DIY 230vac adjustable power limiter - Page 4

Xringer · 01-13-12, 12:17 PM

220 k resistor and a 220 uF cap will give us a 53 sec delay.

220 x 0.220 = 48.4 & 48.4 x 1.1 = 53.25 sec

Pin 2, will be open (or high) unless the over-current sensor switch closes. Then it will ground to Zero volts.
Pin 3, normally low, will keep the SSR(s) turned on. (Cathode connection).
During an over-current event, the timer starts and pin 3 goes high, turning off the SSR(s).

I think 53 seconds is a bit short, but I decided that a longer pause might
be too slow, and drag out the defrost cycle..

Right now, my main concern is to get rid of the old transistor circuit,
and it's very short delay time.
I worry that maybe the controller won't re-set every time the power just hiccups.
A 53 second hiccup seems like a more robust reset period..

Edit: 1/13/2012 8:47PM
Maybe I should have tested my 220 uF cap.?. The time delay is 72 seconds.
Luckily, it's not critical. 72 seconds will work just as good.
The important thing is, the new board is built, installed & working perfectly..

I plan to upgrade Sanyo#2's current limiter, but it's installed inside the ODU.
So, I'll have to wait for some nicer weather before changing it's circuit board.

Edit: 1/18/2012 18:50
The other day, it was near freezing and was damp outside.. As I walked into the living
room, I looked up and noticed the vent was closed on Sanyo #1.
The Remote control was still ON (in heat mode). Since the vent was closed,
I assumed a post-defrost current surge exceeded 10A and shut down #1 for 72 sec..

After 72 seconds, power returned and the system cycled into standby/off with it's vent closed..
I waited a while for the remote to transmit it's stream (Heat Mode, 21C, ION off & etc)
and Sanyo #1 came back up, operating normally..

I LIKE IT!!

Xringer · 01-18-12, 05:42 PM

Using the same value parts, this one times out at 63 seconds.?.

It seemed to be triggering before I could put the ground in on pin 2,
but then I realized that I'm packing kV+ volts of static electricity today.

After self-grounding, the unit tests out okay for installation..

Now, I just need some nice global warming in the back yard for about 20 minutes..

Xringer · 01-24-12, 07:28 PM

For my birthday, I got some good weather!!

High Temperature 54.5°F
Low Temperature 40.6°F

The new 555 timer unit was almost a drop-in replacement.
I did bring the 240vac-to-5Vdc power supply inside,
to add on some heavier wire for connecting to the terminals.
Got to use my new soldering iron (B-Day gift from wife).

The 555 is driving the SSR just fine so far.
Maybe we'll get to see that 63 second delay working,
if the lows get back down in the 20s next week..
(Causing defrost cycles).

The remainder of this month looks pretty mild..
Woburn, MA 01801 Month Weather Report - AccuWeather.com

Daox · 01-25-12, 07:19 AM

Happy birthday!

Xringer · 11-19-12, 08:24 PM

We've had two over-current events this season so far. Not caused by a defrost cycle.

1. Wife turned up the heat from Sanyo #1 and it ran up to a peak of abt 2.5 kW (10A) and reset (with time delay).
She only called for 1 deg C increase.

2. A couple weeks later, I did the same thing with Sanyo #2. Reset for no apparent reason.

Both times, these events occurred in the early morning hours, while bringing
the temperature up from 20 to 21 C.
The over-night temp was left at 19C and one deg of increased had already been clicked in.
And, I think that we may not have allowed enough time before clicking up from 20 to 21C.?.

WOBURN WEATHER CENTER - WU Station History
Because it's getting colder now, starting now, I'll only turn the temp back to 20C while sleeping. Same as we did last winter.

That might alleviate these power hiccups.

Daox · 11-20-12, 07:22 AM

How often does it happen in the middle of winter?

Xringer · 11-20-12, 09:10 AM

Not sure, but since the TED is so unreliable, we don't always get an overload alarm.
So, if there is a defrost cycle, followed by a high-power peak at 3AM, it could go unnoticed.

Last season(IIRC), Sanyo #1 had 2 or 3 reset cycles in a row, when the frost got real bad one morning.

