Author Topic: Building a 6kw pure sine wave inverter using power jack boards part2 the guts..  (Read 38362 times)

0 Members and 1 Guest are viewing this topic.

dgd

  • Jr. Member
  • **
  • Posts: 68
  • Country: nz
  • Never do today what can be done tomorrow
    • Lory Link
The html5 gauges web page listed in previous posting needs to be copied to PC then transferred and renamed to index.htm (not html) on the micro SD card. You windows PC should recognise the SD card and adaptor when plugged into a USB port, drive D or E.
This page is a good test for the Mega xml file output.. When copied plug into the microSD slot on the ethernet shield.

dgd
Off grid since 4/2000
Midnite C150,C250,Clipper, 2.8Kw PV, 2Kw turbine,1025Ah24v FLA (1999), SW3024E (1997), 3q16 48v300Ah LiFeYPO4 6Kw OzInverter, Arduino DUE web monitor.

frackers

  • Sr. Member
  • ****
  • Posts: 398
  • Country: nz
  • Is it finished yet?
The relevant simple web pages are stored on a micro SD card and when a web browser connects (up to 4 TCP connections with the Arduino Wiznet 5100 shield) the Mega wweb server serves the appropriate html5 web page.

The first page I plan to be a live data display where the various data items refresh every second of so. The server will use AJAX to serve XML files to the connected browser hence providing the live data display.
I'm not sure yet whether some sort of web analogue meter display would be useful such as the Classic gauges display shown below or maybe a nice graphics SVG style digital number display would be better, an example is in the second image below
Over time its probably feasible to have a 'skinned' display option with various display formats (html5 pages) available for user selection.

Any questions, suggestions or ideas welcome  :)
Has anyone created a nice OZ inverter graphic that could be used as a background image?

dgd

I love the graphical gauges - any chance of a version that uses json rather than xml ? - I find it so much more human readable for testing!!

It is how I interfaced to the webserver (mongoose + embedded app) on a wireless router that runs my irrigation system (https://github.com/g8ecj/irrigate) via a USB9097 USB to 1-wire adapter to talk to the hardware.

Not sure how I'll do the inverter monitoring - the current system (https://github.com/g8ecj/turbine) uses a serial connection to a wireless router and an SD card for stand alone operation but I have a version that can use an nrf2401+ module to send data over 3-400m on 2.4GHz band (I've been testing it on my tunnel house window opener system!!). I'll have a matching nrf2401+ (connected through a basic Arduino Nano clone) in the house that can poll the various outstations and prepare the ajax data.

I've just about given up on the wind turbine here - too much wind coming off the Alps too often (I'm on the Canterbury Plains) so I'll be concentrating on controlling the direct solar charge, a GTI or 2 and a system of on-demand circuits (well pump, swimming pool, irrigation) that use power on a priority basis when it is available.

Robin Down Under (Or Are You Up Over)

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate

have you downloaded the Arduino IDE to your pc or laptop yet?

Not yet, should I follow this?.......... https://www.arduino.cc/en/Guide/Windows

connected the Mega via its usb cable to a pc usb port and checked its working?

Yes the green led is on near that push button and red/amber led is flashing about 3 to 4 times a second.

The html5 gauges web page listed in previous posting needs to be copied to PC then transferred and renamed to index.htm (not html) on the micro SD card. You windows PC should recognise the SD card and adaptor when plugged into a USB port, drive D or E.

Hmm, okay I said I was dim with this stuff, ......... but how do I get that code of yours from this forum earlier post of yours, onto that SD card, yes the PC see's it, but its blank, although I have created a folder on the SD card and named it index.htm.

This page is a good test for the Mega xml file output.. When copied plug into the microSD slot on the ethernet shield.

dgd

Is the Ethernet shield connected on top of the Arduino card/board and powered up.?


Regards PSU, 48vdc to 5vdc, many thanks regards using a Car 12v cigar lighter to a 5v USB adapter, NEAT that you found that the Arduino does not get so hot with the USB cable connection.......

I use these ........ see photo...... fLeebay, but they are reliable and I have several running permanently nearly 5 years now on my trackers circuits and actuators, and so far no failures. I also use them on the Ozinverter I use 12vdc to run Oz's double cooling circuit, 2 fans with the PJ boards and 2 fans for the toroid.

The car 12vdc to USB adapter 2 amp type I have ordered, awaiting the next couple of days for this.

