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Forum Index : Electronics : Wiseguy (WG) Inverter Build Discussions Australia
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| GleamBright Newbie  Joined: 21/04/2025 Location: AustraliaPosts: 14 |
Starting a new thread to discuss technical and administrative issues related to a Facebook group of the same name, created in late 2025 with the purpose of collaborating as a group to build Wiseguy inverters for DIY solar applications, mainly supported by IFLA (Industrial Flooded Lead Acid) batteries - also in association with a related Facebook group. We were inspired by the Ozinverter and have decided to follow the WiseGuy build, being an updated and improved version of the same. We have several members committed to a build and have already held several online meetings, one in the presence of Wiseguy himself. My toroid is finished, and we're ready to push the button on PCB ordering. Updates and associated posts to follow. |
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KeepIS Guru  Joined: 13/10/2014 Location: AustraliaPosts: 2108 |
It's so pleasing to hear that the Wiseguy design has been taken up by others. You obviously realise just how robust and technically superior it is in almost every way, when compared to what had come before this Inverter design. From a servicing perspective, his design is also brilliant, especially if the build layout is thought thought and designed accordingly.   NANO:Inverter V 8.2ks - Linux AvrDude GUI script V4.1 |
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| GleamBright Newbie Joined: 21/04/2025 Location: AustraliaPosts: 14 |
KeepIS, thanks for the positive reply. We've been trying to get in touch with you. Would you be open to joining one of our conference calls in the next few weeks? your input would be invaluable. Please bear in mind that this is a beginner level DIY project for most of us and we are piecing things together from multiple sources, the technical content of which we often struggle with. However, we're having a go because a completed and functioning project will be a game changer for our systems. |
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| GleamBright Newbie Joined: 21/04/2025 Location: AustraliaPosts: 14 |
A couple of starting questions: 1. Does the Wiseguy inverter accommodate backcharging of a battery from an AC source, as per the AC coupling arrangement suggested in the Ozinverter book? 2. What size and design (toroids, cable type and size, number of windings) would be recommended for my toroid? Images of which are attached below through various stages of building. This has been constructed as per the Ozinverter design to draw 6kW continuously and I'm the first cab off the rank with regards to transformer construction. I gleaned that Wiseguy suggests 37 uH with lower values giving higher idle current and higher values giving better efficiency under load. I need guidance for the design and/or calculations. No.1: OD 181 mm, ID 89 mm, width 170 mm, mass 24.6 kg. No. 2: OD 188 mm, ID 91 mm, width 160 mm, mass 25.1 kg. (one for myself and one for a friend)    |
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| KeepIS Guru Joined: 13/10/2014 Location: AustraliaPosts: 2108 |
That could be possible, however I'm not on social media and not running windows, so it depends on your conference setup. You can always PM me and I can give you contact details if you wish. Mike. NANO:Inverter V 8.2ks - Linux AvrDude GUI script V4.1 |
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| KeepIS Guru Joined: 13/10/2014 Location: AustraliaPosts: 2108 |
As far as Toroid design, it will be the same as the Ozinverter design for a given expected operating, lowest input voltage, for your selected battery type. Those look fine as starting point, primary side (inverter powerboard and choke input) is easy to adjust when testing starts. Those chokes are not going to fly. You want 4AWG around 21mm2 for for the chokes, this gives a little more protection for the FETS, and is easier to wind through the cores. What is the Choke core material? should be a number on them somewhere. If we know what the cores are, we could suggest the correct number of turns for the required inductance. EDIT: For your initial choke testing, you should just grab some 2 Gauge flex copper cable. I used this for a long time on the chokes in testing without any problems, way less costly for testing and extra safety, depending on the cores, we aim for you around 17uH to 21uH with 4 to 6 turns of 2AWG, you would use two chokes for each inverter. Mike. . Edited 2026-03-23 11:50 by KeepIS NANO:Inverter V 8.2ks - Linux AvrDude GUI script V4.1 |
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| GleamBright Newbie Joined: 21/04/2025 Location: AustraliaPosts: 14 |
Thanks Mike, We're buying our chokes new & will order ones made of Sendust, apart from that it's an open book. From another thread you had two types of Choke ring: a black one and blue one, and there were some specs on one of the threads. What do you suggest? I understand they're not expensive and if we have a spec we could start ordering and get a few extra. We have firm quotes for PCBs and are ready to order. Do you have access to Zoom? if so, I'll make an appointment with the group & get back to you by PM, we have had 3 to 5 attendees so far and 5 pm AEST on Saturdays works for most. Otherwise, if you're happy for us to post queries here. Michael |
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| KeepIS Guru Joined: 13/10/2014 Location: AustraliaPosts: 2108 |
Those cores are getting hard to find and were expensive last time I looked, the blue units are fine. No access to Zoom at the moment, fine to ask any questions here, other on here will be happy to chime in and help if they can, good bunch here. I'll send you a PM with some contact info if needed. Notice: I posted a bit more in the previous post. NANO:Inverter V 8.2ks - Linux AvrDude GUI script V4.1 |
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| GleamBright Newbie Joined: 21/04/2025 Location: AustraliaPosts: 14 |
Thanks, in that case I'll have another look through my scrapped inverter components for toroids. I have the chokes from an Aerosharp but they're not suitable, from what I gather. The other builders may have to wear the costs, as they are planning to buy everything new, including primary toroid cores. We'll hold on a conference call for now, but there may be some technical queries that would justify a voice contact and I'll get back to you if and when they arise. So, the choke install isn't just 'plug and play', there is some pre commissioning testing required for each toroid? And if so, what equipment are we looking at? |
