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Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429
Posted: 05:57pm 04 Feb 2018
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I am photographing and doing notes on this particular OzInverter build, and this will be in the new rewrite of the OzInverter Book.
This is about as Big as I can safely go with the toroid at 51kg, which is just about manageable when your on your own, and as big as I can go without special considerations for the toroid damaging itself due to its own weight.
After due consideration over the past couple of years or so, the smaller 6kW OzInverter has plenty of operating/leg room and will actually run at 6kW, so doing the big OzInverter no longer makes sense for the extra work involved.
I will post pics as I go.......
The hardware all in and fixed and the OzInverter is ready for final wiring up.
Everything is possible, just give me time.
3 HughP's 3.7m Wind T's (14 years). 5kW PV on 3 Trackers, (10 yrs). 21kW PV AC coupled SH GTI's. OzInverter created Grid. 1300ah 48v.
Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429
Posted: 05:59pm 04 Feb 2018
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HHmm not having much fun posting images.
Everything is possible, just give me time.
3 HughP's 3.7m Wind T's (14 years). 5kW PV on 3 Trackers, (10 yrs). 21kW PV AC coupled SH GTI's. OzInverter created Grid. 1300ah 48v.
Boppa Guru Joined: 08/11/2016 Location: AustraliaPosts: 814
Posted: 07:21pm 04 Feb 2018
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I had no issues a little while ago- doing it right?
from your computer or from a website?
Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429
Posted: 07:34pm 04 Feb 2018
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....
I use these steel enclosure cabinets, 60cm x 50cm wide and 30cm in depth.
They come with an internal back plate and two access panels top and bottom, I drill these out to match the fans, add silicone glue insect stainless steel mesh on the inside.
The two panels .....
The toroid base mounting plate and the toroid fan arrangement .......
Its a wide/large diameter and takes up 280mm of my 300mm depth. .......
The Pics have posted, I just was not getting the first Image box once you select 'upload image.
Now to do the 3 turns on my large ferrite E core and hard wire stuff in.
Top right inside the box, there is a small panel with a red button for re-set for the OzControl board, and a small toggle switch for switching in the 40ohm resistor on initial power up that dribbles into those 6off big capacitors. Wait a few minutes then I switch on the main battery breaker, then switch off that 40ohm resistor.
There is 9 of those 20amp 230vac EMI filters.
OzCooling board with its PSU above. It takes 48vdc and gets it down to 12vdc. I will also use that PSU 12vdc for the front door monitoring display/controls.
Edited by Clockmanfr 2018-02-06Everything is possible, just give me time.
3 HughP's 3.7m Wind T's (14 years). 5kW PV on 3 Trackers, (10 yrs). 21kW PV AC coupled SH GTI's. OzInverter created Grid. 1300ah 48v.
Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429
Posted: 08:03pm 04 Feb 2018
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....
The 40a RCD for the 230vac out.
A few more holes to drill in the side for cable glands.
Edited by Clockmanfr 2018-02-06Everything is possible, just give me time.
3 HughP's 3.7m Wind T's (14 years). 5kW PV on 3 Trackers, (10 yrs). 21kW PV AC coupled SH GTI's. OzInverter created Grid. 1300ah 48v.
Boppa Guru Joined: 08/11/2016 Location: AustraliaPosts: 814
Posted: 08:04pm 04 Feb 2018
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Jeez thats a monster of a transformer- wall hanging the whole lot would be a right pain!!! Very nicely done tho
Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429
Posted: 08:29pm 04 Feb 2018
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Yes 'Boppa', I allways advice that the unit is wall mounted with some sturdy metal under mounts.
These are for the 6kW....
Case/enclosure Top and bottom brackets......
Edited by Clockmanfr 2018-02-06Everything is possible, just give me time.
3 HughP's 3.7m Wind T's (14 years). 5kW PV on 3 Trackers, (10 yrs). 21kW PV AC coupled SH GTI's. OzInverter created Grid. 1300ah 48v.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 08:46pm 04 Feb 2018
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Great pics of it going together. This site needs a like button.Cheers Caveman Mark Off grid eastern Melb
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 09:26pm 04 Feb 2018
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What power are you getting with this bigger Toroid? I have found with the smaller cores normally used that 8KW is no problem with the extra copper that I added giving 8 & 70 square MM.There are only 10 types of people in the world: those who understand binary, and those who don't.
Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429
Posted: 07:32am 05 Feb 2018
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Hi Madness,
Its happy with 8kW all day, that's if your batteries will stand being sucked at that rate.
This particular BigOzInverter will probably rate at 10kW, but I have not really tested one through yet so I can not definitely say. As normally once they are working quick 24hr soak test, then out they go.
I think that when Off Grid systems get that big, then they are mostly installed by solar installers/electricians, and going on my own experiences with some good honest sparkys,!!! ..... "I just install the stuff and make 20% on the equipment then the installation time charge, and if anything goes wrong, I blame the manufacture and not me, I just stick to what the manufacture says."
So all those retailers/installers are highly unlikely to recommend the OzInverter, and looking at a few retail, so called RE world wide Forums, I am tolerated on them, but talk about the benefits of the OzInverter, then my postings are deleted by the moderators.
Hence me seeing little future for a BigOzInverter.
