Dump load / LVD circuit

Wiring, circuits, batteries etc.

Dump load / LVD circuit

Postby windgat on Wed Dec 02, 2009 2:45 pm

For those building the circuit from my PCB, here is some assistance.

The circuit layout below should help you to place the components correctly. Its set up to view on the screen, so set up your soldering iron in front of the computer and save ink and trees!
lvd10b.png
Dump load / LVD circuit layout

The light blue components are optional, and the red lines are wire jumpers.
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Re: Dump load / LVD circuit

Postby windgat on Wed Dec 02, 2009 4:49 pm

And here is a photo of a built board, without the optional components
lvd10built.jpg
Photo of built circuit board
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Callibration and test procedure

Postby windgat on Wed Dec 02, 2009 11:03 pm

Once the circuit is assembled, follow these steps to set it up
1. Measure these two voltages:
- Battery input (pin 1 of incoming wire connector), e.g. 25V
- Between R1 and R2, e.g. 2.47V
Now divide the first by the second e.g. 25/2.47 = 10.121

2. Choose the voltage at which you want to start dumping, say 28.5V
Divide by the above factor, e.g. 28.5/10.121 = 2.82V
Turn the pot P4 until the voltage at the test point next to it reads this voltage

3. Now choose the voltage at which you want to stop dumping, say 27.9V
Divide by the above factor, e.g. 27.9/10.121 = 2.76V
Turn the pot P3 until the voltage at the test point next to it reads this voltage

4. Now choose the voltage at which you want to turn off the load, say 23.5V
Divide by the above factor, e.g. 23.5/10.121 = 2.32V
Turn the pot P1 until the voltage at the test point next to it reads this voltage

5. Now choose the voltage at which you want to turn the loads back on, say 25V
Divide by the above factor, e.g. 25/10.121 = 2.47V
Turn the pot P2 until the voltage at the test point next to it reads this voltage

Then it should be ready to go!

If you have access to a variable voltage power supply, you can verify the circuit is working as follows:

1. Connect the voltage supply, and dial up the voltage to 29V.
2. Measure output A - it should be high (6V).
3. Now slowly turn down the voltage, and as it passes 27.9V output A should go low (0V).
4. Check output B - it should be high.
5. Turn down the voltage slowly to 23.5V, and as it passes 23.5V, output B should go low.
6. Turn the voltage up again slowly, and as it passes 25V output B should go high again.
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Re: Dump load / LVD circuit

Postby ramos on Sat Mar 27, 2010 9:45 pm

WINDGATE good afternoon, I am Spanish and translates this conversation google, so sorry.
Have long sought a way to make a charge controller for my self-constructed wind turbine, and I 12VDC batteries charged, but the problem I have is I do not know the full electronica, but I dare to make the circuit, just ask for help understand.
Please could put the picture of the connections of the plate.
Thank you in advance, I really liked this forum and try to follow everything I can.
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Re: Dump load / LVD circuit

Postby windgat on Mon Mar 29, 2010 1:23 am

Hola Ramos!

Unfortunately I don't understand "the connections of the plate". What does this mean?
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Re: Dump load / LVD circuit

Postby ramos on Mon Mar 29, 2010 3:13 pm

Google tries, but can not ....
I mean the back of the pcb, where connections components.
Indeed, this circuit disconnects the battery of the wind turbine? , but does so without the risk of accelerating the wind turbine?
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Re: Dump load / LVD circuit

Postby windgat on Mon Mar 29, 2010 4:05 pm

Have you looked at http://windpower.org.za/loadcontrol/loadcontrol.html ?

The battery power comes in at the top left. (Positive above negative).

The right hand side is the connection block for the two outputs. This is a 'two in one' circuit, so you can use either, or both of the outputs.

The top two potentiometers adjust the top output, and the lower two the lower output.

Hope that helps!
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Re: Dump load / LVD circuit

Postby ramos on Mon Mar 29, 2010 4:57 pm

I did not know he had much information and so exquisite. But for a novice in electronics like me, this turns uphill, if not like drawing the circuit.
Gracias por tu ayuda WinGate, sigo intentando do and recommends esta pagina many people. :wink:
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Re: Dump load / LVD circuit

Postby windgat on Mon Mar 29, 2010 10:44 pm

For a novice that is not easy! I could post you a circuit board if that would help you. Then you would need to buy all the components and solder them on.
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Re: Dump load / LVD circuit

Postby ramos on Tue Mar 30, 2010 8:22 am

It's what I need. Given that my system is 12v, and I do not know if the circuit would serve me. Could not you put the drawing back of the PCB?

