OzInverter, 6kW -15kW, PSW, 50HZ/60HZ. Update Info.
‘Make your own 6kW-15kW Pure Sine Wave OzInverter, 48vdc to 240vac/120vac, 50HZ/60HZ'.
The new PCB's, 'OzControl No12', the 'OzCooling', and the 'Power Board' are now very well tested around the World.
I will post the Gerber Files, RS-274X, for the 'OzControl' and 'OzCooling' Board, and parts/components lists for all the PCB's.
I am also rewriting the OzInverter book to implement all the latest information, especially intergrating the 15 page supplement about making the PCB boards, copper masks etc. And a mention of the 60HZ, (pin18 to +5v) and the split secondary for 120vac for North America , and if enough demand, a new OzControl board for the 60HZ..
Catch up.
Over the years I have purchased several well-known manufactured Inverters, all of which are not ideal for general normal use.
In 2014-15 with help from 'Oztules', a real nice guy, I pushed Inverter technology backwards but went forwards with the latest driving control tech.
Firstly we use a toroid core, we stack them together and wind the core to our/ Oztules empirical calculations, depending on the core cross sectional area.
We use a decent size matched inductance on the Primary windings so that idle power use/loss comes down to about 38/40 watts for a real PSW 6kW Inverter.
The power board and the control board are designed for real harsh environments and manufactured with large tracks, large pads, to stop substrate separation and importantly all components are through hole type, so in the field repairs are relatively easy. Especially if you have insect/moisture infestation.
We also put all component values on the boards silk screen, so its "painting by numbers", and therefore very easy to repair without dragging out paperwork to find out what goes where.
We use the 8010 SMD chip, (the only SMD component) and run at 23.4KHz modulation frequency. We have several methods of soft starting the large toroid and this is a key issue. We have also all the normal things, like overtemp shut down and auto restart, etc and can be 50Hz or 60Hz.
In the end I produced a 'How to make a OzInverter' book as a non-profit basis, that's lists and shows everything. And we now also supply the bare Power Board PCB, OzControl Board No12 PCB and the OzCooling PCB as an extra option.
I have replied to questions from the third world, and have advised folk that these OzInverters could easily be manufactured in the thousands, if you have a good Engineer and EE and a good team of assemblers.
In the future I might explain to my young teenager boys what's what, and produce a kit of parts. Manufacturing them myself for resale in this day and age and this present Western culture is a NO NO, just far too many blasted hoops to jump through.
I say, ………. keep it 'Simple', make it 'Robust', and importantly keep it 'Cost Effective'.
Costings. Using new components etc, about $600, scavenging cores, cases, cable etc as low as $250.