250 to 5000 Watts PWM DC_AC 220V Power Inverter

5/28/2018 250 to 5000 Watts PWM DC_AC 220V Power Inverter

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250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)

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This is a heavy duty design of a Pulse Width Modulator DC/AC inverter usingthe chip SG3524 .

I've been using it as a backup to power up all my house when outages occur

since aprox. 6 years non stop.

If you like the work and intend to build the circuit don't forget to click on the

"follow" button so I know how many people benefit from the design, Thanks.

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250 to 5

000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)



3 sur 14 01/03/2014 13:22


4/14

Notes:

1> The schematic circuit design is for a 250 watt output, while the pics are of my

1500 watts inverter that i built, to increase the power of the circuit you have to

add more of the Q7 and Q8 transistors in parallel, each pair you add will

increase your power by 250 watts, ex: to get 750 watts of power from the

inverter you need to add in parallel 2 of Q7 and 2 of Q8 to the original design.

2>If you increase the power transistors you have to enlarge the T2 transformer

to match the new needs, the circuit's transformer is rated 25 amps to handle 250watts of 220v, for every 1 additional amp you need on the 220v side you have to

increase 10 amps on the 12v side, of course there are limits to the thickness of

the winding so if you need more than 750 watts i recommend that you use a

24VDC supply instead of 12 volts:

DC voltage and Transformer " T2" winding recommendation:

Power Supply Winding

750w 12VDC P:24V "12-0-12" / S:220V

1500w 24VDC P:48V "24-0-24" / S:220V

2250w 36VDC P:72V "36-0-36" / S:220V

3000w 48VDC P:96V "48-0-48" / S:220V

3750w 60VDC P:120V "60-0-60" / S:220V

4500w 72VDC P:144V "72-0-72" / S:220V

5250w 84VDC P:168V "84-0-84" / S:220V

*The transformer should be "center tapped" at the primary side.

**You can make the secondary 110v if needed.

***The transformer in the pic is a custom made (48V center tapped / 220v ) 2000

watts, weights like 10 kilos.

3> R1 is to set the PWM duty cycle to 220v. Connect voltmeter to the output of

your inverter and vary VR1 till the voltage reads 220V.

4>R2 is to set the frequency to 50 or 60 Hz (R2 range is between 40Hz to

75Hz), so guys that do not have a frequency meter are advised to blindly put this

variable resistor mid-way which should drop you in the range of 50~60 Hz.

If you want you can substitue the variable resistor with a fixed resistor using the

following formula: F = 1.3 / (RxC)

in our case to get a 50Hz output we remove both the 100K and the variable

100K both from pin 6 and we put instead a 260K fixed resistor and we leave the

0.1uF (the 104 cap) as it is, this change should give out a fixed 50Hz as per the

formula :

1.3 / (260,000 ohm x 0.0000001 farad) = 50Hz

But in reality it will not exactly give 50Hz because the 260K resistor has a

specific error value margin so does the capacitor, that's why i recommend a

variable resistor so that accurate calibration can be achieved.

5>Use either tantalum or polyester film "as in pic" for the 104 caps, ceramic disc

caps change value once hot and this in turn changes the frequency of the

inverter so they are not recommended.

6> Pin 10 of the SG3524 can be used to auto shut down the inverter, once

a positive voltage is given instead of negative to pin10, the SG3524 will stop

oscillating. This is useful for persons wanting to add some cosmetic makeup to

their inverters like overload cutoff, low battery cutoff or overheating cutoff.

7>Wiring connections on the power stage side should be thick enough to

handle the huge amps drain from the batteries. I marked them with dark black

on the schema also I included a pic so you see how thick those wires must be.

8> The design does not include a battery charger since each person will be

building a custom version of the inverter with specific power needs. If you are

ordering a custom made transformer you can ask them to take out for you an

additional output wire on the primary side to give 14v (between point 0 and this

new wire) and use it to charge a 12v battery, of course this needs a seperate

circuit to control charging auto cut-off. But anyway this is not advisable because




4 sur 14 01/03/2014 13:22


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it will shorten the life of the transformer itself since using it as a charger will toast

the enamel coating layer of the copper wires over time. Anyway .. YES can be

done to reduce cost.

9>A cooling fan will be needed to reduce heat off the heat sinks and

transformer, i recommend getting a 220v fan and connecting it to the output T2

transformer, when you power up the circuit the fan will start this will always give

you a simple way to know that 220v is present and everything is OK.. You can

use a computer's old power supply fan if you like.

