Author Topic: testing the egs002 inverter board  (Read 51511 times)

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Offline oztules

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Re: testing the egs002 inverter board
« Reply #345 on: June 14, 2016, 07:04:39 pm »
I have settled on this for the time being.
It does everything I want, others may want more/less.

Yes Zogg, you can action this one without any changes:)

1. It has on/off via pin 6
2. It has temp input as well for disaster situations where fan fails and temp gets out of hand
3. It has off board pins for power led
4. It has off board pins for status led
5. It uses a current transformer coil
6. It uses an isolation transformer for the voltage feed back.
7. It uses a simple voltage supply using the TIP35c... simple, and effective and fails off not on.

There are two things that I don't like particularly.

1. The voltage drifts in the first few minute from say set 230 to 234v... then stabilizes rock solid at 234 or whatever you set for  plus 4 v after the first  5 minutes.

Can't find what is heating this up or what ever causes it. The heat gun makes no difference once stable... so maybe not heat but what else I can't say.
It is stupid simple, which makes finding the fault either dirt simple or impossible. ( inside chip)

2.If you slowly raise the voltage of the supply from 0v to 50v or so slowly, the chip hangs.... no idea why...but it is internal, and does it when you slowly introduce the power to it.
If you splat the terminals which is pretty standard, then no problems forever while it is connected to batteries.
I use a 10 ohm resistor to avoid the splat, and this is fine too, but if you go to say 100r, then it will charge up, but no action... so keep in mind.

Neither of these two problems are show stoppers by a long long way. The plus attributes easily out weigh these foibles, but they need to be mentioned.

Apart form that, these things are quick and simple to build, and run beautifully... and create no fuss , but just run anything thrown at them... really remarkable little devices.

I won't be going any further, as I cant see what else you could ask for in a home inverter. Those that like lots of bells and whistles designed to make them look very complex will be disappointed... they are simple, and work as well... in fact better than all I have encountered as a straight inverter.

It draws a very modest idle current ( 30 watts or so), and go for excursions over 10kw without any worry.... very very versatile.

Ok here is the final PCB I will use from now on

The board complete

5857-0

top left

5859-1

top right

5861-2

bottom left

5863-3

bottom right

5865-4

and the board proper.
1. The wires coming away from the little pins are the on/off pins.
2. The pins beside the led are the led off board pins for status.
3. The pins on the outside of the board next to the heat sink is the temp pins for a 10k@25c ntc.
4. The pins next to them nearer the chip board is the power on led... registers the 5v from the regulator.the chip side of the two pins .

Note... if you don't intend to use the temp pins, ground the temp pin ( the one thats not the 5v ). I suggest you use the pin and a ntc 10k@25c for a safety net in case of fan failure for whatever reason.

5867-5


Will do the pdf later.

Who would have believed that something this simple, and just add fets and transfromer and box, and you have a super inverter... not me for one:)

It just works so well.


.........oztules

Edit:

It took a few boards to get here.... and they all work too....

5869-6

And here in a aerosharp 3kw box for a little 4kw unit... still runs the house totally, and pulls 10kw start up power. very hard to beat .

5870-7


And here with a few more kw... not much movement with the voltage really... It was to be a 240v machine, but I settled for 232v for better power usage.. not much of a change electrically, but saves the battery a bit of pain when these loads come on that are resistive in  nature. otherwise it would be over the 5kw by quite a margin for the hot water, electric jug fridge freezer tv and wall warts etc... all are on in this instance. That 8 or 10v means nothing to all other appliances, but it does take some of the shock out of it for the battery.


5872-8

It works.

Flinders Island...... Australia

Offline oztules

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Re: testing the egs002 inverter board
« Reply #346 on: June 14, 2016, 08:10:04 pm »
Ok pdf

* 80109f.pdf (69.43 kB - downloaded 342 times.)

Hope this helps someone somewhere... and this is from the gerber files

5883-1

And no I don't have a clue how to use gerbers... but this is what came out of the program..may be useful for someone.
EDIT reloaded the gerbers.... these may work better
Edit 2 no they dont for newer cad progs,  but the ones later in the thread apparently do

* 80109f.GTO (66.72 kB - downloaded 181 times.)

* 80109f.GTL (4.62 kB - downloaded 132 times.)

* 80109f.GPM (4.54 kB - downloaded 129 times.)

