Nigeria's (PHCN) ongoing power outages and fluctuating power supply,

delicate appliances and systems in offices, homes, industries, etc. are affected by the

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interrupted power supply and this experience resulted in the introduction of a backup

system such as an inverter.

There are many choices in the application of inverters in the market today. From the

most expensive to the least expensive, these come in a spectrum of quality, efficiency,

and power output levels. There are high-quality products with high efficiency, but

they are typically more expensive financially. The goal of this project is to offer a

dependable 1.5kVA power source that may be used as a backup to power household

appliances in the event of a power outage or energy crisis.

1.3 AIM AND OBJECTIVES OF THE STUDY

This project aims to design and construct a 1.5kVA solar inverter with a frequency of

50Hz that can take a 12V battery's input DC voltage and convert it to a 220V output.

While the specific objectives are:

1. To design a 1.5kVA solar inverter that efficiently converts DC power to AC

power.

2. To integrate a battery management system (BMS) for monitoring and protecting

battery health.

3. To select and optimize batteries with high energy density and long cycle life.

4. To conduct efficiency and performance tests under various conditions.

5. To assess and minimize the environmental impact of the solar inverter system.

6. To ensure the solar inverter system is user-friendly and easy to install and

maintain.

1.4 JUSTIFICATION OF THE STUDY

The design and construction of a 1.5kVA solar inverter will be beneficial in the

following ways:

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1. Efficient Energy Conversion Using Low Power Switching Devices: The primary

goal of this research is to harness a low DC source and efficiently convert it to high

output AC power using low power switching devices. This approach not only

enhances energy conversion efficiency but also reduces the overall cost and

complexity of the system.

2. Alternative and Efficient Mobile Power Source: The DC/AC inverter is

recognized as one of the most efficient mobile power sources available. In

environments such as science laboratories, the inverter serves as a crucial component

of the power supply system, often referred to as the "heart" of the power supply. This

is because it provides a reliable and alternative source of electricity, supplementing

the grid and reducing reliance on traditional generators. The inverter's ability to

provide consistent and clean power makes it an invaluable asset in scenarios where

stable electricity is critical.

3. Promoting Renewable Energy Adoption: By developing a 1.5kVA solar inverter,

the study supports the broader adoption of renewable energy sources. Solar power is a

sustainable and environmentally friendly alternative to fossil fuels, and efficient

inverters are key to maximizing the benefits of solar energy. This project will

contribute to reducing greenhouse gas emissions and dependence on non-renewable

energy sources, aligning with global efforts to combat climate change.

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 CHAPTER TWO

LITERATURE REVIEW

2.1 CONCEPTUAL REVIEW

2.1.1 RENEWABLE ENERGY

Renewable energy refers to energy derived from natural resources that are replenished

continuously, such as sunlight, wind, and water. These resources are abundant and

sustainable, providing a clean alternative to fossil fuels, which are finite and

environmentally harmful (Oseni, 2012). The rising interest in renewable energy

research is driven by the depletion of fossil fuels and the urgent need to mitigate their

negative impacts on the environment (Abu-Rub, 2010).

In modern society, electricity is crucial for domestic consumption, industrial

development, educational institutions, and medical centers. Ensuring a stable power

supply is vital for enhancing productivity and maintaining essential services (Nwofe,

2014). In Nigeria, power supply from generating stations is often inadequate due to

equipment failures, human errors, and issues in transmission and distribution. These

problems lead to frequent power interruptions, causing data loss, inefficiencies in

hospital equipment, and high costs in restarting industrial processes.

To address these issues, alternative energy sources such as fuel generators have been

used. However, fuel generators have significant drawbacks, including the emission of

harmful gases, high maintenance and fuel costs, noise pollution, and bulkiness. Power

inverters offer a better solution by being quieter, cost-effective, non-polluting, and

more efficient, with low or no maintenance costs.