Note that the fan must suck air out from the inverter case and NOT blow inside,

so install it the correct way or it will be useless.Also note how I fixed both the heat sinks and where the fan is, in a way that the

fan sucks hot air from like a channel between the 2 heatsinks.

10>2 circuit breakers are recommended instead of fuses, one on the DC side

and one on the AC side, depending on your design

Ex: for a 24vDC ( 1500 watts design ) put a 60Amp breaker on the DC side and

a 6Amp on the AC side.

For every 1amp of 220vAC you will be draining like 8 to 10 Amps from the 12v

battery, make your calculations !

11>The 2 Heat sinks should be big enough to cool the transistors, they are

separate and should NOT touch each other. "see the pics"

12>Important: If you're building a big design that uses more than 24VDC as

power source, make sure not to supply the driver circuit with more than 24v

maximum. (EX: If you have 4 batteries 4x12 = 48v , connect the v+ supply of the

driver circuit to the second battery's (+) terminal with a thin 1 mm wire which is

more than enough. this supplies the driver circuit with +24v while supplies the

power transformer with +48v) "see the batteries pic example"

13>"Optional" : Deep Cycle batteries are your best choice, consider them for

best results .. read more (http://en.wikipedia.org/wiki/Deep_cycle_battery)

14>Be cautious when building this circuit it involves high voltage which is lethal,

any part you touch when the circuit is ON could give you a nasty painful jolt,

specially the heat-sinks, never touch them when the circuit is on to see if the

transistors are hot !! I ate it several times :)

15>The optional "Low voltage warning" is already embedded in the PCB layout,

you can disregard it and not install it's components if you do not needed. It does

not affect the functionality of the main circuit.

16> The Motorola 2N6277 is a durable heavy duty power transistor, it is used in

many US tanks for it's reliability but unfortunately it is a very hard to find

part, instead you can substitute each 2N6277 with 2 x 2N3773 or any

equivalent.

17>I've included an optional "Battery level indicator" circuit diagram that has 4

LEDs, you can see it installed on the front panel of my inverter pic, it is

functioning great and shows precisely how much juice the batteries still have. I

have included a small relay that is powered by the last LED to auto shutoff the

inverter once last LED is off.

18>Also included an optional "Overload circuit", it is very easy to build and can

be calibrated to the desired overload current threshold cutoff point through the

potentiometer VR1.

R1 is rated 5watts for inverters upto 1000 watts. For bigger versions of the

inverter like 1000 to 3000 watts inverters, replace R1 (1 ohm, 5watts) with (1

ohm, 17watts) which should handle loads upto 10 VA.Make sure you install a proper relay to handle big current drains.

19> Please guys t ake your time to read and understand my notes, browse

and read the posts and questions asked by others because there are many

useful information listed in replies. The main reason for me not

answering your question is because it has already been asked before and




5 sur 14 01/03/2014 13:22


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Make Comment

(/member/safeermaher/)

2 days ago Reply (CMJ4381HS18HR50)

(/member/nickk/)

yesterday Reply (CCEOD1RHS3GV7UU)


yesterday Reply (CEQ14OVHS5OUFT6)

answered upon.

20> It would be nice and inspiring for others if you take some photos and

show us how you built your version, any additions to the circuit are mostly

welcomed to be listed here, we can all benefit fr om them.

safeermaher (/member/safeermaher/)

Hi, it is Micheal

I saw your design in here and i thought about trying it and fortunately i found your

circuit already made in the market so i bought it ;)but after connecting it with transformer (50 Amps) and d313 and tip35 transistors i

got low voltage "around 160v" and the low voltage alarm was already built in that

circuit and it always keeps toning for no reason!!!

can you please help me.. i tried to set the voltage to the higher and the frequency

as well but the voltage didnt exceed 170v i added few capacitors at the output so i

get 200v but it drops down to 170 when loaded with 100w lamp

i've uploaded a pic.. please check it

please any advise.. thank you very much

(http://cdn.instructables.com/FQQ/Y4B2/HS18HR3F/FQQY4B2HS18HR3F.LARGE.jpg)

nickk (/member/nickk/)(author) safeermaher

d313 and tip35??

where do you see those in my

schematic?

safeermaher (/member/safeermaher/) nickk

hi..

thank you for your note about the

transistors..

i replaced them with tip122 and

2n3773 transistors

but i still have low voltage...

can i change the windings of my TS to

9-0-9 ? do you think that this can solve

the problem?

and one more question please.. what

can i do regarding the voltage

decrease while connecting the load?