Bare with me dgd, as I learn to walk.
« Last Edit: March 05, 2016, 03:59:38 AM by clockmanFRA »
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

dgd

  • Jr. Member
  • **
  • Posts: 68
  • Country: nz
  • Never do today what can be done tomorrow
    • Lory Link
Clockman,
yes that link should get you started with downloading the Arduino development tools (IDE), I think the latest is about version1.6.7
The Mega is working, thats the power led and all Arduinos come with a 'blink' program pre-installed and that is it running and blinking that other led.
highlight the html file from previous posting, double click at start of first line and mouse down to end so its all highlighted then use Edit at top of windows screen to 'copy'
Then open Notepad to create new file and using Edit button at top of Notepad window hit Paste and the html file will
appear in Notepad window. Save as index.html is whatever directory you want. Last check it visually that there are no broken lines etc. Last copy to index.htm on SD card in drive e: (or whatever it is)
That is a proper DC to DC converter you have, should be jsut for the Mega

dgd
Off grid since 4/2000
Midnite C150,C250,Clipper, 2.8Kw PV, 2Kw turbine,1025Ah24v FLA (1999), SW3024E (1997), 3q16 48v300Ah LiFeYPO4 6Kw OzInverter, Arduino DUE web monitor.

dgd

  • Jr. Member
  • **
  • Posts: 68
  • Country: nz
  • Never do today what can be done tomorrow
    • Lory Link
I love the graphical gauges - any chance of a version that uses json rather than xml ? - I find it so much more human readable for testing!!
I used XML because there are so few actual data items transferred via AJAX that imposing a record structure and using JSON didn't seem worth the effort (minimal as it was!)
I agree a json format test file is probably easier to deal with. However, I never actually bothered making a test data file, just went straight to using output from Mega.
Now that I have developed a DUE based server for multiple Midnite Classic and Kid controllers a json/Ajax data xfer is looking a better choice.  :D
Also js Highcharts and HighSstocks graphs deal easy with  json format data for some neat graphing options

Quote
  (https://github.com/g8ecj/irrigate
nice
Quote
Not sure how I'll do the inverter monitoring - the current system (https://github.com/g8ecj/turbine) uses a serial connection to a wireless router and an SD card for stand alone operation but I have a version that can use an nrf2401+ module to send data over 3-400m on 2.4GHz band (I've been testing it on my tunnel house window opener system!!). I'll have a matching nrf2401+ (connected through a basic Arduino Nano clone) in the house that can poll the various outstations and prepare the ajax data.
I like the Arduino C3300 2.4Ghz ethernet shield, essentially a wireless version of the Wiznet5100, so easy to setup and all support libs already in place via IDE.
WIth my Oz inverter I eventually want just a Mega using the SimpleModbusSlave lib to provide a modbus TCP and RTU(rs232) interface, even though there would probably only be a dozen or so useful data registers.
Then get data via wireless TCP into my Cubie RE monitoring/web server system.
With that setup I may never have to get out of this couch  ::)

Off grid since 4/2000
Midnite C150,C250,Clipper, 2.8Kw PV, 2Kw turbine,1025Ah24v FLA (1999), SW3024E (1997), 3q16 48v300Ah LiFeYPO4 6Kw OzInverter, Arduino DUE web monitor.

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Thanks dgd, on the SD card now, nice to find some use for Windows Notepad.

I will download the 86mg Arduino development tools (IDE) in the morning, when the boys are at school and my French satellite system here gives me good speed, otherwise I am waiting hours.
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Okay, got the software, (gave them/domated $10).

Followed the process etc, reminds me of the Old DOS days uploading CAD libraries,  and I uploaded the 'Blink' Sketch and got that working.

Spent sometime however, trying to find out how to stop the Blink, blinking. Did the close, did the Quit, but me thinks the 'Blink' sketch is now permanently in the Mega, until I do something about it. Which unfortunately I could not find any simple clear info on.

But getting there....
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

DamonHD

  • Administrator
  • SuperHero Member
  • *****
  • Posts: 3622
  • Country: gb
    • Earth Notes
Loading the next sketch will overwrite the blink sketch.

It's all there in Flash until you replace it!

Rgds

Damon

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Thanks Damon.

Loading the next sketch will overwrite the blink sketch.

It's all there in Flash until you replace it!

