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Forum Index : Electronics : New tranny build 70 pound core

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BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 10:07pm 24 Jan 2021
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I ordered 23 pounds of 12awg wire to go with what I already have

I am thinking about removing some of the core to make more room for wire

This is definitely overkill for me

A few pounds out of the hole i think would make for a better tranny

It would allow me to wind on more copper

After winding a bunch of trannys for testing and lots of help from the people on here i have fingered a few things out

It is all about how much heat will be in the core

If you dont like using fans you will need a bigger core

If you want to use a leaf blower you can use a small core with more copper

For myself i hate hearing fans and think dust is bad  

I think oil will be the future of inverters but that is just a opinion
Edited 2021-01-25 09:02 by BenandAmber
be warned i am good parrot but Dumber than a box of rocks
 
InPhase

Senior Member

Joined: 15/12/2020
Location: United States
Posts: 178
Posted: 11:01pm 24 Jan 2021
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That's a whopper. What is this monster going into?
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 11:03pm 24 Jan 2021
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i am not sure yet maybe nano???
be warned i am good parrot but Dumber than a box of rocks
 
mad jack

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Joined: 26/06/2020
Location: United States
Posts: 9
Posted: 08:39pm 25 Jan 2021
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very nice do you have a link to the supplier you got it from
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 09:23pm 29 Jan 2021
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Sid a friend gave me the core
I think it is a 20k Power Jack core


I took some metal out of the center

I wanted more room for copper

be warned i am good parrot but Dumber than a box of rocks
 
mad jack

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Joined: 26/06/2020
Location: United States
Posts: 9
Posted: 10:57pm 01 Feb 2021
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great looking core , was hoping it was something I could order . been wanting to build a replacement for my 9k split phase powerjack before it gives up the smoke. rural Arkansas is a hard place to find parts.     Thanks BenandAmber
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 09:14pm 10 Feb 2021
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Keep a eye on Ebay for used trannys

You can get by alot cheaper if your not in a hurry

Some times you don't even have to rewind the high side

The best way to find them is the high side and low side can be used for the high side

Like if the high side and the low side can be used for the high side a you wind a new low side

You can wind more turns to get the original low side to the voltage needed for your new high side

This will make your Transformer able to do more wattage for short periods of time

If you don't understand what I'm saying here I can explain it a little better
be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 06:33am 25 Feb 2021
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Genetry solar has as5 PJ trannys for 150 bucks including shipping

I noticed it when checking out there new forms for people to post and talk about solar stuff

Seems to have some good people on them

Gs will soon have a 12k inverter!!!

Gs control board has 8 amp mosfet driver no more voltage drop across mosfets

The wifi board on the gs inverter is more than awesome

It has custom adjustable everything built in to it and the programing can be upgraded over the internet

The programing is constantly being upgraded and MORE!!! INCREDIBLE!!! things are on there way

You can hook gs inverters up together for more wattage or three phase with out having to buy extras to do so

It has many pwm fan plugs regular fan plugs many temp plugs can set the batt charging current every inverter has a multi tap tranny so it can do 12 24 36 48 volts

No more buying a new inverter to upgrade to a higher voltage

This is just a drop in the bucket with what the gs can do it has set the bar very high for off the shelf inverters

I will be hooking up the gs electronics to the over 100 pound tanny I am winding

I will be pushing 20k trying to blow up
the gs components

I have been unable to blow them so far
but I will not give up!!
Edited 2021-02-25 16:44 by BenandAmber
be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 11:38am 19 Apr 2021
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My new batteries arrived one of the modules is a little damaged

The cases are made extremely well
I am not that picky so I didn't make a claim

My new power cv cc supply  came in also

Maybe with it I won't be melting the solder off the legs of my hy5608 lol

I have been down in my back so still haven't wound the big tranny core

Since the weather is warming up it will likely get done soon

I haven't been in a big hurry on it

The big all new board I am building it for is not finished yet


I will most likely make my new batteries 14s they come as 22s

I have been thinking about 16s but that may just make things more difficult

The higher the voltage the better is my opinion

I got a good deal on these brand new never opened batteries

The specs are really good no long waiting and hoping they are in the us

So I couldn't pass them up

My buddy's balancers will be up for sell soon so I will be using them

They are capable of many amps so can keep big banks balanced

I can give the link if anyone is interested in the batteries or balancers

Have a blessed day every one
Edited 2021-04-19 21:49 by BenandAmber
be warned i am good parrot but Dumber than a box of rocks
 