6 sur 14 01/03/2014 13:22


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nickk (/member/nickk/)(author) safeermaher

1- does your 12v battery drop below

12v when the inverter is on ?

2- did you set the frequency 50Hz?

3- did you regulate with R1 to get the

voltage to 220v ?

4- if you checked all the above and

still your 220v drops, try to set the

frequency to 60Hz

5- send us feedback


Dear nick..

thank you for your quick replies.. :)

about your questions:

1- i tried two batteries.. one of then

doesn't drop below 12 while the

other drops to 11.7v but both of the

battery are doing great with

commercial normal inverter 1000w

2- the frequency was already set to

50hz when i bought it.. but it didnt

work well

3- i regulated the R1 to maximum

that what caused in that time about

10v raise.

4- i also set the R2 to maximum i

got a naughty sound from the

transformer in this case, but any

way the voltage still low..

i even tried an other TS made byother manufacturer and i still have

the same problem..

kindly awaiting for your replay :)


about the old d313 and tip35 they was

advised by the one who made the

circuit ;-)

chukzy3700 (/member/chukzy3700/)

Hello Mr. Nickk. Please I want to know the voltage of the Electrolytic Capacitors

used: 220uf, 1uf, 10uf, 4700uf and 47uf. Please what is there voltage.. I hope to

hear from you soon. Thanks..




7 sur 14 01/03/2014 13:22


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nickk (/member/nickk/)(author) chukzy3700

50v should be ok

ssr ivastava11 (/member/ssrivastava11/)

hey Nick nice work

I need some of your advice..!!

I am planning to make 2kVA inverter for my solar panels.I have 250 watt 4 solar panel.

The Voltage rating of each panel at full load is 37.15 volts

The Current rating of each panel is 6.73 amps.

On the AC side I have a load of a water pump (0.5~1 hp) + 200 watt load.

My teachers told me to go for series connection for the solar panel since high

voltage is easy to handle than high current.

I don't have any battery system in my Inverter setup just the dc supply is given by

solar panels.

I would like your opinion and suggestions about it.

Jawaaz (/member/Jawaaz/)

Hello Nick,

I have made the design you have posted and I was successful in getting a

oscillating output from emitter A and emitter B from SG3524.I build a test power

stage using a single pair of IRFZ44N mosfets for negative and positive half cycles

respectively and used a 12-0-12 .5A small transformer for it.I have the following

problem:

WHen I connect the transformer to the supply,The primary reads 24VAC across as

it should be but the secondary reads only 145VAC..I also checked the transformer

at 220VAC output and it gave me exactly 24VAC on primary,so I am puzzled why I

am getting 145VAC when primary is 24VAC,Is there any problem in flux generation

for square wave signal???I am scratching my head..

nickk (/member/nickk/)(author) Jawaaz

Hello Jawaaz,

Please upload a photo of your setup.

Jawaaz (/member/Jawaaz/) nickk

HEllo Mr. Nick,

Well I have rectified my problem now,actually I was only getting 32hz of

frequency and at that frequency ,the induction process fails and cannot

transfer all of the potential to the secondary coil,so I increased the

frequency to about 60hz and the voltage on secondary coil got increased to

optimum level...I guess in a transformer,the voltage on output side is

directly proportional to the frequency of the potential on primary side...SO

FOR ALL THE PEOPLE WHO ARE GETTING LESS OUTPUT VOLTAGE

ON SECONDARY SIDE,TRY TO INCREASE THE FREQUENCY FROM

50HZ TO 60HZ AND RECHECK YOUR SECONDARY VOLTAGE AFTER

THAT...

josfemi ( /member /jos femi/) Jawaaz

i have never experience this before, if i increase my frequency my output

voltage remain the same and if i decrease my out put voltage still remain

the same

nickk (/member/nickk/)(author) Jawaaz




8 sur 14 01/03/2014 13:22


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8 days ago Reply (CIUSRF6HRTKK6EG)

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8 days ago Reply (CM3C94IHRTKK8J9)

Thanks for this

clarification.

reach2beelal (/member/reach2beelal/)

Hi nickk,

Plz i need ur clarification can i wind my inverter transformer to 310v at d output

and brings it back to 220v using feedback to avoid voltagedrop at the output

Plz what do i do to improve ur circuit so that pin10 should dectate low battery and

shutdown

nickk (/member/nickk/)(author) reach2beelal

no it doesn't work this way. the 220v

will not drop unless the battery starts

to get empty, when this happens

nothing will bring your 220 back.