Rgds

Damon

They are very good at telling you how to get started. But, I like to know how to stop and go backwards. lol  :D
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

dgd

  • Jr. Member
  • **
  • Posts: 68
  • Country: nz
  • Never do today what can be done tomorrow
    • Lory Link
.. on the SD card now, nice to find some use for Windows Notepad.

Ok, so when the SD card is in its carrier and in you PC then open the SD card and double click on the saved file index.htm that you have just copied on to the mini SD card.
Your PC will recognize this as an html5 file and display it using its web  browser (IE9, firefox etc) then if the copy worked ok you should see the gauges page displayed on screen.
If its messed up or not displaying then you need to recheck tohe saved file for broken/missing lines.
You should also copy a nice background jpg image onto the sd card and rename it ozinverter.jpg

dgd
Off grid since 4/2000
Midnite C150,C250,Clipper, 2.8Kw PV, 2Kw turbine,1025Ah24v FLA (1999), SW3024E (1997), 3q16 48v300Ah LiFeYPO4 6Kw OzInverter, Arduino DUE web monitor.

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
SD card when opened just comes up with the Code as copied from your earlier post here.

Re-tried, re-copied but just the code, even in my IE10 the Explorer just comes with code as you posted.
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

dgd

  • Jr. Member
  • **
  • Posts: 68
  • Country: nz
  • Never do today what can be done tomorrow
    • Lory Link
I assume you saved the file somewhere on your PC?
Using Notepad open the file then save as index.html
Make sure it is saved as file type .html
then double mouse click on the filename and your web browser should open it and display it
If all you are seeing is text then its probably saved as a .txt file or .doc file

dgd
Off grid since 4/2000
Midnite C150,C250,Clipper, 2.8Kw PV, 2Kw turbine,1025Ah24v FLA (1999), SW3024E (1997), 3q16 48v300Ah LiFeYPO4 6Kw OzInverter, Arduino DUE web monitor.

sean_ork

  • Full Member
  • ***
  • Posts: 160
Perhaps the association of .HTML files has been changed.

Shift, and right clicking the file with give the "open with" option.

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Ok dgd, saved as html.....

First screen shot photo shows what I get now ..... just the rectangular guage ?.

Second shows, note pad about to get your code from your post on page 2....... I have some choices? Unicode?

Third shows about to create your code into html....... again choices of Unicode?
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

Bruce S

  • Global Moderator
  • Super Hero Member Plus
  • *****
  • Posts: 4577
  • Country: us
  • USA
Also:
IF notepad keeps insisting on making it a *.txt file.
You can open a DOS command and rename it.
CMD [press enter button]
rename index.txt[space button once] index.html "though I normally do
copy index.txt[space button once]index.html
[press enter button]
that fixes the save as issue too.
ClockmanFRA I know you're more up on renames or copies, but there could be others watching that may not be.  ;)

Cheers
Bruce S
YES! I'm following along as I'm messing around with  one of the clones too. Much easier to code than the Pi I have.
A kind word often goes unsaid BUT never goes unheard

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Roger Bruce,.......... that's why I am showing screen shots of me getting/ wading through this stuff.

Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

dgd

  • Jr. Member
  • **
  • Posts: 68
  • Country: nz
  • Never do today what can be done tomorrow
    • Lory Link
Clockman,
When saving from Notepad I use the default ANSI encoding.
Looks interesting the various filenames and extensions you ended up with but you got the index.html eventually
and its being executed by your web browser.
The SVG box (the green box) is good but the gauge code seems not to be working. Yet from what I see of it on your screenshot it looks as though it is ok and not broken.
I'm not sure what web browser you are using but this html code runs good on my Windows 10 laptop using Firefox and also the version of IE provided with W10 (also works on my Ipad4, Iphone5,W8 laptop iwth firefox and IE).
In fact I have not seen it fail with any browser but I don't have any PC running OS older than W7.
The version you are using may not support the html <canvas> command (if its quite old!).

And just to make sure all was ok I copied the code as posted here previously into a Notepad window, saved ANSI as indexozzy.html then using file explorer to show it and double clicked on the filename and my firefox displayed it completely with green SVG box and the five canvas round gauges
So it definitely works  :)
dgd
Off grid since 4/2000
Midnite C150,C250,Clipper, 2.8Kw PV, 2Kw turbine,1025Ah24v FLA (1999), SW3024E (1997), 3q16 48v300Ah LiFeYPO4 6Kw OzInverter, Arduino DUE web monitor.

