testing the egs002 inverter board

[Dr_Zogg]

Thanks heaps for that Oz.
I seem to have hit a slight problem though. when i upload it to my PCB manufacturer
i get this error. Could not find Board Outline file. would you know how i go about sorting that out any any chance?
thanks for your help.

Cheers,
            Sam

[tinyt]

If I may be allowed to contribute:
Some PCB fab houses prefer the board outline to be on one of the existing copper layer.
Use a text editor and open file: 5000AW.GTL (gerber top copper layer)
Scroll to the end of the file where you will see these last 2 lines:
D03*
M02*

Insert 6 lines between the two as shown below:
D03*
D14*
X6446Y4631D02*
X6446Y11361D01*
X13536Y11361D01*
X13536Y4631D01*
X6446Y4631D01*
M02*

A board outline will now be added to the top copper layer with the following corner coordinates (6.446,4.631), (13.536,4.631), (13.536,11.361), 6.446,11.361).

Save the updated file, and update to zip.

[Dr_Zogg]

Thanks for that tinyt. but for some reason it still won't accept it.
maybe oz i could get the .pcb file from you and export it using altium designer?
thanks for your help everyone.

Cheers,
            Sam

[Dr_Zogg]

i got it to work. woohoo. i used the code you gave me but added it to the .gts file instead. worked a charm
thanks for the help.

Cheers,
            Sam

[Dr_Zogg]

sorry, I know i am asking a million questions. But what package hy4008's are you using? also do you have a BOM for the power board?
I am unsure as to the main cap voltages and the type and voltages of the others.

Cheers,
            Sam

[Dr_Zogg]

sorry. just noticed the caps were discussed only a couple of pages back. too much rattling around in this head of mine at the moment.

Cheers,
            Sam

[Dr_Zogg]

i thought i would put up the gerbers for the power board that I edited, maybe it will be of some use to someone if their board house wants the outline on a different layer than the original as mine did.

Cheers,
            Sam

[Dr_Zogg]

I have just put my powerjack stuff in the classifieds if anyone is interested. I am open to offers.

[Phaedrus]

Hello !
I had some partial luck with my egs002 board.

For trials I am using a 12V (7Ah) x 2 = 24V battery system.
I connected a 500W lamp load and it held up without any issues.Then I connected a 1000W lamp, and the battery voltage sagged to 20V and output voltage sagged to 190V.This was probably expected.

Then for an experiment,I disconnected the shaping capacitors (2u2 x 2 ) at the output 220v.Subsequently,I am unable to get any voltage at the output.The battery voltage sags drastically to 14V,but there is no output on the 220V side.
I changed the MOSFETs,egs002 board,but there is no result.I checked the waveforms as mentioned in the egs002 board manual,and they are perfect.Of course this check was done without the MOSFET board connected.
Any suggestions or things I can check?
Very perplexed...

[oztules]

Without shaping, the feedback will be very bad, and the pulse width will probably go to max, and maybe kill the mosfets.

If the mosfet board is ok, it will run if your outputs are as you say, and there is no poor joints in your cables etc.

For anyone else looking.... do not run these things under voltage, as they will drive the pulse width to max, and this may be too much for your fets.

I have only ever had these fault if the battery volts were allowed to sag too far... never from overload etc etc. 

Your wave form tells me it was all going fine.... until you starved it.

Fix and go again, but use decent batteries and decent battery leads... or don't use loads over say 100 watts, until you do have big cables and a low impedance battery.


.......oztules

[Phaedrus]

I had the batteries checked and was told that they are in "bad shape". I will be buying new batteries soon and check again.Spent 2 days ,changing MOSFETS,control cards and all sorts of other optimistic activities  .

Fix and go again, but use decent batteries and decent battery leads... or don't use loads over say 100 watts, until you do have big cables and a low impedance battery.

1)Is there a way to check the impedance of batteries in house? I think the guy who checked my batteries used some kind of similar equipment.
2)I think the maximum current draw permissible from a battery is related to the Ah(C) rating of the same.I am using "no maintenance",sealed lead acid batteries.What would be maximum permissible current drawn allowed ?Assuming my batteries have given up,it happened suddenly,without any gradual deterioration.Is this a normal failure mode?
3)The cable manufacturers,give the maximum current that the cable can support.Is it ok to use this figure or should it be de-rated by some percentage ?

I know much of these queries are google-able,but i thought i wiould still post here,to get advice from people who would have gone through the same issues.

Thanks a lot Oztules,for your great support!

[Phaedrus]

Another incomprehensible observation ( to me atleast),the clamp meter shows a totally wrong reading of the current.But with mains power and the same load,it showed the right value as calculated.

I know I am asking too many questions  .
Cheers!

[Dr_Zogg]

hi there,
all of my boards have arrived, woohoo.  (I got them through jlcpcb they were great to deal with)
i am ordering the last of the parts to fill them now and was wondering which package hy4008 fets were the ones to use?

https://www.aliexpress.com/item/Free-Shipping-100pcs-lot-New-original-MOSFET-HY4008-HY4008W-80V-200A-TO-3P-inverter-Ultra-chip/32846471345.html?spm=2114.search0104.3.203.2ef64770KdUZti&ws_ab_test=searchweb0_0,searchweb201602_2_10152_10151_10065_10344_10068_10130_10342_10547_10343_10340_10548_10341_10084_10083_10618_10307_10131_10132_10133_5711215_5722313_10313_10059_10534_100031_10103_10624_10623_10622_10621_10620_10142,searchweb201603_25,ppcSwitch_7&algo_expid=c150d705-fba1-4fce-87b2-8eedbc2ae4db-31&algo_pvid=c150d705-fba1-4fce-87b2-8eedbc2ae4db&priceBeautifyAB=0

OR

https://www.aliexpress.com/item/Free-Shipping-50pcs-lot-100-new-imported-original-HY4008P-HY4008-TO-220-FET-80V200A/32830267684.html?spm=2114.search0104.3.191.2ef64770KdUZti&ws_ab_test=searchweb0_0,searchweb201602_2_10152_10151_10065_10344_10068_10130_10342_10547_10343_10340_10548_10341_10084_10083_10618_10307_10131_10132_10133_5711215_5722313_10313_10059_10534_100031_10103_10624_10623_10622_10621_10620_10142,searchweb201603_25,ppcSwitch_7&algo_expid=c150d705-fba1-4fce-87b2-8eedbc2ae4db-29&algo_pvid=c150d705-fba1-4fce-87b2-8eedbc2ae4db&priceBeautifyAB=0

thanks heaps for your help and time.

Cheers,
            Sam

[Madness]

The 3P version has heavier legs, thats the first option you posted.

[Dr_Zogg]

Thanks for that.
I was thinking it would be better to go the beefier package.

Cheers,
            Sam