reach2beelal (/member/reach2beelal/) nickk

Hi nickk

What I mean is when I wound my

transformer to 12v input and 230v

output. When a connect the

transformer and start d inverter it

gives me 230v at the output BUT

when I connect load at the output the

voltage drops to less than the voltage

without the load. The more I add the

load the more voltage drops SO

WHAT'S IS THE PROBLEM

That is why Isaid if during winding I

increased the number of turn is the

secondary to reach may be 300v and

the used ur circuit to brings it down to

220v CAN THE INVERTER WORK

FINE

reach2beelal (/member/reach2beelal/) nickk

Hi nickk

What I mean is when I wound my

transformer to 12v input and 230v

output. When a connect the

transformer and start d inverter it gives

me 230v at the output BUT when I

connect load at the output the voltage

drops to less than the voltage without

the load. The more I add the load the

more voltage drops SO WHAT'S IS

THE PROBLEM

That is why Isaid if during winding I

increased the number of turn is the

secondary to reach may be 300v and

the used ur circuit to brings it down to

220v CAN THE INVERTER WORK

FINE




9 sur 14 01/03/2014 13:22


10/14

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Anthony 56 (/member /An thony56/)

Need your urgent help & urgent advise for a Solution and possible root causes &

reasons of my problem encountered here ?

Can not obtain AC output Voltage 230V AC& Output Current 2A by using500VA(500W) 12V/230V TRANSFORMER . I hv completed building thecircuit accordingly but the maximum output voltage only 83V ( SecondaryWinding of T2 ) & maximum output current 0.06A only using Load 28W 230V

AC Bulb Or 100W 230V AC Bulb,observation Bulb can light up dimly only.The Input Current of 8A (Ammeter Reading ) 12V at Primary Winding ofTransformer T2. The Transformer T2 used here bought from the shop is500VA(500 Watts) 12V/230V AC. Also Lead Acid Battery 12V DC 60A Maxused in this project.

1.

From the pin 14(SG3524) using Q2 BC337,Q4 TIP122,2N3055,4pcs 2N3773

replaced the 2N6277 that is Not available from the shop and adding a small 0.1

Ohms 10Watts Resistor in series with Primary Winding of Transformer T2.The

Load 28W 230V AC Bulb can not be lighted up without added a 0.1 Ohms 10Watts

Series Resistor. Why Need to add a 0.1 Ohms Resistor to primary winding of T2

only to obtain the 83V Output Voltage ? Not Sure Why need this additional 0.1

Ohms Resistor & Need Urgent Advise.

Wherelse from your project Original Circuit do not require this additional 0.1 Ohms

Resistor to T2 that can even produce Output Voltage 230V AC from Transformer

T2 per your circuit description & explanation ?

From pin 11(SG3524) using Q3 BC337,Q7 TIP122,2N3055,4pcs 2N3773 replaced

2N6277 that is Not available from the shop.

Attached the Photos of the 50 Hz [ Positive Cycle (pin14) & Negative Cycle (pin

11)]

Hope to hear from you all & thks in advance.

Here is my email: [email protected]

(http://cdn.instructables.com/FDC/UVBD/HRTKJ3OS/FDCUVBDHRTKJ3OS.LARGE.jpg)

nickk (/member/nickk/)(author) Anthony56

Also calibrate the frequesncy to 60Hz

instead of 50Hz which I presume you

already did.

Please send feedback.

nickk (/member/nickk/)(author) Anthony56

Hello Anthony56

(http://www.instructables.com/member

/Anthony56/)

Did you calibrate with T1 to bring the

voltage up to 220?

johann es8316 (/member/johannes8316/)

i m almost done in creating this circuit using mosfet IRFP250 as power stage but

when i test the wattage the output is too low.

1. is your figure for power stage using mosfet is the same output as power stage

transistor.?

2. and how many mosfet IRFP250 can generate 1000~1500 watt output?




10 sur 14 01/03/2014 13:22


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nickk (/member/nickk/)(author) johannes8316

how much is (too low) ?, how many

did you install in parallel and what

were you expecting? how big is your

power transformer?

spilgrim1 (/member/spilgrim1/) nickk

We can power a simple hand drill but when we test the fan an Electric fan it

doesn't spin.we are making the inverter to work at atleast 1500 watts for aircondition

unit.

we install 6 parallel mosfets IRFP250 as seen on your diagram..

our transformer is 12 0 12 6 amperes..

should we replace the transformer?

how many mosfets should we add to meed the atleast 1500 watts of

output?

nickk (/member/nickk/)(author) spilgrim1

6 amperes ???? "if you read my note

#10:

"For every 1amp of 220vAC you will

be draining like 8 to 10 Amps from

the 12v battery, make your

calculations !"

for 1500w you'll need a 70 amperes

trans. !

johann es8316 (/member/johannes8316/)

hey nick..there is a problem in the output of my circuit, when i turn on the device

the output is 220 vac and then its suddenly drops to 110 vac.

what do you think is cause of the problem?

and

if its ok for you, i will send my modified design.

nickk (/member/nickk/)(author) johannes8316

did you find out what was the

problem?

lovelyfact (/member/lovelyfact/)

Hello dear,

I need 1500watts inverter for that, can i use 24volt solar panel instead of 24volt

battery?