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 Figure 2.1: Renewable energy source

2.1.2 SOLAR INVERTERS

Solar inverters are a crucial component of photovoltaic (PV) systems, converting the

direct current (DC) generated by solar panels into alternating current (AC) used by

household appliances or fed into the electrical grid. There are several types of solar

inverters, each suited to different applications:

String Inverters: Commonly used in residential and commercial installations for

their cost-effectiveness and efficiency. They connect multiple solar panels in series (a

string) and convert the combined DC output to AC power.

Microinverters: Installed on each solar panel, offering better performance in shaded

conditions. Although more expensive than string inverters, they provide higher

efficiency and flexibility by optimizing the output of individual panels.

Power Optimizers: Combine the features of string inverters and microinverters,

providing high efficiency and flexibility. Power optimizers are installed on each panel

and work with a central inverter to maximize energy production.

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 Figure 2.1: Difference between String and Micro Inverter

Recent advancements in solar inverter technology focus on improving efficiency,

reliability, and integration with battery storage systems. Modern inverters often

include maximum power point tracking (MPPT) technology, which optimizes power

output from solar panels, and grid-tied capabilities that allow excess energy to be fed

back into the grid.

2.1.3 BATTERY MANAGEMENT SYSTEMS (BMS)

Battery management systems are essential for maintaining the health and performance

of batteries in energy storage systems. A BMS monitors parameters such as voltage,

current, temperature, and state of charge (SOC) to ensure safe and efficient operation.

It also provides protection against overcharging, deep discharging, and thermal

runaway, which can damage the battery and pose safety risks.

Advanced BMS technologies incorporate features such as cell balancing, which

equalizes the charge across individual cells to extend battery life, and communication

interfaces for integration with other system components. The development of

intelligent BMS with predictive maintenance capabilities and real-time monitoring is

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a key area of research, aimed at enhancing the reliability and longevity of battery

storage systems.

Figure 2.3: Battery Management System Block Diagram

2.1.4 BATTERIES

Batteries are a critical component of solar energy systems, storing excess energy

generated during the day for use at night or during periods of low sunlight. The most

common types of batteries used in solar applications are lead-acid and lithium-ion

batteries.

Lead-Acid Batteries: Cost-effective with a long history of use, but they have shorter

lifespans and lower energy densities compared to lithium-ion batteries.

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 Figure 2.4: Lead Acid Battery

Lithium-Ion Batteries: Gaining popularity due to their higher energy density, longer

cycle life, and decreasing costs. They offer better efficiency and faster charging times.

Research in battery technology focuses on improving energy density, reducing costs,

and enhancing safety. Emerging technologies such as solid-state batteries and flow

batteries hold promise for future advancements in energy storage.

Figure 2.5: Lithium-ion Battery

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2.1.5 SOLAR PANELS

Solar panels, or photovoltaic (PV) modules, convert sunlight into electricity. The

efficiency of solar panels is determined by the type of photovoltaic material used:

Monocrystalline Solar Panels: Monocrystalline solar panels are made from a single

continuous crystal structure. They are known for their high efficiency and longevity,

typically having the highest efficiency rates among the three types of panels due to the

high purity of the silicon used. Monocrystalline panels are recognizable by their

uniform dark appearance and rounded edges. They are more space-efficient and

durable, making them ideal for residential and commercial installations where space is

limited. However, they are also the most expensive type of solar panel.

Polycrystalline Solar Panels: Polycrystalline solar panels, also known as

multicrystalline panels, are made from silicon crystals that are melted together. They

are generally less efficient than monocrystalline panels but come at a lower cost.

These panels have a bluish hue and a speckled appearance due to the many silicon

crystals in each cell. While slightly less efficient, polycrystalline panels are still a

popular choice for residential and commercial installations, particularly where budget

constraints are a factor.

Thin-Film Solar Panels: Thin-film solar panels are made by depositing one or more

layers of photovoltaic material onto a substrate. They are the least efficient of the

three types but have unique advantages, such as flexibility and lightweight properties.

