Re: AC to DC 65+ volts 60 amp Power Supply Plans?

On Sep 26, 1:00 pm, "Ulysses" <eatmys...@xxxxxxxxxxx/> wrote:
Greetings. I hope I'm in the right place.

I want to build or buy a power supply which will in effect mimic the output
of solarvoltaic panels. I want to feed the output into an OutBack MX60
charge controller. The maximum input is 141 VDC and 60 amps. I can use
any voltage above about 63 VDC (up to 141) to charge my 48 volt battery bank
by programming the MX60. This charge controller will automatically adjust
the absorb, float, and equalize charge rate voltages and times. I plan to
power it with a 120 VAC 60 Hz generator.

What I had in mind is a step-down transformer, a couple of rectifying
diodes, and a smoothing capacitor. The problem that I expect to encounter
is ripple. The MX60 is only designed for solar panels so it may behave
incorrectly (or worse) if there is any ripple or pulsing present. Any
suggestions? I don't want to do anything that might damage my rather
expensive charge controller. I'd be happy to buy a power supply if it's not
too expensive but so far all of my searches have not turned up anything.
Are there any web sites that have high current power supply plans? I
couldn't find any.

Thanks.

That's a lot of solar panels you're wanting to mimic. At 10%
efficiency, I suppose it's about 25 to 30 square meters of surface.
Do you really need that much current? If you really want your source
to look like solar panels, you should have it look like a moderately
high impedance. Into a short circuit, solar panels look about like
constant current sources. Also, if a shadow passes over the panels
(even the right small portion of them) the output drops drastically.
Controllers have to be able to handle that sort of thing.

A mains-frequency transformer that size won't be a small piece of iron
either. You'd probably be a lot better off with switching supplies,
and you can filter the output to get the ripple to a low value with a
lot smaller components than it will take to do it with a mains-
frequency supply. Now if you have three phase mains available, the
ripple can be much more tolerable, but it's still a lot of capacitance
(or a little less capacitance and some inductance; a little inductance
goes a long ways in reducing ripple especially if you want to get to a
very low ripple percentage.

There are surplus houses that deal in power supplies...though 4kW
supplies aren't all that common anyway. Also, I'm not too surprised
you're not finding plans for them (switching type, at least) on the
web. That's a lot of power, potentially kinda dangerous to be playing
with, and because of the currents involved, the physical construction
details and proper selection of components is critical.

Cheers,
Tom

.

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