Phred

  • Newbie
  • *
  • Posts: 8
  • Country: aq
caveat emptor
I have ordered controller & driver board some 5 months ago. They have my money but are not sending the items always asking for information. Email Negotiation in good faith is fruitless. Poweronlinesale put a lock on my ebay purchase so a dispute could not be raised in the 30 day ebay window. Now I cannot leave a neg feedback. So Beware with this mob

Mary B

  • Hero Member
  • *****
  • Posts: 810
Call ebay and explain what happened! They CAN fix it and force a refund. If the first person tells you no ask for a supervisor. They tell you no ask for their supervisor!

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Hi Phred,

Yes getting these boards is becoming a problem and I think PJ may have caught on.

I think PJ had no problem selling a few boards here and there, but I suspect there is little profit in selling these as I doubt they actually make these boards themselves, especially against the profit margins in assembling and selling their own Inverters, coughs & splutters!.

I have just checked, and the PJ LF, 15kw, 48vdc 230vac, 50HZ, pure sine wave boards are out of stock, The folk/agent you are dealing with, have NO boards at all for sale , they are supposed to be operating from Taiwan since 2008.

Each time I get some 15kW boards through these scattered around the globe agents, they actually always get delivered direct from PJ , PowerJack, DONGGANG, DALANG, CHINA.

If you are having difficulty obtaining these boards then contact ….. ‘OTW’ said ….. "For anyone wanting boards, Cher at PJ is very very helpful and I recommending getting in touch with her directly. powerjack.cher )@( gmail dot com "

120v 15kW boards are still available from ..... http://www.ebay.co.uk/itm/121372307145?_trksid=p2060353.m1438.l2649&var=420314377003&ssPageName=STRK%3AMEBIDX%3AIT


If only we could produce a comparable board our selves? ?????  Now that would be the Icing on the cake. !
Then that would be true World Wide Personal empowerment and self-improvement, with a cost effective, Robust, Open Source, Renewable Energy, OzInverter .

I DREAM...............
 
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Okay dgd.

It seems html file has lots of stuff in it that most I Explorers will automatically block.

The first Screen shot shows what I get, at the bottom of the screen there is a bar that says things are blocked, but press here and all is Okay, it goes in a few seconds.
I only found this on my slow laptop when I shoved the SD card in it, its a re-conditioned cheap job that I use for altering my SMA GTI's stuff with a special Bluetooth arrangement. The warning /blocked bar comes and goes very slowly on my Laptop.
On my PC, that bar comes and goes in a blink of an eye.

And they we are dgd.... Its UP....yes, jpeg image 185k for background in on the SD card now.
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

dgd

  • Jr. Member
  • **
  • Posts: 68
  • Country: nz
  • Never do today what can be done tomorrow
    • Lory Link
Ok, progress  :)
Now the html page displays properly with your web browser it needs to be copied to the SD card but the filename needs to be index.htm and NOT index.html  This is because the Arduino ethernet lib only deals with 3 character filename extensions hence .htm instead of .html
Also test on your pc that the background jpg image named ozinverter.jpg loads by placing it in the same directory that you have the index.html file.
Now you have a procedure for loading and testing any updates to html files that are posted  ;D

One more set of testing html5 code and an example xml file is posted over in the Microcontrollers/Ozinverter area
so you could try to get that working as well with your PC.

dgd
Off grid since 4/2000
Midnite C150,C250,Clipper, 2.8Kw PV, 2Kw turbine,1025Ah24v FLA (1999), SW3024E (1997), 3q16 48v300Ah LiFeYPO4 6Kw OzInverter, Arduino DUE web monitor.

Phred

  • Newbie
  • *
  • Posts: 8
  • Country: aq
Having been doing a bit of reading to come up to speed on large power inverters. This design looks very good but there are 3 questions that come to mind. Firstly can someone post the output waveforms @ the transistor stage and the 240v side of the transformer. The second question is to do with efficiency. Powerjack's claim it to be in the 90's but some people they are lucky to achieve 75%. This may explain the need for big fan. The last one is the most critical for how long can the unit provide 6kw endurance with very large battery bank.

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
Hi Phred,

All what you ask, is explained in my booklet...... "Making a Low cost, simple and robust 6kW, 50HZ Pure Sine Wave, 48vdc to 230vac, OzINVERTER".

I have put all the information that is out there, 'Open Source' including all relevant info from 'oztules' 60,000 words on the subject.

