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No brand/5500W inverter disaster porn
lighthunter:
A couple years ago i bought one of these EGS002/8010 based inverter boards, great deal for a 48v backup inverter. Am sure i tested it after i got it cause a few of the necessary control wires had solder on and i faintly remember making sure it worked. Recently after several years my power jack control board quit. No blown fets just no output. Can be repaired i think but needed a quick solution so got this spare off the shelf, after all thats why it there.
It took a while to fit it into place secure it and arrange necessary connections that were not now on board terminals. All connected i decided to precharge and power on before closing the lid. Precharge took little time as the capacitor bank is only 8000uF. Charge indicator came on and i closed the DC breaker. I didnt even get a chance to turn it on before an explosion ensued, immediately, im thinking fets and usually theres no point in saving anything once the noise starts but then another horrendous bang!! Then another!! Like popcorn only x1000!!! By the time i got my wits together and tripped the 100A DC breaker 6 of 8 had gone off!! Of course i somehow hooked a wire up backwards i thought.... Double and tripple checked the wiring. No problems there. Polarity was correct. DC volt meter read 52, caps stamped 63V. Ive no idea why the caps blew the way they did other than they had been sitting unused for maybe 2 years and dried out. Or the obvious...dragon brand... Fitted some suitable replacements to the board and it powered up the toroid with zero noise or hum and 121/242VAC
no adjustment necessary. Now to fix the PJ no wait... its spring time there are other garden/patio/building repair jobs to do first.
Fun times!!
LH
noneyabussiness:
Ive had that happen to a high frequency board... " 63v " caps and same result... probably find they are 35v caps " re-labeled " work for a short time sometimes, then boom... drying out a bit probably didn't help ether, but should not have mattered, unless temp extremes... same fix worked for me too, replaced and all good...
lighthunter:
35v cap in place of 63, yeah that would do it. :P Reminds me of a story years ago when a friend and i built a 4meter wind genny, first week of it being up his dog chewed the cord and unplugged it. Fortunately the caps and diodes all came apart shorting the 3/phase winding which brought it to a stop and saved the mill . Caps and diodes dont like limits disrespected Ha!
this is my first experience with the 8010/egs002 it uses less power to idle, like around 15w only which is great! Its also very unaffected by changes in load power.
The not so great is the AC output volts oscillates by a volt or so at about 2 hz and the AC output also changes with battery voltage. At 52V the output is 121V and at 46.5V its about 115V.
Im sure those two issues can be corrected by tinkering with feedback loop a bit. Since battery volts changes very slowly and a plc already monitors battery volts I could simply drive a relay contact to adjust AC output volts based on batt level.
Its not a perfect solution but it is serving the purpose of a spare inverter which im grateful for!
LH
noneyabussiness:
That's strange, I've been using a bigger version of that board for years, and its rock solid, even pulling a solid 9kw for hours... i would change all the smaller feedback caps, check the solder for " dry joints " etc. , the eg8010 board is very good for feedback usually...
Specially if the bulk caps did what they did, i would suspect all of em...
lighthunter:
. "i would change all the smaller feedback caps, check the solder for " dry joints " etc. ,"
Very good advice!
it also occured to me that the resonant freq. Of the toroid and choke likely is not 90hz as it needs to be. I never checked this one. Never noticed an issue with the PJ boards driving it. Maybe its much lower than 90 and causing the voltage to fluxuate as the wave is influenced by rolling addition and subtraction of the actual resonant frequency. Kind of like the volume of old am radios used to do under the right conditions.
Courtesy to Poida's research or i wouldnt even think about it.
The wave shows a little distortion from incorrect LC filtering.
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