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All in One Portable Solar Power Unit: 220V + 12V + 5V + Automatic Battery
Charge! ;)
by serdaro on June 3, 2014

Table of Contents
All in One Portable Solar Power Unit: 220V + 12V + 5V + Automatic Battery Charge! ;) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intro: All in One Portable Solar Power Unit: 220V + 12V + 5V + Automatic Battery Charge! ;) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1: Main Parts Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 2: Preparing Parts 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 3: Preparing Parts 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 4: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 5: Finished! :) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Intro: All in One Portable Solar Power Unit: 220V + 12V + 5V + Automatic Battery Charge! ;)
My starting point was to see if we can make portable solar power unit:
lightweight
reliable
robust
different voltage outputs (including 220V AC)
capable of storing energy
capable to charge lead acid battery
Answer: Yes we can! ;)
If we well balance size and capacity of the unit, it will be much more useful.
When I search on web, found aluminum "suitcases" which can provide 220V AC output. They are usually very heavy due to lead acid batteries inside and not suitable to
carry easily.
Another option was foldable panels fitted to fabric bases. Some of them has voltage regulators for DC output but only 2-3 different DC voltage levels...

Step 1: Main Parts Required


When I found "Seifert Magnus Midi 63" toolcase in local Bauhaus, very delighted:) Eureka!
it was perfectly matching size and specifications in my mind... Made of uv stable polypropylene and black in color. Dimensions 40.0x30.0x6.5cm and around 670 grams.
Size well suited for two 10 Watts solar panels, has "ribs" on edges to protect switches and other equipments perfectly. Has handle and locks.
If I design a case for only this purpose, it would be very similar to this :)
Also we need 12V DC to 220V AC inverter. Found this 100 Watts unit on the web.
Sanyo 4S lithium ion batteries with over / under voltage protecting and over temperature protecting circuits.
Two 10W solar panels.
7A Lead acid battery charge controller
Digital voltmeter from Dealextreme
Aluminum composite panels to hold solar panels
Diodes to reduce li-ion battery voltage to start inverter (later you can disable them to save power)
Switches, power outlets, screws etc.

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Step 2: Preparing Parts 1


Started to remove aluminum frames around solar panels. You should be very careful to not to break tempered glass on it.
Also removed big connector terminals and make them smaller.
Then fix them to aluminum composite frames by Sika WT40 PU adhesive and test them how to fit inside of the box.
When closed, panels perfectly protected during transportation and storage...
Added two parallel set of three diodes (in series) to reduce top voltage of li-ion pack when required. As they gets hot, prepared cooling fins by aluminum "U" profile.
These parts located on left side of the box, well protected ;)
Also bend a small aluminum sheet to hold voltmeter.

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Step 3: Preparing Parts 2


Also prepared paper labels for more professional look ;).
I'm printing them to photo paper by laser printer, then cut to required size and use transparent tape for surface protecting.
Back side, using double sided tape and 0.4mm grey pet film for digital screen.
I opened battery pack temporarily to show battery protection circuit here.
Then removed all "outer shell" of inverter to make it smaller...

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Step 4: Installation
Here you can find schematics of solar power unit. It is Turkish, but added english explanations on it.
Edit:
Also added schematic as pfd download and gif format, in English :)
Detailed mounting photos with explanations added. Please note that space for additional batteries if required. Charging leads also stored here...
You can direct power to li-ion batteries or 12V external lead acid battery charging port.
Measure both batteries status whenever you want.
All connections completed based on this schematic and looks like spagetti :)
Actually you do need to open inside in normal operation, so it prepared as little bit tight. Also we have enough space for more li-ion battery packs (for more capacity) and
cables etc. inside...

Image Notes
1. 10 Watts solar panels
2. Li ion batteries with
protection circuits
3. Main toggle switch to
li-ion or lead acid
4. Voltmeter switches
5. Inverter
6. 12V outlet, also for 5V adapter
7. Diodes
8. 12V outlet or iverter toggle
9. Lead acid bttery output
10. Charge controller for lead acid

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Image Notes
1. Li-Ion battery pack
2. Lead acid battery charge controller
3. Lead acid battery fuse
4. Charge contoller leds moved here
5. Charge contoller leds moved here
6. Voltmeter and pushbuttons
7. 12V cigarette lighter outlet
8. Power directing toggle
9. Charge output for car battery

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

File Downloads

14-06-22-schematic.pdf (68 KB)


[NOTE: When saving, if you see .tmp as the file ext, rename it to '14-06-22-schematic.pdf']

Step 5: Finished! :)
Here you can see control panel of unit.
Also a photo of open position added...
Everything on same (protected) surface and easily accessible.
Working perfectly...
Here are main specifications:
Very compact and lightweight, 300x400x65mm outer dimensions, 3.74kg
Solar power, 20 Watts, max. charge power 1.1A
Internal Li-ion capacity 40Wh (Sanyo batteries, over voltage, power, charge, temperature and discharge protected)
Nominal charging time 3-4 hours
Outputs: 220V AC, 12.6V DC, 5V DC (by using mobile cigarette lighter adapter)
220V output power is 100 Watts
External fully automatic car battery charging port
All outputs also available by external car battery
All batteries are fused
Digital voltmeter and charge status table
All controls and outputs are on same side and protected...