In that inverter can i run 2HP waterbump?

Need ideas,

nickk (/member/nickk/)(author) lovelyfact

No you can't. you don't have any idea what you're doing .. do you :)

cabingas (/member/cabingas/)




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14 days ago Reply (CVL7D6MHRKR1K4M)

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1 month ago Reply (CODMFBSHQLO51XB)

i made this project and its

working for me thanks Nick.

very useful

nickk (/member/nickk/)(author) cabingas

You're welcome :)

vam540 (/member/vam540/)

i want this inver how much it costs

(/member/%D0%90%D0%BA%D1%80%D0%BE%D0%BC/)

Hello! At the output of your inverter sine

wave amplitude as in the socket? And could

you give all the drawings for the study?here

is my e-mail: [email protected]

Mohammedhanafy (/member/Mohammedhanafy/)

Hello Nick

I build the Mosfet inverter but i got no output

i measure the voltage on pin 11 and pin 14 it

was both together 1.5 volt ... any ideas

Kushlendr (/member/Kushlendr/)

Hello sir,

I am from (Kolkata) India. I am new here and new in electronics field, I have to

complete my college project of 300 watt inverter..I have some question to

complete this project, please sir help me to complete my 300 watt inverter.

1) can i make 300 watt inverter from this circuit ?

2) sir i have 12v 7.2AH SMF Battery, so can i use it for 300 watt inverter or i have

to buy 12v car battery ?

3) how many 2N6277 heavy duty power transistor, i will use for making 300 watt

inverter from 12v battery?

4) or if i have not found this 2N6277 transistor, then how many 2N3773 transistor

will i use?

4) for making 300 watt inverter from 12v battery, what is my transformer rating ? I

mean to say what is the amp of my 12v transformer for making 300 watt inverter ?

5) in the picture 220/12 0.5 Amp transformer is used. Is this used for battery

charger? and 0.5Amp is equal to 500MA ?

sorry for my bad English. please help me sir.


Hi nickk,

Plz i need ur clarification can i wind my inverter transformer to 310v at d outputand brings it back to 220v using feedback to avoid voltagedrop at the output

Plz what do i do to improve ur circuit so that pin10 should dectate low battery and

shutdown




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1 month ago Reply (CAZH47THQ9PXA78)

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grateed (/member/grateed/)

hi sir its this a pure sine wave? thank you

grateed (/member/grateed/)

hi sir its this a pure sine wave? thank you

Jawaaz (/member/Jawaaz/)

HEllo Mr. Nick,

Well I have rectified my problem now,actually I was only getting 32hz of frequency

and at that frequency ,the induction process fails and cannot transfer all of the

potential to the secondary coil,so I increased the frequency to about 60hz and the

voltage on secondary coil got increased to optimum level...I guess in a

transformer,the voltage on output side is directly proportional to the frequency of

the potential on primary side...SO FOR ALL THE PEOPLE WHO ARE GETTING

LESS OUTPUT VOLTAGE ON SECONDARY SIDE,TRY TO INCREASE THE

FREQUENCY FROM 50HZ TO 60HZ AND RECHECK YOUR SECONDARY

VOLTAGE AFTER THAT...


Hi nickk, Plz I deed ur clarification on mosfet wattage n current rating becos am

comfused. Some one told me EX. 1) If u build 1000w inverter u'll need 100amp

current. So if u use IRFP150N which has( 100V,42A) So u assumed d current to b

30A instead of 42A due to temperature therefore u'll have 30A * 4(mosfet) equal to

120A on each side is it correct . 2) Or u'll have if d mosfet is

IRFP150N(100V,42A,160W)frm d datasheet u will need 160w * 7(mosfets) equal

to 1120w on each side forgetin about current. Sir which one is right

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All content on Instructables including How To's, Downloads, Images, Comments are Copyright 2014 Autodesk Inc. All rights reserved.250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)



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250 to 5000 Watts PWM DC_AC 220V Power Inverter