"A comprehensive, easy-to-follow, 76pp A4 working document, in full colour, including 160 colour photographs of the complete process, and 12 detailed diagrams & technical drawings."

I am awaiting The Mrs to do the page on our Web site, that links the necessary ordering system.

But if you go through 'oztules' stuff on the OzInverter, PowerJack etc, you will find the answers. Start......
http://www.fieldlines.com/index.php/topic,148717.0.html

and.............. http://www.anotherpower.com/board/index.php/topic,1044.0.html?PHPSESSID=h7jd5l4edljl6k4ls18pgfj4i1

In summary.. Get the toroid correct, get the connections correct, get the cooling system correct, get the Boards in right...... Do it all properly..... and It will do 6kW for some time if the batteries can take it, but it will also do even bigger/huge loads for a short time. And even better it low cost than a commercially obtainable Inverter at the same ratings.
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

clockmanFRA

  • Sr. Member
  • ****
  • Posts: 494
  • Country: fr
    • Echorenovate
PJ Boards....... Using others.....

A helpful tip......

"You can use the 15kw 110v mainboards as the 240v version ( no difference that I can see) , and a 8kw 240/220v card for the controller, if you want to push it some current bypass will take it higher, or damp the voltage from the CT slightly.     ...........oztules"
Everything is possible, just give me time.

OzInverter man. Normandy France.

3off Hugh P's 3.7m Wind T's (9 years).  .. 5kW PV on 3 Trackers, (5 yrs) .. 9kW PV AC coupled Used/SH GTI's, on my OzInverter created Grid, and back charging with AC Coupling to the OzInverter to my 48v 1300ah batteries.

Phred

  • Newbie
  • *
  • Posts: 8
  • Country: aq
Call ebay and explain what happened! They CAN fix it and force a refund. If the first person tells you no ask for a supervisor. They tell you no ask for their supervisor!
Ebay could not help as this had gone on for 5 months claimed via paypal that had 6 months protection. The last refund is coming as the seller failed to respond to the factitious tracking number.

Phred

  • Newbie
  • *
  • Posts: 8
  • Country: aq
PJ Boards....... Using others.....

A helpful tip......

"You can use the 15kw 110v mainboards as the 240v version ( no difference that I can see) , and a 8kw 240/220v card for the controller, if you want to push it some current bypass will take it higher, or damp the voltage from the CT slightly.     ...........oztules"
I have given up getting any PJ boards. Since then looked @ some utube tests on PJ inverters. Inverters labeled as 6kw barely produce 1-2kw continuous. I can understand why Ozitules used 15kw boards for his 6kw design. My order now is from another manufacture for DIY boards If appears more promising than PJ as the Documentation is supplied. The basic configuration is only 1kw but this can be expanded using more mosfets in // like in the PJ. So Ozitules transformer is still in the planned inverter. Will post when a 1kw trial is made with plenty of photos

oztules

  • Hero Member
  • *****
  • Posts: 1476
  • Country: aq
  • Village idiot
No.

The 15kw and 8kw and 6kw boards are basically the same, except the heat sinks and caps on the 15kw are bigger and same for the 8 to 6, so cooling is much better.
The thing that holds back my inverter from running more than 6-7kw continuous is the transformer size without excessive cooling.

These transformers are bigger than most of the name brand stuff,.... which makes me question their figures too.... they must be pushing the temperature envelope, or their idea of continuous must only be 30 mins or so.

The 15kw boards are easy to keep cool at  high levels, but the transformers need to be even bigger again to go higher power than 5-6kw and stay below 60C, without dedicated cooling.

The reason I stopped at this point, is I cant supply 6kw continuous. Yes it does the 10-15kw in short bursts, but the batteries will go on strike if I tried to keep that up for too long.

As a general rule, houses use only 500w on average, bursts of 2-4kw for a few hours are normal here, but after that 10000w start up for big induction motors is normal ,but running is only 1.5-3000watts, and this means that a 6kw unit is ample for anything I can ask of it.

Everything in the house can be turned on at the same time ( inc hot water) and not bother it... it seems easily big enough already.

The PJ boards have been proven to be very tough in these designs..... in the PJ arrangement, almost nothing is right. Transformers are way too small but for the short burst of 5-10 mins at max.. even then their transformers will o/heat... but the electronics seem to take it easily.

