Author Topic: testing the egs002 inverter board  (Read 147562 times)

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Offline oztules

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Re: testing the egs002 inverter board
« Reply #75 on: March 27, 2016, 04:08:19 pm »
No Frank... just use what you can of it.

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

Offline oztules

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Re: testing the egs002 inverter board
« Reply #76 on: March 27, 2016, 04:28:00 pm »
Here is the new 8010 board as it currently is... still waiting for the adapter boards for the 8010 to dip to arrive, so the dimensions of the 8010 complex are probably wrong, but you can see the way I am going with it.... simple.

Added more copper everywhere..... and just need the parts now.

5329-0

The latest 002 board is of similar ilk.. ie tracks enlarged and minor changes to the circuitry... will post that later.

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

Offline oztules

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Re: testing the egs002 inverter board
« Reply #77 on: March 27, 2016, 06:18:51 pm »
Here is latest 002 not built yet so beware... and check for yourself first.

5338-0

It is truly ridiculous that that simple circuit is running the house for the last week or so... up to and over 7kw surges, and 2-3kw constant for hours on end..

Still blows me away...



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

Offline frwainscott

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Re: testing the egs002 inverter board
« Reply #78 on: March 28, 2016, 12:09:47 am »
Do the Power Jack boards all have a problem with the 5 volt supply being weak or is it just the egs002 setup? I dont think I read where any failures were due to the 5 Volt circuitry. But I tend to wake up in a new world quite often.

 Thanks...  Frank

Offline oztules

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Re: testing the egs002 inverter board
« Reply #79 on: March 28, 2016, 02:23:58 am »
Not in the powerjack, never seen them go.

The way I was trying to use it allowed spurious spikes at connection .... coming through the tip35 drop down tranny. This is mitigated with the resistor and cap, but i changed the whole front end to take the strain off the tip from driving both 5 and 12v lines through the 7805 .

.... john
Flinders Island...... Australia

Offline oztules

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Re: testing the egs002 inverter board
« Reply #80 on: March 28, 2016, 03:31:29 am »
OK.... built 2 of these this after noon....both work perfectly.
Decent track widths and no faults to report.

5342-0

Who would believe you can build a perfectly good pure sine inverter in an afternoon.... much less two

It was all worth it... now for stage two..... no 002 board, just the 8010.... interesting....

As requested, this is what fell out of the pcb program... may help
Bill of Materials

"","SPADE","4","A91 A92 A93 A94"
"0r","AXIAL0.3","3","A60 A62 A63"
"0r","AXIAL0.4","2","A48 A49"
"100uf 100v","RB.2/.4","1","A6"
"104","C2","1","A51"
"10PIN","10PIN","1","A73"
"10PIN","17PINA","1","A88"
"10k","AXIAL0.3","2","A5 A72"
"10k","AXIAL0.4","1","A10"
"10k","POT","1","A1"
"120r","5WRESIST","1","A13"
"13v","D2","1","A65"
"1k","AXIAL0.3","1","A55"
"2k","POT","1","A54"
"2k2","AXIAL0.3","1","A50"
"2uf 400vac","AXIAL1.0","2","A11 A12"
"35c","TO220V","1","A66"
"4u7","2PINCAP","3","A3 A14 A15"
"4u7","C2","1","A53"
"50k","AXIAL0.3","4","A82 A83 A84 A85"
"5v6","DIODE0.4","1","A4"
"fr107","D2","8","A56 A57 A58 A59 A61 A78 A79 A80"
"npn","TO92","1","A2"
"tip35c","TO220V","1","A68"

Will attach pdf of tracks and component o/lay soon.

Looks like anyone can build a pure sine inverter as big as they wish for nuts...



.........oztules

Flinders Island...... Australia

Offline oztules

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Re: testing the egs002 inverter board
« Reply #81 on: March 28, 2016, 04:12:14 am »
* 002INVER.pdf (27.94 kB - downloaded 1142 times.)
Flinders Island...... Australia

Offline oztules

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Re: testing the egs002 inverter board
« Reply #82 on: March 28, 2016, 04:27:20 am »
And finally some afternoon pictures.

First the paper with the oil on it
5345-0

Then the pattern on the copper.. still a bit wet...

5347-1

The top of twin boards

5349-2

and the rear of the thing.

5351-3

Hope that helps someone.