Left both units at 20C last night and clicked them up to 21C this morning, without any problem. It is getting colder.

The inaccurate TED is showing 11.2 kWh used in 10 hours (since midnight).
But now the sun is coming in, the kWh burn rate will be less.

Servicetech · 11-09-13, 08:48 AM

I missed something. What is the overall goal of the project?

Xringer · 11-09-13, 09:30 AM

Quote:

Originally Posted by Servicetech

I missed something. What is the overall goal of the project?

It's discussed back at post #29 & 30

Bare-bones:
Because of the problems experienced with the first unit failing at high power use levels. (In the 3.6kW-plus range).
I do not want my Sanyos to use over 2.4 kW of power. (each).
So, I limit current to 10 amps.(each unit has a limit of 10A).

Servicetech · 11-09-13, 09:40 AM

It seems like Sanyo should make good on this if it's causing reliability problems. You shouldn't have to engineer your own fix for thier issue. If you think the problem is head pressure related have you considered a simple high pressure cutout?

01-13-12, 12:17 PM	#31
Xringer Lex Parsimoniae Join Date: Feb 2009 Location: Woburn, MA Posts: 4,918 Thanks: 114 Thanked 250 Times in 230 Posts	53 seconds 220 k resistor and a 220 uF cap will give us a 53 sec delay. 220 x 0.220 = 48.4 & 48.4 x 1.1 = 53.25 sec Pin 2, will be open (or high) unless the over-current sensor switch closes. Then it will ground to Zero volts. Pin 3, normally low, will keep the SSR(s) turned on. (Cathode connection). During an over-current event, the timer starts and pin 3 goes high, turning off the SSR(s). I think 53 seconds is a bit short, but I decided that a longer pause might be too slow, and drag out the defrost cycle.. Right now, my main concern is to get rid of the old transistor circuit, and it's very short delay time. I worry that maybe the controller won't re-set every time the power just hiccups. A 53 second hiccup seems like a more robust reset period.. Edit: 1/13/2012 8:47PM Maybe I should have tested my 220 uF cap.?. The time delay is 72 seconds. Luckily, it's not critical. 72 seconds will work just as good. The important thing is, the new board is built, installed & working perfectly.. I plan to upgrade Sanyo#2's current limiter, but it's installed inside the ODU. So, I'll have to wait for some nicer weather before changing it's circuit board. Edit: 1/18/2012 18:50 The other day, it was near freezing and was damp outside.. As I walked into the living room, I looked up and noticed the vent was closed on Sanyo #1. The Remote control was still ON (in heat mode). Since the vent was closed, I assumed a post-defrost current surge exceeded 10A and shut down #1 for 72 sec.. After 72 seconds, power returned and the system cycled into standby/off with it's vent closed.. I waited a while for the remote to transmit it's stream (Heat Mode, 21C, ION off & etc) and Sanyo #1 came back up, operating normally.. I LIKE IT!! Attached Thumbnails __________________ My hobby is installing & trying to repair mini-splits EPA 608 Type 1 Technician Certification ~ 5 lbs or less.. Last edited by Xringer; 01-25-12 at 06:07 PM.. Reason: change to jpeg

01-18-12, 05:42 PM	#32
Xringer Lex Parsimoniae Join Date: Feb 2009 Location: Woburn, MA Posts: 4,918 Thanks: 114 Thanked 250 Times in 230 Posts	555 timer for ODU #2 Using the same value parts, this one times out at 63 seconds.?. It seemed to be triggering before I could put the ground in on pin 2, but then I realized that I'm packing kV+ volts of static electricity today. After self-grounding, the unit tests out okay for installation.. Now, I just need some nice global warming in the back yard for about 20 minutes.. __________________ My hobby is installing & trying to repair mini-splits EPA 608 Type 1 Technician Certification ~ 5 lbs or less.. Last edited by Xringer; 09-05-12 at 01:11 PM.. Reason: Adding updated diagram of hack