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

I' m planning to add led surface lights on empty surface for an improvement.
Cost is around 220 USD (including some mistakes) but value of the success is priceless :))

Image Notes
1. Inverter power switch
2. 220V AC outlet
3. 12V DC outlet
4. Toggle for 12V output or
Li-Ion charge
5. Voltmeter for Li-Ion and Lead Acid Batteries
6. Main directing switch of
solar power
7. Lead acid battery charge output
8. Battery charge
indicator leds

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

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Comments
50 comments Add Comment

kota95 says:

view all 96 comments

Sep 29, 2014. 8:51 PM REPLY

question... could i run straight dc current from solar panel to battery and run from battery pack to converter and car outlet?

serdaro says:

Sep 30, 2014. 8:23 AM REPLY

I do not understand clearly what you mean, but I think my unit already works similar like that.
Power flows over diodes to battery pack.
Battery pack has over voltage and thermal protection to cut off excess power...
You may check schematic to understand it clearly.

michaelgc says:

Sep 17, 2014. 9:32 AM REPLY

Really great work, congrats on the win...

emilygraceking says:

Sep 9, 2014. 11:16 AM REPLY

Congratulations on your well-deserved "Great Outdoors" contest win!

serdaro says:

Sep 9, 2014. 12:08 PM REPLY

I'm feeling great! Thanks very much :)

TrollFaceTheMan says:
Nice Job :D

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Aug 30, 2014. 11:14 AM REPLY

serdaro says:

Aug 30, 2014. 1:13 PM REPLY

Thank you :)

WildOne1985 says:

Aug 3, 2014. 3:25 AM REPLY


Li-ion batteries will degrade faster if exposed to high temperatures. The box itself is of a dark colour and it will be placed in the sun (obviously). I would
recommend that you do a temperature check to see how got it gets inside the box during charging to prevent having to replace the batteries too soon.

serdaro says:

Aug 5, 2014. 3:47 PM REPLY

Thanks very much for information.


Yes, it gets warm under the sun. May be it is better to add a small fan inside of it powered by panels...

WildOne1985 says:

Aug 9, 2014. 3:13 AM REPLY

*hot
Solutions to the problem:
1) Brighter colour on the box.
2) Very small fan that vents hot air out of the box. A dust filter is needed of course.
Just having a fan blow air inside the box won't help much compared to actually removing it.

serdaro says:

Aug 9, 2014. 2:57 PM REPLY


As surface of solar panels also dark and we have to expose them to sun, I'm afraid that brighter color box can not help so much.
Small fan to upper side with dust cover will be added :)

tberry7348 says:

Jun 23, 2014. 3:11 PM REPLY


I love it looks awesome and professional i would like to see links on all the parts lists to pages giving full details of the parts used for example i googled
"Sanyo 4S lithium ion batteries with over / under voltage protecting and over temperature protecting circuits" and nothing useful came up so i went to the
sanyo website and it's pretty much useless. however the sanyo website does have some cool looking rack mountable batteries but no links as to where to
buy or pricing or exact stats.... I really love what ya came up with here i prefer a 120v, 12v, 5v(usb) output so i'd modify it a bit but that would be much easier
with links to the items used :P thanks for the awesome post

serdaro says:

Jun 23, 2014. 11:19 PM REPLY

Hi,
actually I did not buy all parts from internet, but for batteries you cand find here for example:
http://www.dx.com/p/genuine-sanyo-18650-2600mah-re...
My battery pack is not ready made, 4S means four battery connected serial and protection circuit added later on. Batteries glued to each other by
cyronacrylate type glue...
You can find battery pack inside photo in my instructables

terrefirmax2 says:

Aug 2, 2014. 9:22 AM REPLY


Hello- I admire and respect your work ethic and intelligence and am wondering where you went to school, and also whether your interest in
technology and alternative power was encouraged/nurtured by your parents, teachers, or anyone else. I'm trying to identify the missing part in our
U.S. educational system that is missing this crucial point. To support curiosity and thinking differently, to enable new ideas to come to light.
Instructibles is a good model of how a community can support and encourage while still critiqing in a helpful way.

serdaro says:

Aug 2, 2014. 1:09 PM REPLY

Hi,
thanks very much for your comments, I embarassed so much :)
Probably this is not related to education system but personality.
I'm a mechanical engineer worked as R&D manager formerly and like camping so much.
Yes, Instructables is best site I have ever seen to support thinking differently and distibute ideas all around the world.
I'm proud to be a part of it...