* 80109f.GBL (34.39 kB - downloaded 143 times.)

maybe those will work better



..............oztules
Flinders Island...... Australia

Offline Dr_Zogg

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Re: testing the egs002 inverter board
« Reply #347 on: June 15, 2016, 05:24:29 am »
thanks oz. I will get on it.
at least i have had some practice making pcbs with the kinsten boards now.
I have always used toner transfer but this is way better once you get the hang of it.

would i be able to pull 12v off of the tip35c for my fans, or would that be asking a bit much of it?

anyhow great work as useual,

Cheers,
           Zogg
Of all the things I've lost, I miss my mind the most

Offline oztules

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Re: testing the egs002 inverter board
« Reply #348 on: June 15, 2016, 06:41:01 am »
No, the tip would need a whole heap of cooling..... don't do it.
Your better to get this
http://www.ebay.com.au/itm/191816717709?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT

Cheap as nuts, and more power than you know what to do with.


...............oztules

Flinders Island...... Australia

Offline Dr_Zogg

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Re: testing the egs002 inverter board
« Reply #349 on: June 15, 2016, 06:55:42 am »
yeah. i have a fair few of them I was just being lazy haha.

thanks for that.

Cheers,
           Zogg
Of all the things I've lost, I miss my mind the most

Offline oztules

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Re: testing the egs002 inverter board
« Reply #350 on: June 15, 2016, 07:10:27 pm »
and here is the pcb file for those that can read protel

* 80109f.PCB (52 kB - downloaded 296 times.)

.............oztules
Flinders Island...... Australia

Offline billy

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Re: testing the egs002 inverter board
« Reply #351 on: June 16, 2016, 12:28:21 pm »
Oztules,

can that protel convert pcb to dxf?

billy

Offline billy

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Re: testing the egs002 inverter board
« Reply #352 on: June 16, 2016, 02:16:10 pm »
Oztules,

sorry never seen your other post regarding the files that you can put out with the program.

Billy

Offline oztules

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Re: testing the egs002 inverter board
« Reply #353 on: June 16, 2016, 11:03:25 pm »
Clockman was good enough to send some fet boards to test.....not sure how he will take to this.... but
Feeling very slack, and having no small heat sinks to fit, the next thing was to cut up the huge heat sinks from the grid ties... it all looked to hard today.. so

5904-0
 and  testing  was fine

5906-1

It is simple and easy way to do it with much less drilling and tapping... also you could mount it on any heat sink or even water tank if your going all out for power.

So Clockman, board worked fine.

The little caps seemed too big. I know the schematic says 104, but in the end 472 was used or the resistors smoked up on the 23khz sides.
Flinders Island...... Australia

Offline ClockmanFrance

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Re: testing the egs002 inverter board
« Reply #354 on: June 18, 2016, 02:10:48 am »
Excellent news, 'oztules'.

Good to see you giving that Power Board a good thrashing/testing. !...... well done!

Okay those 4off 104, 100nf disc caps changed to 4.7nf, thanks for finding that.

I think that's about it for the time being, a Good OzControl Board, (the Pin6 design), a Good Power Board, and your DoubleOzCooling board, ....... brilliant.

I note your comment on the Power Board not needing to much cooling now, but I will still go safe with your OzCooling circuits  on the PCB's and on the toroid.

I do like the stonking big single 50mm/2 or 75mm/2 cable for the Primary, just so much easier to get cool air circulating through the toroid and around the Primary. Just never sure where in the World the OzInverter could be operating.

I will post some pics on my BigOzInverter, (41kg toroid core) soon, that will be interesting......

Thanks again for your help.

Note, ......as a matter of interest, I have been following Midnite Solar as they build there New modular 48vdc  Inverter, they have just submitted for 8 patents, Its taken them 4 years, yea due diligence and the like.
'Oztules' and friends thrashed out everything in the real world in about 4 months.

The World moves forwards with folk like 'oztules'.

Thanks



Offline Dr_Zogg

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Re: testing the egs002 inverter board
« Reply #355 on: June 18, 2016, 08:16:02 pm »
hi oz would it be possible to get a bill of materials for your latest design. and are there any small changes to the design or parts from what is pictured?
just trying to be prepared this time. i'm going to build 3 in one go, one for each of my inverters and one as a spare.

