Transformer can be replaced to work with 110V/220V/230V outputs
Has output voltage feedback (constant AC voltage output)
Undistorted pure sine wave output (with load)
Selectable Output Frequency (60Hz/ 50Hz)
Current Protection
Voltage Protection
TemperatureProtection
Cooling Fan Output
LCD Screen (V, I, Freq, Temp)
Modular swappable design
Powerplants use generators that generate a pure sinewave output. It's what you would find from the grid. All our AC appliances were originally designed to run on this waveform.
A few years back sine wave inverters were extremely expensive ($200-$1000).
As a result square wave and modified square wave were the common and affordable options.
Square wave inverters are less efficient and can damage sensitive appliances.
Aside from being cheap and common, square wave inverters creates that obnoxious humming noises in motors, transformers, mostly on everything you plug to it.
Theoretically, sine wave inverters are more efficient than square wave inverters depending on the implementation quality.
Part 2 of the video will show how to implement a single coil inductor for fast switching, replacing the EI core design used in this project. I'll see if it yields a higher efficiency than the EI core design from this tutorial.
Will update this tutorial for a more detailed bench test. I'm currently building a DC & AC Wattmeter SD datalogger to monitor the data for this project and my future power electronics project.
Will implement SMT components to make the board smaller
The next single coil inductor design is expected to yield a smaller form factor, higher conversion efficiency and lower standby power consumption. The one on this project consumes 12W of power without load (a bit mehhh)
The current board in this board is limited to a 20VDC input due to the MOSFET driver gate drive source being tied to the Vcc and the 7805 regulator's input voltage limitation. I will reconfigure the board and replace the 7805 regulator with an XL7005A switching regulator and some linear regulators for different rails for the inverter board to work with 80V power sources (12V/24V/48V/72V).
Be extra careful with this project as it produces a high voltage - high current output. The board was designed to cater a 1kW transformer. Due to unavailability, I was only able to acquire a surplus 500W 12V-220V UPS Transformer. As far as it goes I was only able to reach 400W with minimal sine wave distortion. Part 2 of the video tutorial will show the troubleshooting process and connecting it to a bigger transformer. Part 3 will show the process behind designing user specific inverter using the EGS002 module and Part 4 on building a better inverter with a 48V input for my off-grid solar panel setup.
The EGS002 is a versatile $3 all-in-one solution for building Pure Sine Wave inverters. You can build low power to high power inverter units out of it! Right out of the box, it is not an inverter just yet. You would have to build a few components around it to make it into a functional inverter unit.
Why It Is So Good?
Decent high power commercial pure sine wave inverters are very expensive! They range from $120-$400. With the EGS002 you can design all sorts of inverters with input voltage, output voltage and power ratings of your choice! For as low as $20, depending on your specs and where you source your components.
What's On The EGS002 Board?
EG8010 SOIC Microcontroller - The EGS002 uses an EG8010 an ASIC (Application Specific Integrated Circuit) microcontroller chip designed to output SPWM logic signals for driving H-Bridge inverters. The chip is also equipped with I/Os specifically designed for closed loop voltage monitoring, cut-off current monitoring, temperature monitoring and fan drive output. Unlike Arduino based inverter project, the chip is preprogrammed and ready to use.
High Side & Low Side MOSFET/IGBT Driver - The board also contains two IR2110S MOSFET drivers for driving an All N-Channel H-bridge MOSFET arrangement for SPWM and polarity switching to the transformer or inductor. This chip ensures that the low side and the high side MOSFETs (specifically) are fully saturated. This prevent power losses from on-resistance by supplying the gates with their proper gate voltages to ensure they have the least on-resistance with respect to its specs.
OP-AMP For Current Sensing - The board has a LM393 OP-AMP to amplify the voltage from the shunt resistor. The amplified voltage goes back to the EG8010's analog input as the chip uses it for overcurrent protection
LCD Ready Display Output - The EG8010 microcontroller has already been pre-programmed to work with a proprietary LCD display. You can add a dollar to the $3 EGS002 unit to get the extra LCD screen. This displays the output voltage, current, temperature and frequency mode.
Single LED Error Display - There's one red LED on the board that would blink for a spec
ific number of times to display errors for troubleshooting.
Stay tuned for the next video and Instructable tutorial as I won't delve much into the reverse engineering and design process of building user specific inverter board with the EGS002 on this tutorial.
Enable LCD Backlight Solder JP9.
Disable LCD Backlight - Desolder JP9.
Soft Start Mode - Soft start mode is a nice feature to prevent a surge of power draw once you connect the DC power source to the inverter while a load is attached. With soft start mode, the voltage will slowly increase to your set output voltage for 3 seconds (ex: 0V-220V in 3 seconds). This also prevents huge sparks when connecting your inverter to your battery. If you are planning to build a UPS circuit, you will have to disable it.
Enable 3s Soft Start Solder JP2 together and desolder JP6.
Disable Soft Start - Solder JP6 together and desolder JP2.
Deadtime - Deadtime is the time in seconds for the MOSFETs to turn off before switching phases. This is done to prevent cross-conduction (quick short) across the half-bridge MOSFET (vertical MOSFET pair) during high speed switching of he H-Bridge setup. 300ns seems fine for most setups, a slower deadtime of 1.5us must be used for high gate capacitance MOSFETs. I suggest to leave these jumpers by default.
300ns Deadtime - Desolder JP3 and JP4 then solder JP7 and JP8.
500ns Deadtime - Desolder JP4 and JP7 then solder JP3 and JP8.
1.0us Deadtime - Desolder JP3 and JP8 then solder JP4 and JP7.
