Powerstar W7 Inverter modification

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Re: Powerstar W7 Inverter modification

Postby davidg » Sun May 21, 2017 11:34 pm

Jimbo007 wrote:Graham'
the thought of you doing a "spark test" on a 400 amp fuse worries me a little as at 24 volts you will be playing with a 10 Kwatt arc and at 48 volts would be a 20 Kwatt plus arc.


Yes...............

Seriously, consider changing to HRC fuses the break point is contained within a ceramic case with, I'm going to call it "sand" which creates a glass insulator guaranteeing an arc is extinguished if it blows.
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Re: Powerstar W7 Inverter modification

Postby Jimbo007 » Mon May 22, 2017 2:38 am

Good idea.
Be careful though, I've seen one of these fuses explode with hot ceramic shrapnel flying in all directions and the immediate area sandblasted ! It did break the circuit though.
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Re: Powerstar W7 Inverter modification

Postby Graham_West_Wyalong » Mon May 22, 2017 6:36 am

Hahahahah yeah, that was meant to have a grin after it in my suggestion that I might do a spark test!

I have seen footage of this kind of spark test. I would tend not to do it on the main bank and it would require a very fast recording of current flow which would take some time to prepare. Best way would be a progressive load until it pops.....

Nice to see such concern though.

Seriously though, having read the specs on these fuses, I believe that one fully loaded could pop under my max peak load.

I see the fuse as a protection against shorts rather than overloads (in this. Situation) as we know the inverter power board acts as an expensive circuit breaker at that end (grin) but the current sense and heat sense are effective at protecting the inverter.

As I said or implied before I am not a fuse specialist and I beleive these fuses are simple fast blows and as such do not have the advantage of being progressively loaded way beyond the 400 amps but I may be incorrect hence the question to davidg.

And no I was not really going to do an uncontrolled spark test.

Cheers.
G.
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Re: Powerstar W7 Inverter modification

Postby Graham_West_Wyalong » Mon May 22, 2017 6:40 am

davidg wrote:Seriously, consider changing to HRC fuses the break point is contained within a ceramic case with, I'm going to call it "sand" which creates a glass insulator guaranteeing an arc is extinguished if it blows.


Thanks David and Jimbo Maybe this is the way to go.

Are these Bussmann Fwh fuses really that poor at short circuit protection?

Cheers. G.
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Re: Powerstar W7 Inverter modification

Postby davidg » Mon May 22, 2017 8:19 am

Graham_West_Wyalong wrote:Are these Bussmann Fwh fuses really that poor at short circuit protection?

Cheers. G.

Are they these ones?

gG type fuses tend to be what I've used.
http://www.cooperindustries.com/content ... 0B_220.jpg
If so then maybe no. There's more to it, here's a short read about fuses, design and selection from bussman :)

Batteries are a bit different to lot's of loads, to rely only on short circuit could be an issue, there is the inverter design limits excessive overload you need to protect or they can turn into a thing with lots of smoke that escaped.

http://www.cooperindustries.com/content ... 07-hsf.pdf

Keep in mind this particular manual might not be totally applicable to inverter/battery use.


A couple of others.
http://www1.cooperbussmann.com/pdf/deb5 ... 541498.pdf

http://ep-us.mersen.com/fileadmin/catal ... -Curve.pdf
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Re: Powerstar W7 Inverter modification

Postby Graham_West_Wyalong » Mon May 22, 2017 9:07 am

davidg wrote:Are they these ones?


Yep in the larger 400amp package.

Batteries are a bit different to lot's of loads, to rely only on short circuit could be an issue, there is the inverter design limits excessive overload you need to protect or they can turn into a thing with lots of smoke that escaped.


Yep got all of that. We have repaired many power and control boards since starting to experiment with the limits etc.

As regards protection, I have many breaker spots for other overloads etc but the main battery bank to bus bar is a thing that I think needs a solid full dead fuse for the times when you simply forget to disconnect the switches before mucking around with your best sidchromes!


cheers.
G.
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Re: Powerstar W7 Inverter modification

Postby Jimbo007 » Mon May 22, 2017 10:50 am

It's all good folks.
The fuse is only there as a failsafe in the event of a catastrphic failure.
In all fairness to the fuse manufacturers, I must confess the ones I saw explode were at the top of a power pole and being replaced by a techo. It took him several attempts and a new fuse each attempt, at the end of an insulated pole to sucsesfully replace the fuse in the live circuit. It seemed his sucses depended on how quickly he could jam the fuse holder closed.
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Re: Powerstar W7 Inverter modification

Postby Jimbo007 » Thu May 25, 2017 3:28 pm

On the subject of over current protection, Jaycar Has a number of breakers rated at 60, 120, and 200 amps.
They are supposed to be suitable for 12 And 24 volt systems.My personal experience at 24 volts was that the 200 amp unit would hold just over 100 amps but open within a few seconds at 120 amps.
Although not rated for 48 volts, I tried the same breaker at loads of 3kw and it held ok. I do also have a fuse in line as well. When I feel brave enough, I'll load up the inverter with a couple of kwatts and open the breaker to see if it actually works or sustains an arc.
I'll post my results later.
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Re: Powerstar W7 Inverter modification

Postby Solar@wind » Tue Jul 18, 2017 12:57 pm

HI.

I have purchased the remote control panel and extension cable for the inverter.

The inverter has a db9 cable connector on the panel where the do cables are . This db connector ,I read in the instructions is for the remote controller.
My problem is the remote able has an rg 45 type telecom. Connector .. Do I have to discard the original control panel and plug the new remote panel in here?. Not happy with that.

Can I cut the new remote connector off and solder a db9 male. Plug so to connect .

Also , will this remote ,when it,s correctly connected, work in conjunction with th eoriginal panel ,,,ie , a two way switch ,so I can control inverter from workshop and living room independently???.

A bit drawn out , but I,d like to get it right ,thanks


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Re: Powerstar W7 Inverter modification

Postby Gordon-Loomberah » Fri Jul 21, 2017 11:05 am

[Moderator - this might have more chance at success here.]

>>
Circuit drawings for W7 inverter

Pos tby Solar@wind » Thu Jul 20, 2017 5:57 pm
HI crew,.
Long time back ,in the very long postings on the W7 mods, someone posted the drawings for the workings of the inverter.

IF you remember or have tagged these drawings ,could you please submit the page again.,I,Ve tried for an hour or so ,that will tell us how long this post went for ,,months.

WHat oI,Ve done is removed the little remote board from the unit holding the DB 9 remote connection connector, I,Ve got the three control pin outs,OK, but would like to know a bit more about those three connections.
On later models ,they had RJ type connectors at both ends ,so it was easy ,but no color matching on the DB ,it,apcb.

Thanks

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