Cheers,
            Zogg
Of all the things I've lost, I miss my mind the most

Offline ClockmanFrance

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Re: testing the egs002 inverter board
« Reply #356 on: June 19, 2016, 03:35:17 am »
Here is mine...........

The PIN6 start/stop.

As 'oztules' says, that 7k5 resistor on the 500r trimmer, (AC voltage adjust) might need to be slightly lower value, as I am using a 12vac input where 'oztules' was using a 14vac.


From The OzInverter Book.
PCB Component details for the 6-15kW OzControl Board 9.
These Boards have been designed for easily obtainable components and parts.  This list will be updated as required.    Most of the component/parts details are from Ebay and may be purchased there, however some parts may only be found on Allibaba, so the Web Link is given.
Please find below a list of the majority of parts required.   19/06/2016

220vac, 12V 1W Output Voltage Isolation Dry Type Transformer Toroidal Tube. …  Or  220v:12V 3W Output Voltage Isolation/ Dry Type Transformer.
EG8010 LQFP-32 Sine wave inverter chip, HN1518HT1536,  http://www.aliexpress.com/item/10pcs-lot-New-EG8010-LQFP-32-Sine-wave-inverter-chip/32605461001.html.
 
Single sided copper clad PCB, 86mm x 170mm x 1.5mm 35um thick copper.

0.65mm to 0.8mm QFN32/QFP32 IC DIP Mounting PCB Adapter Converter Plate for  SMD chip, (1 off). …. 40Pin (we need 2 off 16pin), 2.54mm Male & Female SIL Header Socket Row Strips PCB Connectors.
HC-49S 12.000MHZ 12MHZ  20PF DIP Crystal Oscillator, (1 off).

IR2110PBF IR2110 IR FETS DRIVER CHIP DIP-14 IC 5V, (2 off).  …. TIP35C TRANSISTOR, (2 off) …. 5.6v (1.3W) Zener Diode, BZX55C5V6, (1 off). ….. 13v  (1.3W) Zener Diode, BZX85C5V6, (1 off). … DIODES fast/RAPIDES FR107 - 1A, (2 off). ….  IN4007 Diode - Rectifier - 1A  1000V , (8 off). …
DC 2.5V-3.0V 5mm Red LED Lamp Emitting Diode, (2 off, one red, one green).
   
Monolithic Ceramic Chip Capacitor 475  4.7UF 50V 20% 5.08mm Pitch, (2 off).  …. Monolithic Ceramic Chip Capacitor  10UF 50V , (5 off).  ….  CBB61 Polypropylene Film Motor Start Run Capacitor, 2uF 50/60Hz 450V AC, (1off). …   22pF - Ceramic Disc Capacitor, 50V , (2 off). …. 100nf Ceramic Disc Capacitor, 50V, (9 off).  …. 1nf Ceramic Disc Capacitor, 50V, (1 off).  …  10uF Electrolytic Capacitor, (can), 63V (max) 105°, (4 off). …  100uF Electrolytic Capacitor, (can), 63V (max) 105°, (1 off).

100r Ohm 1/2W Metal Film Resistor, (2 off)… …Resistor 2K Variable TRIMMER, (1 off). …. Resistor 500r Variable TRIMMER, (1 off). ….  120 Ohm 5W Ceramic Wirewound Resistor, (1 off). …..   0.6W Metal Film Resistor 10K , (3 off). … 0.6W Metal Film Resistor 7K6 , (1 off). … 0.6W Metal Film Resistor 1K , (5 off). ….. 0.6W Metal Film Resistor 1K8 , (1 off). … 0.6W Metal Film Resistor 1K5, (1 off).

IDC Straight Latched PCB Plug (male) Connector 10 Way, (1 off). …  Molex KK Connector Housing 2 Way (5 off). … Molex KK Straight Header Connector 2 Way (5 off) & 10 Molex crimp terminals to match. …. 
14-Pin DIL DIP IC Socket PCB Mount Connector, (2 off). …. -50~70? LCD Panel Digital Thermometer Temperature Meter  Probe sensor, (1 off). … PCB Blade 6.3mm Connector Terminal Vertical (2 off). … DL-CT08CL5 20A/10MA 2000/1 0~120A MICRO CURRENT TRANSFORMER X9N0, (1 off), for the 230vac sense cable from the secondary.