It is the lousy PJ build  and quality control that caused me to modify them, but I won't say their boards are rubbish when they are not.

As you know I have moved on from them to my new designs with the egs002 using the 8010 chips. This is proving to be an amazing combination, and is as tough as the PJ cards now they have been modded too. This is the direction I will be moving, as I will build the thing from scratch soon without the EGS002 board......... then we need not blame the suppliers for anything... just ourselves....In fact I  was running the big old mig welder again today... still gobsmacked at how well this new design is running.... but at 2days old, it only has 20kwh under it's belt in the last 2 days testing.... we will see how it goes longer term... but I feel confident..... thrown everything at it I have access to, and I can't stall it or blow it up.

For readers, the whole story is here http://www.anotherpower.com/board/index.php/topic,1116.0.html
Interesting read if you want to make very high powered pure sine inverters for peanuts.
Have the 8010 chips now, waiting for the driver chips, and the new scratch build will start.

Will be interested in your endeavours on your new boards.... or are they the egs002's. If so, you should end up with a very very useful tool.

I have so many high power inverters now, I don't know why I am doing this anymore really...... just the village idiot I guess

Here are pics of the inverter and a 4kw load in testing.
The inverter pic is the initial test picture, now it sports much heavier wiring in the 240v lines



9587-1

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

« Last Edit: March 16, 2016, 02:21:27 AM by oztules »
Flinders Island Australia

oztules

  • Hero Member
  • *****
  • Posts: 1476
  • Country: aq
  • Village idiot
Phred pics you asked for:

The unit had been running the house for the last three or so days... no problem, so time to go out and try to take pics with elcheapo tablet camera

Set up the scope using 24v transformer as the output source, while still running the house.

Here is the waveform under 3kw of stress.
9607-0
Not sure why there is a gap in the wave in the pic, it is not there in real life, so I guess it must be interaction with the scanning rate of the camera... looks weird.
Note there is no clipping, which surprises me as the primary is only 16mmsq.... I would have thought it would sag under 3kw loads... but no looks fine.

There is some cross over distortion there, but not enough to bother with, and I have not even bothered to get a filter on the output yet... apart from the 4uf shaping caps.

power reading here:
9608-1

this is the welder I use to stress test inverters.... if they can drive this full power, then they are worthy contenders.... this one can.. easily from the looks of it.
9609-2


Now full of pride, i went inside to post this, and boiled the 3kw kettle... so now running at over 6kw.... then power went off......... hmmmmm.

Went outside with mixed feelings, this has been running so well, and here it failed... or  at last, I can find a weak spot, and see if we can improve it.

Well it was a complete let down as far as improvement was concerned... the 68 amp o/loader had given up. It had been running in excess of 68 amps for too long.... and trying to push it to 125 amps to boil the kettle on top of the 65 to run the house was just too much for 2 mins.... which is about right for this style of overloader.

Reset the o/load, and all was well again.

So we have had a highly inductive long spark failure mode, and it just didn't care... starting to really like this thing.... seems unkillable.
Still running on the 68a o/load, but may soon upgrade to 140amp one... but the transfromer is still to small really to do that, it is really only a 3kw torroid, and even then with an undersize primary.... it was only to be a quick test.


................oztules
« Last Edit: March 18, 2016, 07:36:45 PM by oztules »
Flinders Island Australia

jan04

  • Newbie
  • *
  • Posts: 14
  • Country: de
Hi there,
I had a little time and used it for some experiments. I built a new trafo, I think it’s good enough for 5kW continuous. To this a new board of 15kW and
I added a controller of an 3kW inverter.
It’s time to built the current bypass, so that the main chip supports the wanted over 5kW power.
Now I’m a little bit confused. ‘Cause I read by oztules that he measured at the CT a cross section of 2 sq mm. So I also checked on the 3kW controller, there are two-hand 1.2 sq mm; in sum 2.25 sq mm.
It seems that all CT’s on the controllers are nearly the same. Only the chip is encoded equal to the bought power rating.
Now my question is:  How do I calculate the bypass?
Ohms Low doesn’t help in anyway, because the adjust resistor on the controller is populated in a different way.
Furthermore the CT seems to be a limited factor, according to the current rating table for a 2.5 sq mm core at 50° C is allowed a max 30A flow. But 30A aren’t even 7 kW.
What is your opinion? At which power rate will I get in trouble?

jan


« Last Edit: March 26, 2016, 03:08:33 AM by jan04 »