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Bryan1 Guru Joined: 22/02/2006 Location: AustraliaPosts: 1872 |
Hi GleamBright I got my choke senddust toroids on Ali I used 6 of them on each choke and 25qm wire for 4 turns thru. |
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| KeepIS Guru Joined: 13/10/2014 Location: AustraliaPosts: 2108 |
Volume: 57.1x26.4x15.2mm AU$31.19 for three. Last selection box. Allow 6 for each choke, 4 sets of 3 needed. Model:MS226060-2 Outer diameter:57.1 mm Inner diameter:26.4 mm Height:15.2 mm Magnetic conductivity:60μ Inductance coefficient:138 nH/N2 Material:85% iron +6% aluminum+9% silicon FYI, despite what they say, they are slow to ship and tracking sucks. But my last lot from them at least arrived. NANO:Inverter V 8.2ks - Linux AvrDude GUI script V4.1 |
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| mab1 Senior Member  Joined: 10/02/2015 Location: United KingdomPosts: 277 |
I can answer q1:- mine accepts backfeed from a gti (or 2) just fine. |
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| GleamBright Newbie Joined: 21/04/2025 Location: AustraliaPosts: 14 |
Minutes of meeting held today @ 5 pm AEST: Atrendees: M Habner (Gleambright) A Ve, M Hatheier, Steve D (inactive), S Denis Discussion points: Work and other duties have been pressing for all, but we're committed to the task. Keen to get started before prices move any more adversely. PCBs: no further progress, but Alex intends to have them re-quoted to incorporate Wiseguys' updates. Has the Gerber files. BOMs: sourcing mostly complete, but there are a half dozen or so items for which information is insufficient to ensure that the correct part will be sourced. Alex will post on the backshed within a week to elicit responses from Wiseguy/KeepIS & get back to us if no joy. Basically, we estimate that we're about 2-3 weeks away from being able to press go for PCB & BOM orders. S Denis asked questions about PCB and transformer component sourcing for an intended US based build. T Becker was a suggested contact. M Hatheier has met with Peter McConaghy in person in the interim and confirms that he remains willing and able to assist with materials procurement for all transformer materials, possibly assist with winding as well. M Habner: has been poring over the Backshed threads with mixed success due to the volume of advanced technical content. Can confirm sourcing of the kilovac and choke toroid rings. Can specify links to specific info regarding various enclosure designs and detailed layouts, has given up for now on a detailed BOM for intermediate components. Has KeepISs' number and an offer of assistance for beginner level questions and intends to call on the offer in the near future. Is increasingly confident that it's doable, with support. Note that we intend to be more active on the BackShed forum for technical and build-specific discussion. All attendees are able to access this forum. |
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Revlac Guru Joined: 31/12/2016 Location: AustraliaPosts: 1239 |
Thats Good. Cheers Aaron Off The Grid |
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| Bryan1 Guru Joined: 22/02/2006 Location: AustraliaPosts: 1872 |
Hi Micheal where the Mikes just rocks please consider the Madboard as that does rock, Decided to start an old pump motor where I saw a 8Kw draw on startup then it went down to 600 watts so I do consider this JUST works. It wasn't my fault there was hole in the tank but the inverter JUST powered it. |
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| GleamBright Newbie Joined: 21/04/2025 Location: AustraliaPosts: 14 |
Hi Bryan, What's the Madboard? We're pretty well committed to a standard WG build. We were discussing today that we haven't heard of any that have failed, even under extreme duty, abuse even (KeepIS!). |
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| nickskethisniks Guru Joined: 17/10/2017 Location: BelgiumPosts: 472 |
I think the madboard was developed as an improvement for the powerboard used in the ozzinverter. It uses a proper npn/pnp drive for the mosfet gate drive on the powerboard itself, wich makes the gateloop a lot smaller. In the original ozzinverter the gatedrivers are on the controllerboard and gatesignals must go thrue the ribbon cable, wich works also just fine, I use the ozzinverter since 2018, and it delivers between 6- 7000kwh/year, 10kw peaks no problem. I have some madboards but there is no provision to make a decent mechanical connection between the pcb and the heatsinks, this is better on the ozzinverter powerboard, so I never used them. But both designs have been proven for years now also in combination with poida's software. I'm currently testing the wiseguy boards, wich is just superior to anything else we've seen over here. I only trade the ozz inverter in for that one. If you look at it from a pcb designer perspective you can't believe how well the madboard and ozz inverter actually works. The build is like a marathon, no cutting edges, and use genuine parts. Make sure you have all the right testing gear. The build could look (or it is) expensive, but it's more like an investment for the long run. Edited 2026-04-19 07:36 by nickskethisniks |
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| GleamBright Newbie Joined: 21/04/2025 Location: AustraliaPosts: 14 |
We went through a period of review and discussion of various available designs, including the Warpverter, after initially proposing to build Ozinverters, then settled on the Wiseguy design & we're committed to that path. Refer warpverter.com/WG Things are getting expensive now but not unreasonably so yet. Many earlier builders had access to key parts from scrapped units that are now hard to get or unavailable. The inverter itself is a game changer when paired with IFLA batteries, in comparison to commercial inverters and worth the effort of the build. Edited 2026-04-19 08:16 by GleamBright |
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| KeepIS Guru Joined: 13/10/2014 Location: AustraliaPosts: 2108 |
Trying not to sound like a broken record, but I agree, I have not found a single glitch in any part of the WG design, the Nano controller has NEVER had an unknown glitch. Just solid day in day out reliable power. Getting Toroids and winding one is the only pain in the build, but seriously worth it as the ability to repair your own Inverter and battery setup is becoming priceless in these uncertain times   . Edited 2026-04-19 14:47 by KeepIS NANO:Inverter V 8.2ks - Linux AvrDude GUI script V4.1 |
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