Please forgive the translation, thanks.
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Re: Dump load / LVD circuit

Postby windgat on Tue Mar 30, 2010 9:09 am

It will work for 12V. All the drawings are on the web page I mentioned, are they not?
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Re: Dump load / LVD circuit

Postby ramos on Tue Mar 30, 2010 10:42 pm

if they are, the problem is that I do not know to play the circuit.
Thanks for your help Wingate, keep trying
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Re: Dump load / LVD circuit

Postby windgat on Sat Apr 03, 2010 7:29 pm

"play the circuit" ??
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Re: Dump load / LVD circuit

Postby ramos on Mon Apr 05, 2010 9:37 pm

Thank you for your attention WINDGATE, it's hard work to make a decent translation with google.
The problem is that I can not draw the back of the PCB.
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Re: Dump load / LVD circuit

Postby windgat on Thu Apr 08, 2010 11:29 pm

Hola Ramos. Have you looked carefully at http://192.168.0.14/windpower/loadcontrol/loadcontrol.html ? I'm sorry, but I can't think of how to help you further!
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Re: Dump load / LVD circuit

Postby windgat on Thu Apr 08, 2010 11:29 pm

Hola Ramos. Have you looked carefully at http://192.168.0.14/windpower/loadcontrol/loadcontrol.html ? I'm sorry, but I can't think of how to help you further!
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Re: Dump load / LVD circuit

Postby rod on Mon May 31, 2010 8:22 pm

hi windgat
rod here,i have a 10foot wind turbine 24 volt system .i have the compleat system up and charging.what i need is the dump controll unit, can you build me a unit and what will be the cost.the units from the suppliers are to high in cost.
i live in the northwest a town Bloemhof.cell no 0723804148.

regards rod.

ps 1500 watt max normal output +- 800watt.

,
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Re: Dump load / LVD circuit

Postby windgat on Tue Jun 01, 2010 8:50 am

Hi Rod. If I just send you a board and components that will be quite cheap, max R300 (I would need to add it up). That means assembling and soldering yourself. And of course making a box, and connecting the actual dump load (e.g. high resistance wire). If you are unhappy doing the soldering, I could do that for you, for a bit extra.
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Re: Dump load / LVD circuit

Postby rod on Tue Jun 01, 2010 7:31 pm

hi windgat
would you please solder the unit for me and would you do the callibration and test procedure for a 24 volt system.

i can build my own box,could you be so kind as to supply me with a drawing of the wiring as i am not good with wiring.

as soon as you are ready please let me have your details so that i can deposit the funds in your account.
give me a total of unit pluss postage or road transport.
my adress
R G Randall
No 31 Noord Street
Bloemhof
2660.
rodney
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Re: Dump load / LVD circuit

Postby rod on Tue Jun 08, 2010 6:29 pm

hi windgat

rod, can you please let me know what progress we have on the dump\load unit.
can not wait to connect the whole system.

thank you,

rod.
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Re: Dump load / LVD circuit

Postby windgat on Wed Jun 09, 2010 11:28 am

Hi Rod. I am too busy to actually solder the board, but there is a young guy who was on my course about the dump load who is really good at soldering. I am getting him to make one for you, and I should have it by Monday.
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Re: Dump load / LVD circuit

Postby rod on Wed Jun 09, 2010 5:14 pm

hi windgat

thank you for the reply will wait for your call or e mail next week.

thanx,

rod.
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Re: Dump load / LVD circuit

Postby rod on Tue Jun 22, 2010 6:22 pm

Hi Windgat

would you let me know what the cost of the dump load components plus board is .

i will try and solder it.

rodney.
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Re: Dump load / LVD circuit

Postby windgat on Sat Jun 26, 2010 2:03 pm

Hey Rod. I got two of those boards made up! They are soldered, calibrated, and tested. Just need to get my head around costing it out, and will post to you next week!
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Re: Dump load / LVD circuit

Postby rod on Tue Jun 29, 2010 6:03 pm

Hi Windgat,

Just need some info,
I have a 24 volt wind turbine what i would like to know is can i charge a single 12 volt 200ah battrey from it.

Thanx,

Rod.
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