MasterCATZ
Regular Member

Joined: 25/03/2011
Location: Australia
Posts: 52
Posted: 11:45am 08 May 2021
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I was also wanting the GS inverters but I can not wait any longer its winter and I need to use power for heating fish tanks now  , HF inverters just pop

thinking about undoing the external weld on my core  and letting it loosen up hopefully opening up the center of the core for me to have more room

I figure get the troid sorted out I can always upgrade the rest latter on when the circuit-board gets fried

thankfully GS are also selling their boards as kits in a few weeks time


only large cores I have found made are these

https://www.aliexpress.com/i/32832176000.html
Edited 2021-05-08 21:46 by MasterCATZ
 
InPhase

Senior Member

Joined: 15/12/2020
Location: United States
Posts: 178
Posted: 01:02pm 08 May 2021
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Genetry hasn't worked out all the bugs and manufacturing supply and delivery problems yet. I have no doubt they will EVENTUALLY have a great product, but I'm not willing to spend that kind of money waiting months for an inverter that glitches out when I get it. The designer has his hands full and it just keeps piling up. Great ideas but no help.
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 09:27am 04 Jun 2021
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Ok I got a good one for ya then

And with all the talk lately about shoot through with paralleling mosfets it may get a laugh

Only 36 bucks for 5 boards jlcpcb lol
Yes I uploaded Gerber for kicks and giggles

I was thinking about sending a few out to get a laugh

be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 09:35am 04 Jun 2021
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If you didn't like that one maybe th his one is more your speed



The 40 mosfet one was 35 bucks
be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 04:04am 06 Jun 2021
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There is a wiggle at top and bottom as seen seen in pics

It kinda seems like it is pulsing by the very low hum and how it looks live on scope

Kind of a little rev up and down but it could be in my head lol

I took three pics the wiggles almost not there in one pic another just had wiggle on top

I uploaded the third pic

The back ground of inverter pic also happens to have wiggle top and bottom

There is a filter cap on the inverter board by the little step down voltage feedback transformer

There is two two pin plugs side by side that seems to be for voltage feedback

They have continuity in between them with the beep test

Farthest right pin of first plug and farthest left pin of second plug  beep then the two inside pins one from each plug beep

Even though they shere continuity could only one plug go through the on board filter cap?

The small red board close to tranny that has two filter caps on it and a three way screw down connector

The three terminal screw down connector
Joins the tranny two the outlets

Each of the two filter caps on this small board have a leg going to the center tap zero volts of tranny

the other leg of each going to opposite 120 volt legs of tranny output

The voltage feed back is not hooked to the center tap it is 240 volts back to the board

Out put voltage dose move around a little
but not even a volt

maybe my volt meter is not fast enough to catch it if it is fluctuating more than 1/2  volt

I am trying to figure out why any ideas?



I have used this inverter for a long time

It was 120 volt only the last year or two

I rewired it for 240 volts and added some big dc input caps

The idle is not to bad

But the wiggles bother me

I also put two outlets in it one off each leg of 120 volts and each have resetable fuses

The bus plugs into the big 240 plug
Edited 2021-06-06 15:06 by BenandAmber
be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 05:22am 06 Jun 2021
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It definitely sounds like it is revving up and down

tranny is so quite you almost have to put ear on it to hear it hum

I didn't wind this tanny the ones I have wound don't hum at all at idle

Warpspeed instructed me to wind transformers

His way makes a salient tranny with lowest possible idle loss

I am very grateful he told me 5 billion times until I finally understood!!!