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



Flinders Island...... Australia

Offline RFburns

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Re: testing the egs002 inverter board
« Reply #83 on: March 29, 2016, 01:04:47 am »
Great work Oz  :); I have linked to this page on another forum to spread the word. How are the output boards from Clockman going? and will they be posted here when finised?
Get With It ,Get Over It , Get On With It ...Or Leave

Cheap and reliable wont be fast.
Cheap and fast wont be reliable.
Reliable and fast wont be cheap.

Offline ClockmanFrance

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Re: testing the egs002 inverter board
« Reply #84 on: March 29, 2016, 04:19:24 am »
Getting there...........

Its getting my files converted to RS-274X gerber format. It seems folk would like ready made cost effective Boards.

My PDF output is good, and to real size, and all masks are done and can print out nicely. But getting the correct File format for the PCB manufactures is a nightmare. Just trying to keep the cost down.

File types my CAD can output.......

Offline Antman

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Re: testing the egs002 inverter board
« Reply #85 on: March 29, 2016, 05:03:48 am »
Hey guys

Great work on the EGS002 driver board everyone! I had ordered a few and designed a test board to see how it would work a couple of years ago but ran out of time and motivation very quickly.

This thread and all of the hard work you guys have done has re inspired me to look into it again this long weekend. It turns out my board worked the whole time I just had to adjust the voltage regulation and solder everything properly :)

Here's a photo showing it in action. Don't mind the messy desk and crappy test board. When I designed it I had no experience with electronics.
The toroidal is just a salvaged 300VA rewound with 2 x 2.5mm domestic wiring.

Offline Antman

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Re: testing the egs002 inverter board
« Reply #86 on: March 29, 2016, 05:29:03 am »
Since I was inspired this long weekend and had a few hours to kill I started working on a proper power board so I can put one of these things to use.

The goal is to make myself a 3000W 12V unit. Yes I know 12V is a waste of time but it suits my applications since I'm using second hand batteries and keeping them in balance is too hard in higher voltage systems. I'm not running the house off it but reliability is big on my list.

I want to keep the size down too as I want to fit it into a 3 RU rack mount case.

Photos below are my progress so far. I like using all SMD components except for caps of course. Its way harder to get the heat away like this but I've made similar boards before and with the right thermal VIA's and mounted to a heatsink the heat should be manageable fingers crossed  ???

There is still some things to add and decisions to make. I was thinking of adding an arduino in to manage the cooling, over current, low voltage cut off and also I need to add an off switch.

I just get the PCB's made in china. It's trouble and stress free that way and they usually come in a week to AUS.

Thanks for looking. Should be a fun project!

Offline RFburns

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Re: testing the egs002 inverter board
« Reply #87 on: March 29, 2016, 06:15:58 am »
Nice work Antman; look forward to seeing it finished. RF

Clockman nice to hear the progress there, BIG THUMBS UP ; I thought you maybe able to import your .dxf's into a PCB programme to give the Gerber's ?(not that I have ever done that myself). RF
Get With It ,Get Over It , Get On With It ...Or Leave

Cheap and reliable wont be fast.
Cheap and fast wont be reliable.
Reliable and fast wont be cheap.

Offline oztules

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Re: testing the egs002 inverter board
« Reply #88 on: March 29, 2016, 04:37:08 pm »
Very nice Antman.

@48v you would get your 3kw with that layout... with 12v.... not easy with 300 amps to cover..... if the copper was 2mm thick you would do it.
Nice layout too.

The cooling and under voltage is best done third party I think, current by the 002 is fine ( with some mods).

Order a few spare boards... i think you may be in need of them. If your board can carry 80amps or more cont.... I suspect there will be some interest.

Glad we pricked your imagination, that  what it is about.


Wish I could still see the surface components... never mind manipulating them....... envy....

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

Offline Antman

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Re: testing the egs002 inverter board
« Reply #89 on: March 29, 2016, 07:51:32 pm »
Thanks RF and OZ

Yep the current becomes an issue at such low voltages. The two long exposed copper sections on the outside are the outputs to the transformer primary. I will probably solder 12 x 12 mm brass bar onto it and tap in a M8 bolt so the transformer leads can be lugged onto it.

The power input will probably done in a similar way. This is the only part I'm not happy with at the moment. It'll handle 150 amps easily but 300 will be pushing it. I may have to spread the input over a few smaller cables instead of 1 large one. The caps will probably have to be enlarged too.

Ill probably add a spot for a Buck converter module and jumpers so that the board can work with 24 and 48V too. That way somebody else can get some use out of the board it it's successful. Ill be ordering 5 or 10 boards anyway. I was considering scrapping the EGS002 board and just putting everything onto my board but I honestly cant be bothered.