01-24-12, 07:28 PM	#33
Xringer Lex Parsimoniae Join Date: Feb 2009 Location: Woburn, MA Posts: 4,918 Thanks: 114 Thanked 250 Times in 230 Posts	Wow! global warming! For my birthday, I got some good weather!! High Temperature 54.5°F Low Temperature 40.6°F The new 555 timer unit was almost a drop-in replacement. I did bring the 240vac-to-5Vdc power supply inside, to add on some heavier wire for connecting to the terminals. Got to use my new soldering iron (B-Day gift from wife). The 555 is driving the SSR just fine so far. Maybe we'll get to see that 63 second delay working, if the lows get back down in the 20s next week.. (Causing defrost cycles). The remainder of this month looks pretty mild.. Woburn, MA 01801 Month Weather Report - AccuWeather.com __________________ My hobby is installing & trying to repair mini-splits EPA 608 Type 1 Technician Certification ~ 5 lbs or less..

01-25-12, 07:19 AM	#34
Daox Administrator Join Date: Aug 2008 Location: Germantown, WI Posts: 5,525 Thanks: 1,162 Thanked 374 Times in 305 Posts	Happy birthday! __________________ Current project - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. & To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

11-19-12, 08:24 PM	#35
Xringer Lex Parsimoniae Join Date: Feb 2009 Location: Woburn, MA Posts: 4,918 Thanks: 114 Thanked 250 Times in 230 Posts	We've had two over-current events this season so far. Not caused by a defrost cycle. 1. Wife turned up the heat from Sanyo #1 and it ran up to a peak of abt 2.5 kW (10A) and reset (with time delay). She only called for 1 deg C increase. 2. A couple weeks later, I did the same thing with Sanyo #2. Reset for no apparent reason. Both times, these events occurred in the early morning hours, while bringing the temperature up from 20 to 21 C. The over-night temp was left at 19C and one deg of increased had already been clicked in. And, I think that we may not have allowed enough time before clicking up from 20 to 21C.?. WOBURN WEATHER CENTER - WU Station History Because it's getting colder now, starting now, I'll only turn the temp back to 20C while sleeping. Same as we did last winter. That might alleviate these power hiccups. __________________ My hobby is installing & trying to repair mini-splits EPA 608 Type 1 Technician Certification ~ 5 lbs or less.. Last edited by Xringer; 11-19-12 at 08:26 PM..

11-20-12, 07:22 AM	#36
Daox Administrator Join Date: Aug 2008 Location: Germantown, WI Posts: 5,525 Thanks: 1,162 Thanked 374 Times in 305 Posts	How often does it happen in the middle of winter? __________________ Current project - To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts. & To view links or images in signatures your post count must be 0 or greater. You currently have 0 posts.

11-20-12, 09:10 AM	#37
Xringer Lex Parsimoniae Join Date: Feb 2009 Location: Woburn, MA Posts: 4,918 Thanks: 114 Thanked 250 Times in 230 Posts	Not sure, but since the TED is so unreliable, we don't always get an overload alarm. So, if there is a defrost cycle, followed by a high-power peak at 3AM, it could go unnoticed. Last season(IIRC), Sanyo #1 had 2 or 3 reset cycles in a row, when the frost got real bad one morning. Left both units at 20C last night and clicked them up to 21C this morning, without any problem. It is getting colder. The inaccurate TED is showing 11.2 kWh used in 10 hours (since midnight). But now the sun is coming in, the kWh burn rate will be less. Attached Thumbnails __________________ My hobby is installing & trying to repair mini-splits EPA 608 Type 1 Technician Certification ~ 5 lbs or less..

11-09-13, 08:48 AM	#38
Servicetech Apprentice EcoRenovator Join Date: Nov 2013 Location: Moore Oklahoma Posts: 267 Thanks: 108 Thanked 23 Times in 21 Posts	I missed something. What is the overall goal of the project?

11-09-13, 09:40 AM	#40
Servicetech Apprentice EcoRenovator Join Date: Nov 2013 Location: Moore Oklahoma Posts: 267 Thanks: 108 Thanked 23 Times in 21 Posts	It seems like Sanyo should make good on this if it's causing reliability problems. You shouldn't have to engineer your own fix for thier issue. If you think the problem is head pressure related have you considered a simple high pressure cutout?