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Forum Index : Electronics : 8 KW Inverter Build
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Madness Guru  Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
I am talking about the sharp 90 degree bends already in the wire from the corners of the toroid, only way I have found to get them out is to use Oztules method with 3 ball bearings. There are only 10 types of people in the world: those who understand binary, and those who don't. |
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mackoffgrid Guru Joined: 13/03/2017 Location: AustraliaPosts: 460 |
Thanks Madness, Oz, Warp, Et al. I successfully made my primary cable using 19 strands and wrapped it with tape as Oz did. Transformer seems good but wont be able to do much testing - I'm pretty slow and life / other projects slow me even more. Cheers |
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| Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
Just received my order from PCBway for PCB's 7 days from order to having them in my hand. I have not had the chance to do anything more than look at them but they look perfect, they are in a whole different league to my home made boards.  Close up looks really good  This is the latest version of the Oztules control board  This my adaption of Oztules solar controller   There are only 10 types of people in the world: those who understand binary, and those who don't. |
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| Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406 |
[quote]They are in a whole different league to my home made boards.[/quote] Yes indeed, long gone are the days of messing around in the sink with ferric chloride or drilling all those nasty little holes. Cheers, Tony. |
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oztules Guru Joined: 26/07/2007 Location: AustraliaPosts: 1686 |
I don't know what happened to my control board when I finished it on the cap end... I did not check the board dimension I think.... makes no difference, but would have looked better with a few mm more perhaps. Looking good.... as expected..... just wondering of your red ones will run speedier than the blue ones  .........oztules Village idiot...or... just another hack out of his depth |
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| Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
Hi Oz, I cut a few mm off with the camera. Red ones go faster and are sexier. There are only 10 types of people in the world: those who understand binary, and those who don't. |
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Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429 |
I am green. Ha Ha! I still get stick, from the PCB boys, for painting by numbers.  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. |
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| Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
I just realised seeing your green boards I forgot to allow pads to solder the negative cable to the bottom of the power PCB. Didn't matter with no solder mask, no big deal I will just have to scrape off the areas where the cables attach. I put mine straight on the bottom so there are no holes required, leaves more copper on the top for the bridge too. There are only 10 types of people in the world: those who understand binary, and those who don't. |
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| Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406 |
Ah yes, green is for us energy conservative types. Red is for the more sensuous among us. Blue boards must be for the truly unhappy. And black boards only for the really bad guys... Your circuit boards say much about you. Cheers, Tony. |
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| oztules Guru Joined: 26/07/2007 Location: AustraliaPosts: 1686 |
My last lot I put a 15mm solder mask all the way across. Now I use a 12mmx6mm copper bus bar with threaded 6mm hole in the over extended end sticking out. I solder the bussbar to the circuit board, and still use the holes for mechanical fixing ( of the buss)as an adjunct.... this needs a gas torch or a lot of hot air gun to achieve a decent bond. .......blue oztules Village idiot...or... just another hack out of his depth |
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| Warpspeed Guru Joined: 09/08/2007 Location: AustraliaPosts: 4406 |
Sounds more like shipbuilding than microelectronics. But I like it ! Cheers, Tony. |
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| Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
I have a couple small refillable butane gas torches I bought from Aldi that are intended to be used in the kitchen but they are perfect for soldering heavy copper connections. I don't need to be green with my power most of the time, on a sunny day I can make 3 times the KWH's I need so I am only green in really cloudy weather, the rest of the time I am on full boar in the RED  There are only 10 types of people in the world: those who understand binary, and those who don't. |
