Posted: 10:55pm 04 Jan 2016 Copy link to clipboard Print this post

This may interest those toying with making a low frequency pure sine inverter.. of whatever
voltage you choose for input and output.
Guru
This will be fairly brief, as it is experimental at this stage.
Joined:
26/07/2007 This involves a EGS002 board which can be had for around the $7 mark on aliexpress and ebay.
Location:
Australia
Posts: 1686 The test board looks like this.. a simple dual voltage output stage to keep the volts to 12v and 5v
for the EGS002, with a transistor for the main step down voltage stage.
The card, a CT etc.

I made a quick h bridge to use for the initial test, but designed the control card to interface with the
PJ power board.. it has the caps and heat sinks already.

The down and dirty H bridge is this: ( your allowed to laugh)

Once that found out a few flaws ( voltage regulator went west for no apparent reason ) we then
plugged it into the PJ board.

The PJ had only 1 mosfet per leg... now there's confidence ( less to replace ) like so:

The fired it up, with a 40w load.. it was the only filament thing in the place....so it was pressed into
service...
Well it worked..

The voltage control went from 68acv to over 260vac. Transformer was 32:240v.

The temp probe was heated up, and the unit stopped, restarted 8 seconds or so later, the current
transformer will have to wait until I have it connected to the battery bank, and a big transformer
attached.

Suffice to say I was pleased to see it running at all.. didn't expect it to be so easy I must admit.

Fets stayed cold ( touching the front of them, there was no heat...... so....

Put 2x 560r 20w ceramic resistors as well as the load.

Unit started smoothly, constant frequency, and soft start voltage... straight to the 240v mark....
nice so far.

Ran for a few minutes, until the load resistors started to smoke....checked the fets, and with 240
watts, the temp was barely warm on the front of the fets... so I guess that 600 or more watts on a
single h bridge is well within reach... but my 56v power supply was topped out at 300w... so that
will have to wait until I get it all better resourced.

The wave looks like this:

It didn't change even as I dropped the load on off on off etc.... until I got tired of trying to fool it.

I am hoping that this translates into the high power phase as well, we'll see.

It is looking promising.

Next step is to put 6 fets on each leg, and see how the switching transitions degenerat, or if the
drivers can handle it nicely without further conditioning... I live in hope.... but not confidence.
 I would prefer to use galvanically isolated supplies for the high side drivers, rather than the pump,
and if this is necessary, will probably end up just buying the chips, and designing the power
supply with pwm for the drives and logic separately. and then driving with high current totems....
but we'll see.

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

Village idiot...or... just another hack out of his depth

Gizmo
Posted: 11:50pm 04 Jan 2016 Copy link to clipboard Print this post

Nice work Oz.

Admin Group I did order in one of the EGS002 boards, but haven't taken it any further yet.

Joined: Glenn
05/06/2004
Location:
Australia The best time to plant a tree was twenty years ago, the second best time is right now.
Posts: 4859 JAQ

oztules
Posted: 01:12am 30 Jan 2016 Copy link to clipboard Print this post

Problem i found is that the PJ works so well, that you lose the desire/drive to make another one....
the pj just works so well, there is little to improve ( the converted units like ours.... not the
Guru originals.....)

Joined:
26/07/2007 I bet if you had not made a reliable PJ conversion, you would have done this already
Location:
Australia .............oztules
Posts: 1686
Village idiot...or... just another hack out of his depth

oztules
Posted: 02:05pm 11 Feb 2016 Copy link to clipboard Print this post

Been very busy with other stuff, but got a chance to do a few hours with this thing.
Wound a small 3kw torroid.
Guru put in another fet in the h bridge legs.
we ended up with this little beauty.
Joined:
26/07/2007
Location:
Australia
Posts: 1686
Thats an oven element with about 2100watts.

The heat sinks stayed pretty cool over the 10 min test.

voltage was stable... very stable.

..............oztules
 Village idiot...or... just another hack out of his depth

Clockmanfr
Posted: 11:10pm 11 Feb 2016 Copy link to clipboard Print this post

That looks like a nice circuit you have put together with that driver board.

The PJ Board reliance does concern me, but now you are pushing the boundaries again, I can
sleep a little bit better.
Guru

My life has certainly changed, thanks to the 'oztules' endeavour's.

Joined:
23/10/2015
Location: PS, Book will be 84 pages, 100 odd colour photographs and drawings, A4 size, about 20,000
France words. At present, mornings and evenings, when its dark, I am formatting the pages at page 41
Posts: 344 today.

Everything is possible, just give me time.

3 HughP's 3.7m Wind T's (12 years). 5kW PV on 3 Trackers, (8 yrs). 9kW PV AC coupled SH
GTI's. OzInverter created Grid. 1300ah 48v.

frwainscott
Newbie Posted: 04:29pm 13 Feb 2016 Copy link to clipboard Print this post

Joined:
I have A question that I could use some input on, If your using A 220 center tap transformer for
04/01/2016
Location: 220 and two 110 circuits would you reference the 220 or 110 and if you reference the 110 which
United States leg would you reference? I have A EGS002 board im going to start playing with as soon as I can
Posts: 3 find everything,since I just moved. Also, would it be more trouble than its worth to revamp a 12/24
volt board for 48 volts? Thanks..... Frank

oztules
Posted: 09:13pm 13 Feb 2016 Copy link to clipboard Print this post

Frank
Guru I would use the 220v as the reference.
The boards have no preference for DC voltage. It is up to you to provide the 5v and the 12v for it's
Joined: operation... thats all.
26/07/2007 So it is only your transformer and fets that have to match the load.. ie 48v is lower current fets,
Location:
and higher voltage, and conversely fore 12 and 24v.
Australia
Posts: 1686
You can in theory just use taps on the primary to go from 12 to 24 to 36 to 48 or 96 or whatever
you want.