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

terrefirmax2 says:

Aug 2, 2014. 7:18 PM REPLY


Thank you for responding- you are probably somewhat correct. I suppose that anyone with a desire for tinkering will manage to find a
screwdriver and something to take apart. I just wish there was more DOING in school, to reach all types of learners. But keep up the good
work and passion!

tberry7348 says:

Jun 28, 2014. 6:13 PM REPLY


ty, for your quick responce! could i get the brand/part#'s/name of all the parts you used? may not be able to find all parts on the net but if i had more
info on the parts i could at least get an idea how much money it would take....

jamiep says:

Jul 21, 2014. 6:24 AM REPLY

Would love to see a couple of usb port chargers on this for phones and such.

serdaro says:

Jul 21, 2014. 7:13 AM REPLY

I'm using this type unit to charge my phone/tablet with this device. Just plug it in to 12V outlet :)
Aldo you can use your own wall charger...

wishn4fishn says:

Jul 18, 2014. 7:05 AM REPLY


This is awesome and perfect for camping. I cant seem to find a supplier in the US for that type of box, any idea if its sold in the US?

serdaro says:

Jul 18, 2014. 10:42 AM REPLY


I do not know in US market, but in Europe, Bauhaus stores (German originated) are selling it as a part of stackable box sets.
Here is the manufacturer:
www.seifertinn.com/
But anyhow, it is not necessary to have exactly same box, even you can built it by plywood ;)

tucker4instructables says:

Jul 15, 2014. 5:04 PM REPLY


Looking for a portable unit that will keep a portable dental unit with drills running all day and be charged for the next day. This is for in the Philippines in
remote areas. Can you unit do that? If not, is there a way to design one that would? Looking to make or buy one before January 2014. Would appreciate
your help.

serdaro says:

Jul 16, 2014. 1:31 PM REPLY

Hi,
it depends on the power consumption of dental unit. Do you know wattage of it?
My unit is around 40Wh in capacity and 100Watts of maximum power continiously.
Probably you need "mobile" power unit instead of "portable".
Anyway, if you can tell how many hours it should work and what is power consumption than I can try to help you to find solution...

omikeo says:
what can you power with it for how long ?

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Jul 1, 2014. 9:42 PM REPLY

serdaro says:

Jul 2, 2014. 1:28 AM REPLY

Its current capacity with four cells is around 40Wh.


For example I can use my soldering gun or my laptop or external harddisc
approx. 1 hour, my inkjet printer around 3 hours...
Of course you can add more batteries for more capacity; we have space in it ;)

omikeo says:

Jul 2, 2014. 8:22 PM REPLY

nice job well done, so it would be like a 40 watt bulb for an hour or a more efficient one for 4-6 hours
so from nuclear to light to electricity to chemical then back to electricity into either mechanical, light or heat, right ? do you know how efficient the
panels are ?
thanks, mike

serdaro says:

Jul 2, 2014. 10:59 PM REPLY

This kind polycyrstalline panel efficiency should be around 16%...


You may check here for more information:
http://en.wikipedia.org/wiki/Solar_cell

deadlistcach says:

Jul 2, 2014. 1:13 PM REPLY

Buralarda trk grmek ?a??rt?c?, devre ?emas? son anda dikkatimi ekti, tekbik ederim gzel al??ma olmu? :)

serdaro says:

Jul 2, 2014. 2:09 PM REPLY

Te?ekkrler :) ....

fhopkins1 says:

Jun 29, 2014. 10:56 PM REPLY


can you use some kind of wall charger? i cant really see it i mean i love the design of this and everything and i want to make one similar but with a few things
added
1. usb charging port
2.AC or usb in port (wall charging)
3.lights to show how much battery is left
also can you send the schematics for the whole thing?

serdaro says:

Jun 29, 2014. 11:51 PM REPLY

1. I'm already using usb charging port in 12V outlet; things to put inside cigarette lighter socket.
2. Of course you can add wall charger and/or car charger to unit. This is mentioned somewhere in instructable comments, please check.
3. It has digital (much more sensitive than leds) voltmeter on it to show battery charge level for both batteries on it.
You can find schematic at the bottom of Step 4 in pdf format...