Thin-film panels can be made from various materials, including cadmium telluride

(CdTe), amorphous silicon (a-Si), and copper indium gallium selenide (CIGS). These

panels are ideal for applications where weight and flexibility are crucial, such as on

roofs that cannot support heavy loads or on portable devices. Additionally, they tend

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to perform better in high-temperature conditions and partial shading compared to

crystalline-based panels.

Figure 2.6: The three type of Solar Panel

2.2 EMPIRICAL REVIEW

2.2.1 HISTORICAL DEVELOPMENT OF INVERTERS

The earliest back-up power systems, known as motor-generators, were developed

during World War II to provide reliable power (Cherp, 2013). These systems were

effective but inefficient. In the early 1960s, solid-state transistors replaced mechanical

vibrators, leading to the development of solid-state inverters. These inverters were not

motor-generators and offered a new level of efficiency. However, their unregulated

square wave design limited their use to resistive loads, and they could not handle

reactive loads such as fans or microwave ovens (Marquardt et al., 2010).

In the 1980s, companies like Heart Interface and GTO Electronics began

manufacturing backup power supplies using Field Effect Transistors (FETs) (Zhang et

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al., 2008). These advancements marked significant improvements in inverter

technology, leading to the development of more efficient and reliable systems.

2.2.2 RELATED STUDIES ON SOLAR INVERTER SYSTEMS

Al-Salaymeh et al. (2010) conducted a study on the feasibility of utilizing PV systems

in residential apartments in Amman, Jordan. The study found that standalone PV

systems had a longer payback period compared to grid electricity. To mitigate this, a

grid-connected PV system was suggested. The study concluded that installing a PV

system in residential flats in Jordan may not be economically viable due to the high

cost of PV systems relative to grid electricity.

Nur et al. (2016) focused on designing and implementing a push-pull inverter for a

photovoltaic portable lamp. The project aimed to power a 3W LED lamp using a 12V

battery, supported by a 10W solar panel. Although the design was innovative, the

study did not determine a power rating for the inverter, highlighting a gap in the

research.

Li et al. (2012) examined a grid-connected PV system installed in an institutional

building in Hong Kong. Their analysis, based on two years of measured data,

systematically recorded and analyzed the output energy generated. The study found

that feed-in-tariff schemes and high electricity selling prices could significantly

shorten the payback period for grid-connected PV systems to a reasonable timeframe,

much shorter than the system's lifespan. The PV system was designed primarily as a

backup to the national grid supply, ensuring a constant supply of electricity.

This review of related works highlights the evolution and technological advancements

in inverter design and PV systems, addressing the need for efficient, reliable, and

economically viable power solutions. The gaps identified in these studies provide a

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foundation for designing more reliable and stable solar inverter systems, ensuring

consistent and sustainable energy supply.

2.3 REQUIRED COMPONENTS

The major components for the design and construction of a 1.5kVA power inverter

are as follows:

Batteries: The 12V 65Ah lead-acid battery serves as the energy storage, supplying

DC power to the inverter during AC mains unavailability. It ensures a reliable power

source, commonly found in automobiles for its robustness and rechargeability.

Figure 2.7: Tubular Inverter Battery 12V/220AH

Charge Controller: This component regulates voltage from the AC mains to prevent

battery overcharging. It ensures the battery receives around 13 to 13.5 volts for

optimal charging, safeguarding against potential battery damage.

Figure 2.8: 60A 12V/24V Dual USB Solar Panel Controller Charge Regulator

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AC Mains Supply: The public 220V AC, 50Hz supply is utilized when available. It

undergoes step-down, rectification, and relay switching to charge the battery or

directly supply power to the inverter.

AC Mains Sensor: Utilizing a regulator and transformer, this sensor detects AC

mains availability, providing a stable 12V DC supply to the inverter. It ensures

constant operation even during fluctuations in the AC mains.