As an aside, the current regulation using a torroid is dangerous to the fets. The EI transformers
have enough leakage to sustain switching changes.. the torroids don't.

So I had no trouble with the EI, but the torroid blew/exploded the fets the moment I fiddled the
current pot to get it to limit.

I may just end up buying the main chip and crystal, and go from there I think in the end..... not
sure just yet... or maybe use a nano micro to take care of house keeping, and just use the board
for pwm.

.......oztules
 Village idiot...or... just another hack out of his depth

frwainscott
Newbie Posted: 05:08pm 15 Feb 2016 Copy link to clipboard Print this post

Joined:
Oztules
04/01/2016
Location:
United States Thanks for the reply, im way in over my head here but after envisioning it in my head I could see
Posts: 3 that using the 220 for reference is the way to go. I need to find a program for experimenting so i
dont waste so much time. Any suggestions?
Thanks, ... Frank

mason

Posted: 02:55am 16 Mar 2016 Copy link to clipboard Print this post

Regular Oztules, could you post what components you used for your simple dual voltage output stage
Member circuit, for all the novice techs here.

Joined:
07/11/2015 thanks
Location: Billy
Canada
Posts: 67

yahoo2

Posted: 01:12pm 16 Mar 2016 Copy link to clipboard Print this post

Guru there has been some interesting developments in the last few days testing the egs002 you can
have a sneak peak, hoping oz will post it here once the dust settles.
Joined:
05/04/2011
I'm confused, no wait... maybe I'm not...
Location:
Australia
Posts: 1166

oztules
Posted: 11:16am 17 Mar 2016 Copy link to clipboard Print this post

Yes it is significant, and really a game changer for folks that want to roll their own.
I have not seen anything that will surpass the performance now, even the big selectronics can do
Guru no better, and in fact worse with some loads that use phase switching..... and long run high power
periods.
Joined:
26/07/2007 Will get the story going here when it is further refined....I can't make it work any better, as it is
Location:
everything I could ask for now, but I want to reduce it to it's minimum, and have no 002 board
Australia
Posts: 1686 involved also, so it is independent of manufactures whims.... plug in chips, and a true remote area
solution, where everything can be fixed on site easily

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

Village idiot...or... just another hack out of his depth

oztules
Posted: 01:32pm 17 Mar 2016 Copy link to clipboard Print this post

I forgot to give mason the stuff he asked for.... try this:

Guru well that didn't work as it is a png file so go here:
Joined: http://www.anotherpower.com/board/index.php/topic,1116.msg11457.html#msg11457
26/07/2007
Location:
Australia ...........oztules
Posts: 1686

Edited by oztules 2016-03-18

Village idiot...or... just another hack out of his depth

mason

Posted: 02:09am 18 Mar 2016 Copy link to clipboard Print this post

Regular
Member
Oztules, thanks for sharing all your work.
Joined:
07/11/2015
Location: Mason
Canada
Posts: 67

yahoo2
Posted: 01:53pm 21 Mar 2016 Copy link to clipboard Print this post

Oz, reading your egs002 thread on anotherpower, I am interested in the comments about the
Guru 4110 fets (mainly because I am avoiding having a go at building the PCB )

Joined:
05/04/2011 How are you testing the aftermarket TO-220 4110 fet? Is it a precise test to grade them into
Location: matched sets or just weed out the real smokies.
Australia
Posts: 1166 are you passing 10 amps @ ?? volts and measuring the RDS ON mOhm value with the fet cold?
20A @ 5V ?
10A @ 97V for a voltage test?

I have seen some old tests on genuine IRFB4110 Fets, 20 amps @ 5Volts and let the case
temperature settle at 86C after a few minutes. They all measured very close to 15 mOhm.

I assume you haven't made a test jig and it is alligator clips or clamps to hook-up the fet.

Do they come in a static bag when you get them?

I'm confused, no wait... maybe I'm not...

oztules
Posted: 11:45pm 27 Mar 2016 Copy link to clipboard Print this post

Sorry Mason, didn't see this

Yes 10A with gate source of 12v and measure the mv and calculate.
Guru It is a quick test to sort same with same.

Joined: Should get 3-4mo.... usually 3-6mo.

26/07/2007
Location:
Voltage has never been an issue and don't test for it.
Australia
Posts: 1686
I use the old computer power supplies converted for current and voltage.
Edited by oztules 2016-03-29
 Village idiot...or... just another hack out of his depth

oztules
Posted: 12:00am 28 Mar 2016 Copy link to clipboard Print this post

Pic of todays paper print out for the board etch

Guru

Joined:
26/07/2007
Location:
Australia
Posts: 1686

Then the copper with pattern from the kinston

Then the boards ( twin )

and the back

and the pcb in the program

Worked first up... always good.

Simply amazed at the simplicity of these things, and the sheer power you can call up if you have
the fets and transformer to suit.... very solid so far after week or more running the house. Two hrs
a day at at lest 2.5kw, surges of over 7kw ( seen 9kw too).

How they can be so simple and work so well I don't know.

Next step is only the 8010 and board to suit.

BOM from the program may help

"","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"

Hope this helps someone

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