This inverter didn't do this pulsing the last year or two when hooked up as 120 volt only

I used the builtin on board filter cap and another across 120 volt out of tranny

This is the same tranny

Before the two windings was paralleled

Now they are hooked in series with one wire of each winding being center tap

Got to love usa electrical system

I always check dot with ligh bulb switch trick before hooking winding in series or parallel

As I was taught on here

The inverter is putting out 120 on both legs and 240 across both legs

This inverter board has a current shunt built into the board on the negative side

The big caps are hooked in after that shunt on negative bus bar on bottom of the board

The positive is hooked into positive heat sink

I used sawdust in resin when potting tranny

I am thinking the backfeed circuit is not getting filtered enough

But I would really appreciate some input from you guys

Thanks everyone I appreciate you guys!!
Edited 2021-06-06 16:14 by BenandAmber
be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 02:51am 16 Jul 2021
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A good friend's tranny I wound for his 8k power jack
He wanted it to do 5k









I twisted 4 around 1mm wires together to make each wire

All of them are 120 volt windings that will need put together for center tap so it will be 120 volt and 240 volt

No low side yet but the low side is fast and easy if there is enough hole

This will be a tight one like usual
I am happy if I have room for a bolt lol
be warned i am good parrot but Dumber than a box of rocks
 
APR_
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Joined: 19/07/2021
Location: Australia
Posts: 1
Posted: 11:34pm 26 Jul 2021
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Hi all. I am new here, and have to say the friendliness of members and assistance to others seen here is really encouraging. Just the place I need to be if I am to build an inverter.

I am considering trying to build a 48v inverter, and am looking at buying a few items I feel I will need. I would like the inverter to be capable of 6000w for 30 minutes, or maybe longer, although, I expect this power level would not be regularly used.

I have sourced 2 x 3kW Aerosharp GTIs specifically for the toroidal transformers, but after reading here I see there are a few more parts usable from the Aerosharp. I propose I will use the cases as others have done, and the chokes are evidently a usable item.

A question I currently have is if I rewind a toroid, what are the tapes I should use, and what width is recommended?

Edit: I am specifically wondering if there is any stretch in the tapes, and whether a 30mm wide tape is too wide to have it wrap flat on the curvature of the toroid?
Edited 2021-07-27 09:39 by APR_
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 06:19am 02 Sep 2021
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Sorry apr I am not on here very often
You can buy tranny tape or you can use
Clear boxing tape both stretch and work well
be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 06:48am 02 Sep 2021
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This tranny is over 100 pounds
I think it is a 25k pj

We have 4 or five sets of fets plan on seeing what it will do with a genetry solar driver board fun fun fun

I might get the chance to test and try to blow up a 12k genetry solar inverter before there ever on the market
can't wait!!!

There driver and wifi board is incredible and is tougher than nails it has everything and you can custom change anything from your phone

it even has built
In oscilloscope it will do 12 24 36 or 48 volt batterys And voltages in-between all those and likly higher than 48 volt bank
With out buying nothing muti tap tranny

A long while back I was trying hard to break the GS wifi and controler board

you should have seen felt and heard a over 70 pound tranny dancing and shaking my whole shop when I shorted the high side out to its self and powered it up

It was a awe inspiring moment!!!

I melted the solder off the legs of 360 amp hy5608 mosfets I beat that thing to death we nick named it un blowable
the mosfet drivers pushes 8 amps

After that sid turned on over wifi the protection stuff that would not let it happen again lol

Like I said it is tough!!!  


Friends big pj inverter

Tranny for my next inverter it is going to be stupid heavy

Plenty of hole for 4 more 2.3 mm windings making 8 in total may do ten and then the low side winding
Edited 2021-09-02 17:43 by BenandAmber
be warned i am good parrot but Dumber than a box of rocks
 
BenandAmber
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Joined: 16/02/2019
Location: United States
Posts: 961
Posted: 04:14am 16 Sep 2021
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I have lots of i5 laptops that have broken screens but everything else works great

Any ideas what could be made with them?

The laptop boards out of the laptop case would likely be cheap to ship and I have plenty if anyone would like one or a few

I think most of the ones i  I have left only have I think 8 gigs of ram

I am not on here very often but will try to check in incase someone wants some
be warned i am good parrot but Dumber than a box of rocks
 
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