Figure 2.9: 230v/110v AC Mains Detection Module

Oscillator: The SG3524 PWM IC generates a 50Hz frequency essential for AC

supply. It controls MOSFET gate switching, enabling DC-to-AC conversion,

facilitating various domestic appliances' usage.

Figure 2.10: SG3525 PWM Controller Module

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Driver and Output Amplifier: MOS driver transistors amplify the 50Hz MOS drive

signals, ensuring efficient switching of MOSFETs. This amplification process

guarantees effective gate control, enabling smooth AC output.

Inverter Transformer: This transformer converts 12V DC to 220V AC through

electromagnetic induction. Its center-tapped design divides primary voltage,

facilitating push-pull-mode conversion for efficient power delivery.

Figure 2.11: 12V - 220V Boost Module Step Up Transformer

Changeover: A double-pole 12V relay manages inverter operation based on AC

mains availability. It seamlessly switches power sources between AC mains and

battery supply, ensuring continuous operation.

Inverter AC Output: The inverter directly sources 220V AC, 50Hz power from the

mains when available, or from the battery during mains unavailability, ensuring

consistent power delivery.

Protections: A 5A 250V fuse safeguards the transformer and rectifying circuit from

short-circuit currents, ensuring system integrity and safety.

Indicators: Four LED indicators provide visual feedback on the inverter's operational

status, including AC supply, battery usage, low battery, and battery connection issues,

enhancing user awareness.

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Switch: A 16/32A 250VAC switch regulates the inverter's AC power input and

output, allowing manual control over power flow and usage.

Additional Components: Some other additional compoenents required in the

construction are:

i. Metal Oxide Semiconductor Field Effect Transistor (MOSFET)

ii. Bipolar Transistor

iii. Relay Switch

iv. Rectifier

v. Capacitor

vi. Diode, Light-Emitting Diodes (LEDs), and Zener diode

vii. Resistors

Figure 2.12: Some other additional compoenents

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 CHAPTER THREE

MATERIALS AND METHODOLOGY

3.1 DESIGN ANALYSIS

This project block diagram explains the various basic unit/stages. The source voltage

is the 12v battery, which shall supply the biasing voltage for the electronic

components and also serving as the input voltage for the transformation component.

The first major stage is the frequency generation stage. This consist of a 555 timer

pulse width modulation arrangement with carefully selected RC arrangement to cater

for 50HZ voltage frequency required by appliances (using Nigeria Power Standard).

Here, pulse-wave signal are generated via the oscillator circuit.

Closely following frequency-generating stage is the duty cycle shaper stage where the

lower and upper threshold are maintained and corrected for the pulse-wave voltage.

Here the possible effect of chatter is been taking care of:

Figure 3.1: Block diagram of the Inverter system

The power driver stage involves the amplification of the current to achieve the goal of

higher power. This is achievable with the use of two stages MOSFET. Here the

advantage in field effect transistor (FET) most especially MOSFET shall be explored.

The final main stage is the power transformation stage, which mainly comprises of

step up transformer. The transformer should be carefully designed to accommodate

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the required power of 1.5KVA. Current and voltage transformation should be

carefully doctored during design of the transformer.

Also proper winding and the former compatibility are necessary to prevent

unnecessary noise from the circuit. The battery and the earthing technique in the unit

provide a feedback network for effective output control.

3.2 CIRCUIT DESIGN

The inverter follows the Circuit showing below. From the input voltage stage to the

controlling and Output.

Figure 3.2: Circuit Diagram of the Inverter system

The circuit of the inverter system is group into sections:

1. Changeover Section: This is a section that makes use of a relay to perform

switching from inverter mode to MAINS supply mode when there is availability

of mains and verse visa. The changeover relay has a COMMON pin, normally

open pin, and normally close pin. The common pin stands as AC output.