1.5us Deadtime - Desolder JP7 and JP8 then solder JP3 and JP4
Transformer can be replaced to work with 110V/220V/230V outputs
Has output voltage feedback (constant AC voltage output)
Undistorted pure sine wave output (with load)
Selectable Output Frequency (60Hz/ 50Hz)
Current Protection
Voltage Protection
TemperatureProtection
Cooling Fan Output
LCD Screen (V, I, Freq, Temp)
Modular swappable design
Powerplants use generators that generate a pure sinewave output. It's what you would find from the grid. All our AC appliances were originally designed to run on this waveform.
A few years back sine wave inverters were extremely expensive ($200-$1000).
As a result square wave and modified square wave were the common and affordable options.
Square wave inverters are less efficient and can damage sensitive appliances.
Aside from being cheap and common, square wave inverters creates that obnoxious humming noises in motors, transformers, mostly on everything you plug to it.
Theoretically, sine wave inverters are more efficient than square wave inverters depending on the implementation quality.
Part 2 of the video will show how to implement a single coil inductor for fast switching, replacing the EI core design used in this project. I'll see if it yields a higher efficiency than the EI core design from this tutorial.
Will update this tutorial for a more detailed bench test. I'm currently building a DC & AC Wattmeter SD datalogger to monitor the data for this project and my future power electronics project.
Will implement SMT components to make the board smaller
The next single coil inductor design is expected to yield a smaller form factor, higher conversion efficiency and lower standby power consumption. The one on this project consumes 12W of power without load (a bit mehhh)
The current board in this board is limited to a 20VDC input due to the MOSFET driver gate drive source being tied to the Vcc and the 7805 regulator's input voltage limitation. I will reconfigure the board and replace the 7805 regulator with an XL7005A switching regulator and some linear regulators for different rails for the inverter board to work with 80V power sources (12V/24V/48V/72V).
Be extra careful with this project as it produces a high voltage - high current output. The board was designed to cater a 1kW transformer. Due to unavailability, I was only able to acquire a surplus 500W 12V-220V UPS Transformer. As far as it goes I was only able to reach 400W with minimal sine wave distortion. Part 2 of the video tutorial will show the troubleshooting process and connecting it to a bigger transformer. Part 3 will show the process behind designing user specific inverter using the EGS002 module and Part 4 on building a better inverter with a 48V input for my off-grid solar panel setup.
The EGS002 is a versatile $3 all-in-one solution for building Pure Sine Wave inverters. You can build low power to high power inverter units out of it! Right out of the box, it is not an inverter just yet. You would have to build a few components around it to make it into a functional inverter unit.
Why It Is So Good?
Decent high power commercial pure sine wave inverters are very expensive! They range from $120-$400. With the EGS002 you can design all sorts of inverters with input voltage, output voltage and power ratings of your choice! For as low as $20, depending on your specs and where you source your components.
What's On The EGS002 Board?
EG8010 SOIC Microcontroller - The EGS002 uses an EG8010 an ASIC (Application Specific Integrated Circuit) microcontroller chip designed to output SPWM logic signals for driving H-Bridge inverters. The chip is also equipped with I/Os specifically designed for closed loop voltage monitoring, cut-off current monitoring, temperature monitoring and fan drive output. Unlike Arduino based inverter project, the chip is preprogrammed and ready to use.
High Side & Low Side MOSFET/IGBT Driver - The board also contains two IR2110S MOSFET drivers for driving an All N-Channel H-bridge MOSFET arrangement for SPWM and polarity switching to the transformer or inductor. This chip ensures that the low side and the high side MOSFETs (specifically) are fully saturated. This prevent power losses from on-resistance by supplying the gates with their proper gate voltages to ensure they have the least on-resistance with respect to its specs.
OP-AMP For Current Sensing - The board has a LM393 OP-AMP to amplify the voltage from the shunt resistor. The amplified voltage goes back to the EG8010's analog input as the chip uses it for overcurrent protection
LCD Ready Display Output - The EG8010 microcontroller has already been pre-programmed to work with a proprietary LCD display. You can add a dollar to the $3 EGS002 unit to get the extra LCD screen. This displays the output voltage, current, temperature and frequency mode.
Single LED Error Display - There's one red LED on the board that would blink for a spec
ific number of times to display errors for troubleshooting.
Stay tuned for the next video and Instructable tutorial as I won't delve much into the reverse engineering and design process of building user specific inverter board with the EGS002 on this tutorial.
Enable LCD Backlight Solder JP9.
Disable LCD Backlight - Desolder JP9.
Soft Start Mode - Soft start mode is a nice feature to prevent a surge of power draw once you connect the DC power source to the inverter while a load is attached. With soft start mode, the voltage will slowly increase to your set output voltage for 3 seconds (ex: 0V-220V in 3 seconds). This also prevents huge sparks when connecting your inverter to your battery. If you are planning to build a UPS circuit, you will have to disable it.
Enable 3s Soft Start Solder JP2 together and desolder JP6.
Disable Soft Start - Solder JP6 together and desolder JP2.
Deadtime - Deadtime is the time in seconds for the MOSFETs to turn off before switching phases. This is done to prevent cross-conduction (quick short) across the half-bridge MOSFET (vertical MOSFET pair) during high speed switching of he H-Bridge setup. 300ns seems fine for most setups, a slower deadtime of 1.5us must be used for high gate capacitance MOSFETs. I suggest to leave these jumpers by default.
300ns Deadtime - Desolder JP3 and JP4 then solder JP7 and JP8.
500ns Deadtime - Desolder JP4 and JP7 then solder JP3 and JP8.
1.0us Deadtime - Desolder JP3 and JP8 then solder JP4 and JP7.
1.5us Deadtime - Desolder JP7 and JP8 then solder JP3 and JP4
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