testing the egs002 inverter board

[ClockmanFrance]

The OzCooling board.

I have the gerber files for this PCB, but not sure if I can post a Zip file on here?

This is Oz's well tested and proved circuit.

Its a double circuit as failure on one in the field means the other can be switched over, also I cool the torroid and the PCB's separately, as its surprising that the 2 heat up and cool down very differently.

On the latest 'OzControl PCB No12' I have also left the 2 temp molex connectors as the over temp is a trusted way of starting and stopping the OzInverter safely and was used on the OzControl No8 PCB.

[ClockmanFrance]

The OzControl PCB No12.

Its the same structure as Oztules, its just that in the very beginning I developed the PCB slightly differently.

[ClockmanFrance]

OzCooling Zip file for the PCB manufacture Gerber RS 274X files.

OzControl Zip File for the PCB manufacturer Gerber RS 274X files.

[ClockmanFrance]

OzCooling and the OzControl No12 PCB's, direct scan on a sheet of A4.

These were originally designed so folk could make them the acid etch method.

The jumpers/links have become the double sided PCB. The manufacturers Gerber files as posted.

[ClockmanFrance]

The OzInverter PowerBoard.

This design and layout works well, and 'oztules' has well tested them. And since they work I am reluctant to change anything.

This Power board size just sits on a sheet of A4, ie, designed so I can laser print out all the tracks, drill, solder stop etc, with a standard A4 printer.

Its Double sided with double copper thickness both sides.

So its reletavely costly to have made, $20 to $30.

[ClockmanFrance]

The other side of the OzInverter Power Board .......


It should be remembered that these boards are not your normal electronic industry type of design and layout.

The power board takes serious amounts of Power.

These completed OzInverters would live outside in all sorts of climatic conditions and should have a good longer than normal operational life.

We wanted PCB's that were hardy, good size tracks, good size via pin holes so that substrate separation would be kept minimal, and easy to repair.

Through hole components were used as its a DIY project and folks assembly methods skills vary widely.

And if repairs are necessary, insects etc, they are easily achieved as we have good tracks/solder size, and importantly we list all the components on the PCB silk screen ie, its a painting by numbers job. 

[ClockmanFrance]

The OzInverter Power Board parts list etc.

[ClockmanFrance]

The latest OzInverter Block diagram.

Here is a old short utube vid done by my 16 year old, ..... but it does show the parts (OzcontrolPCB No8) for the OzInverter being put together in my workshop.

[Phaedrus]

Amazing work ClockmanFrance !!
Element N0.8 in the layout sketch,says "Shunt 300A". Is it an MCB ?

[noneyabussiness]

DC 120V 300A Wireless Digital LCD Display Digital Current Voltmeter Ammeter Power Energy Multimeter Panel Tester Meter Monitor

 http://s.aliexpress.com/QnEVNnYR


I use one of these... they work quite well and log how much A/H in or out etc...

[ClockmanFrance]

No, Phaedrus.

Element No8 is a 300amp shunt, with a 50mV rated for amp meters to understand what amperage is flowing backwards and forwards from the batteries.

Got to keep an eye on your precious batteries!

I normally fit one of these 250amp rated MIDNITE big breakers (about $140) from the batteries. Trouble is its so big so it sits in its own enclosure outside the OzInverter enclosure.

Pic 1 ...... show the Shunt, this one is a 500amp 50mv, 10mm thread bolts, for my Big OzInverters.

Pic 2 ....The Midnite breaker, this one is 250amp rated, the securing lugs/bolts for the cables are 10mm diameter .

I think Oztules parallels his breakers, but over the past 8 years or so I never had much fun with paralleling them up. Hence the one big Midnite one.


 

[Phaedrus]

Clockman ,thanks.

I normally fit one of these 250amp rated MIDNITE big breakers (about $140) from the batteries.

That's expensive switchgear!
Why not put a cheaper low ampere , MCB on the 230VAC side ,and a slow fuse on the DC side?Would that be a cheaper bet?
https://www.amazon.in/Siemens-Miniature-Circuit-Breaker-5SL62327RC/dp/B01D4QL3WK

Noneyabusiness,thanks for helping with my addiction to Aliexpress ;-).Seriously though,these Chinese are amazing.

[noneyabussiness]

  you are very welcome. ..

I always look on Ali first. .. for anything im looking for... then usually get amazed on what is on offer...

[tinyt]

Wow, thanks ClockmanFrance, not sure if this old fart can absorb all if them. It will exercise whatever is left in my coconut.

[ClockmanFrance]

OzInverter PCB's.    30th December 2017.

A few Photos of the assembled latest boards ..........

Might do a 60HZ, (pin18 to +5v) and the split secondary for 120vac for North America , and if enough demand, a new OzControl PCB for 60HZ..