2. Charging Section: The circuitry here comprised of a voltage regulator of 7812,

555timer and LM358 OPAMPs, a signal diode of IN4148, 10k ohms resistor, 3

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 pieces of 1k resistors, 10k variable resistor preset, 47uf electrolytic capacitor and

single NPN transistor driver. The battery output is 14.7 V maximum (threshold).

3. Low Battery Section: The components here consists of a 1000uf by 35 V and

100uf by 50 V capacitor, 2.2K resistor of 3 pieces, 1k resistor of 1 piece,

1N4007,1 piece of 9V zener diode, 1piece and BC337 of 3 pieces of NPN

transistors, with 1 small 12V/10A relay. The zener diode activates the saturation

point for the NPN (BC337) transistor which Bias the 1N4007 diode that enable

the 100 uf/ 50V capacitor to charge up which determine the low battery shunt

down.

4. Modified Sine Wave Oscillation Section: The component here comprises of the

SG3524 component which is the principal component, with a 104pico-farad

mylar capacitor, 2.2uf electrolytic capacitor of 2pieces, 4.7uf all rated 50v of 2

pieces which is used for band gap timing (PWM). Variable resistor of 5K and

20kpreset. And then 4.7K resistor of 4 pieces, C945 NPN transistor with 47k

ohms fixed resistor and single IN4007 diode. The oscillator stage is where the

frequency is been generated. The oscillator frequency is 50HZ.

5. Driver Stage Design/MOSFET Calculation: This comprises of 10k and 47 Ω

resistor of 6 piece, MOSFET transistors of N-type (IRFP260N), heat zinc, and a

mica paper being used as an insulating paper. The MOSFET used is the IRF 260

in the power switching circuit due to high switching speed. The number of

MOSFETs appropriate for 1500VA is calculated using equation 7 to 9. The

MOSFETs is arranged in two channels which at each channels comprises of 3

MOSFET in total with a 10k resistor is been twined between the gate and source

of the each MOSFET while one channels will handle 750 watts.

MOSFET design parameters are:

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Input voltage = 12V,

output power = 1500W,

MOSFET maximum current = 46A

The continuous drain current of the popular MOSFET IRF 260 N is 46 A at 25°C

6. Feedback Section: It comprises of a 4 unit or pieces of 1N4007 diode, 200k

ohms resistor by 2watts (power rating of the resistor) with an optical isolator

4N35. The bridge rectification is archived by the helps of the diode. The feedback

is to control the PWM (4N35).

7. Inverter Cooling System: This is achieved using a12VDC fan. The positive

terminal of this fan is connected to pin 1 of the Anly timer relay via a 22Ω

resistor. The negative terminal is connected to general ground. Immediately the

inverter comes on, the fan starts blowing. This is possible via the Anly timing

relay (the relay takes care of timing and normal switching operations). In order

not to run the MOSFETS above 25°C, a large heat since is also incorporated into

the design to prevent the MOSFETs from burning out as a result of excessive

heat.

3.3 DESIGN PROCEDURE

3.3.1 Battery and Inverter

A 100AH/12V battery serves as the energy reservoir, providing a current output of

100A per hour. The inverter, rated at 1.5KVA, converts the DC output from the

battery into essential AC power. Calculating the energy capacity of the battery:

Energy Capacity = Current × Voltage × Time

=100A×12V×1hour

= 1200Wh

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3.3.2 Oscillator Stage:

The oscillator stage, powered by the 12V battery, employs an SG3524 integrated

circuit and NPN transistor drivers. Calculating the frequency of oscillation:

3.3.3 Switching Stage

Metal oxide semiconductor transistors (MOSFETs) in the switching stage facilitate

the conversion of DC to AC power. Calculating the number of MOSFETs required:

3.3.3 Relay Switch

A relay switch facilitates seamless transitions between mains and battery power

sources. Calculating the power rating of the relay switch:

Power Rating=Voltage×Current

= 240V × 20A

=4800VA

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