The above list is now duly amended as per 'oztules' post below.  I think?

Offline oztules

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Re: testing the egs002 inverter board
« Reply #357 on: June 19, 2016, 03:48:05 am »
Clockman, check your list against this BOM

"Bill of Material for Z:\HOME\OZTULES\DESKTOP\80109F.PCB"
"On 19-Jun-2016 at 18:40:09"

"Comment","Pattern","Quantity","Components"


"","10PIN","1","A79"
"","CON2","2","A57 A58"
"","SPADE","4","A51 A60 A61 A62"
"0r","AXIAL0.3","8","A4 A13 A14 A17 A26 A34 A44 A50"
"0r","AXIAL0.4","4","A27 A29 A41 A52"
"0r","AXIAL0.5","1","A28"
"100r","AXIAL0.3","2","A77 A78"
"100uf 63v","RB.2/.4","1","A71"
"104","C1","2","A22 A23"
"104","C1C","2","A48 A66"
"104","CAP2","5","A10 A12 A30 A68 A82"
"10k","AXIAL0.3","1","A38"
"10k","AXIAL0.4","2","A6 A40"
"10uf","C2S","4","A18 A19 A20 A21"
"10uf","CAP2","5","A8 A15 A45 A76 A83"
"120r","AXIAL1.1","1","A7"
"13v","DIODE0.4","1","A39"
"14v/240","TRANS","1","A9"
"1k","AXIAL0.3","5","A1 A33 A49 A63 A65"
"1k5","AXIAL0.3","1","A42"
"1k8","AXIAL0.3","1","A81"
"1n","CAP2","1","A5"
"2110","DIP14","2","A2 A3"
"22p","C2","2","A74 A75"
"2k","POT","1","A46"
"2uf","11PINCAP","1","A69"
"4007","DIODE0.3","8","A53 A54 A55 A56 A59 A64 A84 A85"
"4u7","CAP2","2","A31 A37"
"500r","POT","1","A47"
"5v6","D3","1","A16"
"7k5","AXIAL0.3","1","A67"
"8010","801032","1","A72"
"ct","CON2","1","A11"
"fr107","D3","2","A25 A80"
"led","LED","1","A32"
"tip35c","TO220V","2","A35 A36"
"xtal","RAD0.2","1","A24"

There seems to be too many 1k8 and 1k  in your list.
Electro 10uf are now 4 on the outputs of the 2110 only

2x4u7 ceramic now
9x10uf, 4 of them electro 5 of them ceramic etc.

Some of the 104 on mine are 2 pin spaced, and some one pin space.. c1c and c1 are the same thing  ( in the BOM).. so 4 of the single space and 5 of the 2 pin space.

Sorry for this, but this is the final one as per pics above .... may be slightly different to yours, but I understood only 1 led should have been different and the resistor for it ( yours had a pwr led on board as well as the off board pins I think.)

This was the trouble with a work in progress.. but all good in the end.

I just wish everyone could read protel files, and the version I have does old gerbers that no-one else can read with modern programs... will try to find my old design 99se, and see if it can do  gerber 247 or what ever it is now.


.............oztules
Flinders Island...... Australia

Offline Dr_Zogg

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Re: testing the egs002 inverter board
« Reply #358 on: June 19, 2016, 03:50:50 am »
thanks for that fellas  8)
it is appreciated

Cheers,
           Zogg
Of all the things I've lost, I miss my mind the most

Offline ClockmanFrance

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Re: testing the egs002 inverter board
« Reply #359 on: June 19, 2016, 04:49:54 am »
Yes, Sorry about that 'Oztules' and 'Dr Zogg'.

Its a dynamic project, and sometimes I am running to keep up!.

Yes, the 4 10uf cans on the 2110 driver outputs was essential, I left 2 on the other side, but if we do not need cans there, then they are changed for Monolithic types.

Regards Pin outs... I have tried to leave room for manoeuvring, as folk may not be able to get specific sizes, hence those Trimmers have Pin hole options.

Regards PCB software Gerber files etc, last used that stuff 30 odd years ago, seems nothing much has changed today.
I leapt in feet first, 6 months ago I Purchased the latest TARGET PCB software as it could import my DXF files from my CAD, but what a heck of a swim to get ones head around, especially nowadays, as you need to be a part number/package number, Monkey. 

Thanks.