And more importantly the AC coupling changes everything, as we get the GTI's to put into the OzInverter created 230vac mini grid, so most of the time the batteries are not being hammered.
And thinking that further, if we have a 6kW OzInverter the battery size just needs to be sufficient for those dull PV/no wind days, if you have wind power. So huge battery packs become a thing of the past.
My secondary is 16mm/2, and brakes out to 3off 6mm/2 where they connect to the EMI filters that are good to 60amp at 230vac. Mark , Note that Blue coloured sense coil on the 16mm/2 secondary. The primary is 75mm/2, (I see that I can not get 75mm/2 any more all my suppliers have only 70mm/2).
Me beating the c..p out of the 75mm/2. with my winding table clamped to the back of a flat bed trailer so it does not move but gives me space to move that long cable about.! Yep 75mm/2 is the max for that.!
Edited by Clockmanfr 2018-02-06Everything is possible, just give me time.
3 HughP's 3.7m Wind T's (14 years). 5kW PV on 3 Trackers, (10 yrs). 21kW PV AC coupled SH GTI's. OzInverter created Grid. 1300ah 48v.
johnmc Senior Member Joined: 21/01/2011 Location: AustraliaPosts: 282
Posted: 05:51am 20 Feb 2018
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Good day Clockmanfr
The new inverter looks the part, I have made a similar sized inverter with your boards , using 24 HY4008 fets and the IR2110 drives but there seem to be a problem driving the fets ( blown the 12 highside fets).
Are you using genuine fet drivers or chinese look alikes?
The sine wave form is good under no load as well as under a 3kw load, also the inverter no load current is 50w.
cheers john
johnmc
Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406
Posted: 06:11am 20 Feb 2018
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That deserves a nomination for the Rambo "balls of steel" award. Cheers, Tony.
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 06:15am 20 Feb 2018
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IR2110's from RS Components are about $5 each from memory.There are only 10 types of people in the world: those who understand binary, and those who don't.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 06:34am 20 Feb 2018
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Reckon I'll fling my Chinese ones over the fence and get some of the RS ones just for insurance. Thanks Mad Cheers Caveman Mark Off grid eastern Melb
Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429
Posted: 08:03am 20 Feb 2018
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Yes, always best to get the best genuine components if you can, or soak test what you do get. Although I have had some fake stuff from a so called reputable supplier.
Those driver chips, if genuine seem okay, but there may be an issue with driving those 4008 24off FET's, but I am not really that much of a bright spark on those kind of issues, if it works then great I leave it alone!
I did notice that 'Oztules' did bring his latest Power board down to fewer FFT'S when using 4008's so maybe his normal testing methods were not applicable. In all his nearly 200,000 words on the OzInverter stuff, I do not recollect any Driver chip issues with our particular OzInverter designs.
Not having much spare time here, very very busy, so this particular BigOzinverter and book update will have to wait a few weeks. sigh!
Edited by Clockmanfr 2018-02-21Everything is possible, just give me time.
3 HughP's 3.7m Wind T's (14 years). 5kW PV on 3 Trackers, (10 yrs). 21kW PV AC coupled SH GTI's. OzInverter created Grid. 1300ah 48v.
noneyabussiness Guru Joined: 31/07/2017 Location: AustraliaPosts: 513
Posted: 06:48pm 20 Feb 2018
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I actually have had 2 bad batches of ir2110's personally... you have to be careful and as clockman said soak test everything.I think it works !!
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 08:55pm 20 Feb 2018
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Oztules said to me that his experience with the IR2110's is that if they work initially they just keep working.
However, I have to wonder if the cheap ones have as much grunt as they should. If that was the case though it would result in slower turn-on of the MOSFETs which would show up as more heat in the FETs than there should be. I have had a few times where at idle a PCB has got extremely hot in a minute or so. At idle the FETs should stay cool no heatsink at all.
One thing to look for on the CRO is that there is a clean transition from off to on, no trace from 0 to on voltage just a blank gap in between, at that is what I get on my CRO.There are only 10 types of people in the world: those who understand binary, and those who don't.
renewableMark Guru Joined: 09/12/2017 Location: AustraliaPosts: 1678
Posted: 09:15pm 20 Feb 2018
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Can you just leave off a few 4008's off the board since they can handle more?Cheers Caveman Mark Off grid eastern Melb
Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498
Posted: 09:29pm 20 Feb 2018
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Yes, put 1 in each leg if you want for testing, or as many as you want, no need to take out gate resistors and diodes if they are already there.There are only 10 types of people in the world: those who understand binary, and those who don't.
noneyabussiness Guru Joined: 31/07/2017 Location: AustraliaPosts: 513
Posted: 10:59pm 20 Feb 2018
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The first batch that were bad actually did just that, it would run 1 per leg no worries. . Thinking all was good would put 6 mosfets per leg (to220's) and it would ether blow a/all banks at turn on or run stupid hot at idle... of course replace 6 with 1 and check waveform... perfect. ... did that a few times until i cottoned on that something was a miss... i accidently fixed it building a new one and ordered new everything just to be sure...
Turned out the current the dodgy ir2110s was enough for 1 gate, but no where near enough for 6, and being a toroidal transformer ANY change in frequency etc would be really hard (read catastrophic) to the mosfets..I think it works !!
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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