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| brac321 Regular Member  Joined: 30/11/2016 Location: SloveniaPosts: 54 |
Any source for the usable 10000 uF 105 ºC caps? OffGrid 24/7: 250w black mono solar panels 6.4kWp, 1x Midnite Classic 150, 1x MorningStar MPPT 60, battery bank 840 Ah @ 48v, modified LF-8K inverter, DC/DC, hot water harvesting, etc. |
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| Solar Mike Guru Joined: 08/02/2015 Location: New ZealandPosts: 1138 |
I used these in a test inverter from Element14, at least you know what you are getting; however the best ones are those with screw terminals with very high ripple rating and low esr, not too expensive second hand ones can be obtained from old switch mode power supplies like 80,000uf 100volt that you can get from electronic equipment wreckers Casa Modular NZ, current inverter uses 2 in parallel. Tried the cheap chinese hunlo brands from aliexpress and they were mostly crap, some very leaky, ie draw 200 ma constant drain at 50 volts with capacity varing +- 60%, out of a bunch of 20, 4 or 5 were ok the rest are in the bin, very much hit and miss getting anything suitable on ebay or ailexpress, same goes for power mosfets, not worth the trouble, unless you are lucky... Cheers Mike |
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| oztules Guru Joined: 26/07/2007 Location: AustraliaPosts: 1686 |
Madness, I forgot to mention, that your new control boards have three changes to do . 1. the 1n becomes 22n ( near pin 16 2. the 4k3 becomes 1k 3. and this is more important.... the pin 6 on the 8010 needs to be heated up, and pushed through the board so it is on the top of the mini board. This becomes the on/off pin, the other two pins on the control board are +5v and gnd, so use a spdt switch for on/off. 4. your monitoring transformer will be different to my 14v one. I think a 12v one will use a 3k9 or similar instead of the 7k5. If you miss this it will be indeterminate as to being on or off and will feather between the two states. Will take a pic later on. .........oztules Village idiot...or... just another hack out of his depth |
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| Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
Okay, thanks, have not got to it yet, few other jobs have higher priority ATM. Trying to rewind a tiny transformer from one of my Trace inverters so I can get them sold. I wound one winding on but it is open circuit for some reason, maybe the Chinese 0.1mm wire I bought. There are only 10 types of people in the world: those who understand binary, and those who don't. |
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| Clockmanfr Guru Joined: 23/10/2015 Location: FrancePosts: 429 |
Thanks Oztules, I did wonder? About to update and test the latest OzControl board, now at Mk 12. Especially as winter starts to descend on Europe with shorter days, and the boys go back to school next week, so time to think. I actually have a few French folk wanting me to build OzInverters, its the AC coupling thing, and backcharging that's got them interested with the not so huge battery bank, and the low power use on standby for the OzInverter. At first they want the Big OzInverter, but a discussion about power use soon gets them to the 6KW OzInverter. And the stupidly low price of good quality GTI's available in this part of the world is a no brainer. Like..... http://www.ebay.co.uk/itm/SMA-SunnyBoy-SB2500-2-5kW-Inverter-/222602994335?hash=item33d42c229f:g:yyUAAOSwEW5ZeLwZ Note, ..... Even though I can set each GTI, Exact AC voltage switch out and 10 seconds before switching back in, each still behaves slightly differently. I much prefer using the smaller GTI's as then more control from the PV energy is possible. ie, I split a PV array to 2 GTI's a 1.2kW and a 3.8kw. The larger is always switching in and out with the sun intensity, state of battery with backcharging and power loads, the smaller is just about always on. So more small GTI's seem to give better control. Price is cheaper to boot. 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. |
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| Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
With control over the GTI a bigger unit should be fine, it will ramp up or down as required. There are only 10 types of people in the world: those who understand binary, and those who don't. |
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| Madness Guru Joined: 08/10/2011 Location: AustraliaPosts: 2498 |
I know you are busy man Oz but any chance of getting the photo you mentioned? There are only 10 types of people in the world: those who understand binary, and those who don't. |
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| oztules Guru Joined: 26/07/2007 Location: AustraliaPosts: 1686 |
sorry Mad, just cant seem to find the camera.....lost in space.... hopefully it turns up soon. Which part are you unsure of? ..........oztules Village idiot...or... just another hack out of his depth |
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