fhopkins1 says:

Jun 30, 2014. 7:17 PM REPLY

i cant download it lol have to be a pro member get the pdf lol thats why i asked... sorry i should have been a bit more clear

serdaro says:

Jul 2, 2014. 1:34 AM REPLY

Hi,
I also added English schematic in gif format. Hope this helps...

fhopkins1 says:

Jul 2, 2014. 2:20 AM REPLY


i uh dont see it lol remember? Im not a pro member so i cant download the pdf like period and i see no changes to the page but if u can email it
to me thatd be nice :) hopkinsfj@gmail.com ive been looking to make one of these since everyone at my unit ran out of power out in the field and
on the range sitting there for the entire day waiting for people to get done shooting... Not fun

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Tyler_Luoma says:

Jul 2, 2014. 1:15 PM REPLY

just right click the file name of the pdf the click save link as, i am not a pro member but i can do it :p

fhopkins1 says:

Jul 2, 2014. 2:25 AM REPLY

lol never mind i found it i didnt have all the steps up i feel like an idiot

sal9000 says:

Jun 29, 2014. 2:58 PM REPLY


Serdaro, could you please add a 120V AC 60hz output outlet so your Portable Solar Power Unit can also be useful in countries where most appliances use
110/120V AC 60hz, and also add parts list with website and prices and find out if any stores where you bought parts can give a website where people can
order same part from? Please ask your closest sibling or best friends, etc. to help out with this task in some way. We all need at least one or two of the most
efficient type SolarandWind, andacouplesecretzeropointenergy Portable Power Units with outlets to handle most of the appliances we use, plus instructions
for a supper long extension cord from the part that needs to be outdoors to the converter with outlets. That way, even if camping outdoors in woods, the cord
could extend from the top of the canopy to your tent, outdoors above a cave type safety-from-storms place, or also reach the rooftop 5 floors above your 1st
floor apartment plus be move-able if someone messes with it in the initial location it is put! Thank you!

ppereira14 says:

Jun 27, 2014. 6:31 AM REPLY


I was looking for a higher capacity Solar System (400W or more). I found a really nice instructable. Heres a linkhttp://www.instructables.com/id/Apartment-SolarSystem/

serdaro says:

Jun 27, 2014. 7:15 AM REPLY

That seems like a good system; but concept and targets are completely different.
Instead of portability and versatility, it is a static system for apartments...

emerson.john says:

Jun 23, 2014. 3:09 PM REPLY


This is a fine piece of work. It is not just practical, but is engineered to be simple, robust, and compact. Impressive, and it gets my vote!

serdaro says:

Jun 23, 2014. 11:27 PM REPLY

My english is not enough to express how I feel...


Thank you very much! :))

tisaconundrum says:

Jun 25, 2014. 1:21 PM REPLY

You have my vote too. Very cool, thanks for the ible

serdaro says:

Jun 26, 2014. 1:35 AM REPLY

Thanks very much! :)

amekdala says:

Jun 22, 2014. 12:13 AM REPLY

ya i?te kamp karavan hayat?n? sevmek bunlar? yapt?rt?yor :)


sper kullan??l? gzkyor, bu sene sezonu amadan bunu yapmam laz?m :)

serdaro says:

Jun 25, 2014. 12:50 AM REPLY

?ema ok zor de?il, do?ru malzemeleri toparlarsan?z yapabilirsiniz....

msjordan says:

Jun 21, 2014. 6:31 PM REPLY

Very Nicely done and well thought out.


Maybe at some point you can expand this, with more mounting details.
Thank you for your work here

serdaro says:
Detailed mounting photos with explanations added ;)

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Jun 25, 2014. 12:48 AM REPLY

serdaro says:

Jun 22, 2014. 3:14 AM REPLY

Thanks very much msjordan.


Okay, I'm going to add more pictures about mounting ;)

Eric T says:

Jun 24, 2014. 6:25 PM REPLY

Can the batteries be charged by a vehicle when the sun does not shine?

serdaro says:
This unit is not designed for that purpose. But actually can be added easily.
There are field chargers for rc modelers, for example:
http://hobbyking.com/hobbyking/store/__33407__Hobb...
I used it succesfully for my another project here to charge same type batteries:
http://www.instructables.com/id/600300-lumen-li-io...
Also we can add a small adaptor to charge unit over wall outlet.
But Sun is the best choice of course ;) ...

view all 96 comments

http://www.instructables.com/id/All-in-One-Portable-Solar-Power-Unit-220V-12V-5V-A/

Jun 24, 2014. 10:37 PM REPLY