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brucedownunder2 Guru Joined: 14/09/2005 Location: AustraliaPosts: 1548
Posted: 11:37am 12 Apr 2014
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Hi Crew , I have a big 48v inverter wired into my system ..
It was drawing approx 230 watts ,just in the stand-by mode-not good.
So, along with the help of some very smart guys on the 'energy-matters" forum ,a few of us decided to try and modify these "power-hungry" inverters..
Most of the guys from this other site are very familiar with the Backshed and ,some are actually original members here.
OK, so, after a few months of fiddling and hospital stays, I finally finished the "conversion"
Guess what , I now draw approx 23 watts on standby--Thats a 10 fold reduction in standby power ,plus the 23 watts is all that is added to any load I now draw from the inverter..
basically, the "Toridial" transformer and the "squarish choke" is the parts I've added,discarding the original big heavy transformers..I rewound the "Toridial" transformer, thats 25mm square primary winding in Green you can see.
There is lots of "other" parts to this story ,but I'll wait and see if anyone is interested..
bruceEdited by brucedownunder2 2014-04-13Bushboy
Bryan1 Guru Joined: 22/02/2006 Location: AustraliaPosts: 1345
Posted: 01:05pm 12 Apr 2014
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Well done mate, great to see you got it finished and working
M Del Senior Member Joined: 09/04/2012 Location: AustraliaPosts: 155
Posted: 10:02pm 12 Apr 2014
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Well done Bruce, that's an extra 6kwhr a day to play with if my thinking is correct.
I take it there is a little more than the rewire of the toroid and the choke.
I am very interested in the details of your mods as I am looking at a standalone system myself and the more info the better, especially if I end up with a hungry inverter. Mark
brucedownunder2 Guru Joined: 14/09/2005 Location: AustraliaPosts: 1548
Posted: 10:35pm 12 Apr 2014
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Thanks Bryan ,you have allways been a support to us guys on the back shed..
M. Del ,, first up mate, get a real name , like bill, jack, anything but "Sue".lol.
OK, not much in the electronics Dept. ,just getting the Toridial from a "inspire" grid tie solar inverter was the first thing, around $80 delivered.... strip it out of the box , strip the outer secondary winding off , and replace that with the huge 25mm winding that is now the primary..,about $20 from the scrap dealer.
Go to "energy matters" forum and look at the 61 pages of what we did -- takes at least an hour.
She's up and going been all day just consuming a mere 25 watts odd of internal power.
..
BruceBushboy
Tinker Guru Joined: 07/11/2007 Location: AustraliaPosts: 1904
Posted: 04:26am 13 Apr 2014
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Bruce, just out of curiosity: Normally toroidal transformers are held in place by a central bolt and large disk on top. There is no room for such a bolt with your conversion so how do you keep that big heavy thing in place?Klaus
brucedownunder2 Guru Joined: 14/09/2005 Location: AustraliaPosts: 1548
Posted: 10:29am 13 Apr 2014
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Hi Klaus,
You are right,there is no room at all ..It was very hard to pull,push the cable through around the last 10 turns.. And, this cable was not the muti strand super flexable cable that most electronics projects are used to.
The bolt --- Thats why i made that semi-circular waste water pipe support-Think it's a cut off from 300mm plastic pipe.
The finished Transformer weighs in at around 13-15 Kg's , so actually when she's sitting in place , she's not going anywhere . i didn't even use cable ties , just the ends of the stiff cable bolted in place kept it fixed.
Oh, M Del , sorry mate,, you can keep your name, i was just in a happy mind at the time.
You all have a good week
bruceBushboy
M Del Senior Member Joined: 09/04/2012 Location: AustraliaPosts: 155
Posted: 06:23pm 13 Apr 2014
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Hi Bruce,
Started reading the thread in energy matters, how many were modified all up?
I normally add my name at the end of posts, must spend some time to work out how to auto add it;)
Mark Mark
Tinker Guru Joined: 07/11/2007 Location: AustraliaPosts: 1904
Posted: 11:36pm 13 Apr 2014
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Hi Bruce,
I gathered that's what that semi circle thingie might be for, just had to ask So, weight is holding it there and its not some equipment you have to move around. But, does it hum or buzz when going?
I have not yet looked up the messages you mentioned on another forum as I'm only generally interested in what you did there. Earth wire might be cheap but has excessive stiffness for such a job - as you found out .
How many volts are in that winding?Klaus
brucedownunder2 Guru Joined: 14/09/2005 Location: AustraliaPosts: 1548
Posted: 12:19pm 14 Apr 2014
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Hi Klaus and Mark,
The humming , The "e" core ferrite former is in 2 parts , when together and passing current there could be a bit of hum, but mine is minimal,barely noticable at more than 200 watts.
No hum from the Toridial transformer at all.
Wire -- this transformer is capable of delivering up to 8Kw. So, with a 48v supply ,thats why the big primary winding- next time , i would buy welding wire ,it's more friendly in the bending dept.
Volts. the primary has 30 volts ,when the secondary is fed with 240vac.
Actually , around 1 volt per turn through the centre = 30 turns.
Thats about it - this power hungry inverter problem is fairly widespread, possibly this project will encourage others to have a serious look at the power they are wasting.
BruceBushboy
domwild Guru Joined: 16/12/2005 Location: AustraliaPosts: 873
Posted: 01:10pm 24 Apr 2014
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Bruce,
Well done, congrats! Must have read this story before, perhaps on Otherpower. For one inverter brand, which has been converted multiple times there is even an Aussie agent who managed to convince the Chinese factory to modify their wasteful design. Taxation as a means of achieving prosperity is like a man standing inside a bucket trying to lift himself up.
Winston Churchill
brucedownunder2 Guru Joined: 14/09/2005 Location: AustraliaPosts: 1548
Posted: 12:08pm 26 Apr 2014
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Hi Dom, That Aussie Agent , could you send me his location/Etc. Would be interesting to find out if the Chinese are really going to change their design ..
So simple, just a huge Toridial plus a choke -no other mods required at all .
BruceBushboy
yahoo2 Guru Joined: 05/04/2011 Location: AustraliaPosts: 1166
Posted: 03:00pm 27 Apr 2014
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Tip my hat to you Bruce,
I got offered one of those inverters cheapish and said thanks but no thanks, I may have been tempted if I had a decent toroid laying around gathering dust. I'm confused, no wait... maybe I'm not...
brucedownunder2 Guru Joined: 14/09/2005 Location: AustraliaPosts: 1548
Posted: 10:14pm 27 Apr 2014
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Hi Yahoo, thanks for the compliments ,, it was bloody hard work winding that 25mm hard drawn earthing wire +plus it's insulation around ,in and out , of that huge donut transformer.LOL.
It was worth it , and I'll help any of you that want to do the conversion.
She's working perfectly ,, .
BruceBushboy
Wombat Regular Member Joined: 27/05/2011 Location: AustraliaPosts: 72
Posted: 03:47am 28 Apr 2014
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Hi Bruce
Job well done! I have a 3000W/24V Powerstar with much
the same problem.
I'm happy to hear more people are modding them now.
I just may take up the challenge myself.
Found a 80VA 2x12V toroid on Ebay for $72.
don't know if its usable... more reading required.
Notice. New forum software under development. It's going to miss a few functions and look a bit ugly for a while, but I'm working on it full time now as the old forum was too unstable. Couple days, all good. If you notice any issues, please contact me.
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