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9W2ZSU = http://qrz.com/db/9w2zsu
9W2ZSU = http://qrz.com/db/9w2zsu Circuit diagram below is my full 1000W SMPS inverter circuit
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MANDATORY COMPONENT NTC resistor -for prevent inrush current surge what can cause H bridge mosfet BLOW Fast Recovery Diode this SMPS need fast diode..if use normal diode will cause entire circuit less power output then expected. DO NOT alter voltage limiter resistor value-(feedback dc bus voltage at pin 1) alter this resister value can cause output ac voltage increase or decrease.
FIRST TIME START UP PROCEDURE Set oscilloscope probe.clamp it at TP1 and TP2 test point Turn on 12v main power source circuit and set 50hz frequency at 100k pot DO NOT touch any circuit with hand.!! electric shock!! this inverter can KILL you! After done set frequency, please discharge 330uf 400v capacitor with 36R 5W resistor! Use digital TRUE RMS multimeter for measure output ac voltage.do not use cheap china multimeter will give you false reading voltage.
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TRANSFORMER CALCULATION A good starting point is using 5 turns for each primary (that is, 5 turns, centre tap and another 5 turns IN THE SAME DIRECTION). To calculate the number of turns of the secondary winding, multiply by the turns ratio. For example, if you want to build a +/- 400VDC bus supply from 12VDC, the turns ratio is 400V/12V=33.3 approx, so 33.3 x 5 = 166T (The 5 is primary) The secondary turn is 166T (better 176 turns, to overcome the diode losses) . You MUST use enamelled copper wire for all the windings. Keep also in mind that when working with high frequencies, the effective section of the wire is much smaller than the physical one, due to the "skin" effect (the current concentrates only in the outer part of the wire). As high currents are involved here, the section of the wire is very important, (if you don't want the enamel to fuse due to the heating produced by the resistive losses of the wire and short all the windings). A good practice is to use several thinner wires in parallel rather than a single thick one. This also eases winding. For example, three AWG 13 diameter wires can form a suitable primary for a 1000w DC bus supply.Three AWG13 winding in PARALLEL The same applies to the secondary, although the current is reduced so you can use less wires
9W2ZSU = http://qrz.com/db/9w2zsu
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For perform 1200w you will need two ferrite torodial core for high power dc-dc converter with high switching frequency 50-60khz
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I am use this Ferrite torodial spec: FT 37 77 OD 37mm ID 23mm Height 15mm Material code -77
This single toroid capable supply load 600w continuously at 55khz frequency
Becareful..make sure double check your winding core before assamble..wrong winder will cause short circuit or blow the power mosfet..all wire winding in one direction..follow the step number.
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Do not use iron powder toroid..or the project will failed..the iron powder has lower Q For application dc-dc converter need high Q rating,high volume resistivity and permeability. FT ferrite was choosen..material type 77
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The tiny ferrite FT-37 has more power if compare bulky iron core 9 0 9 400VA Iron core 9-0-9 400va -Price = RM 200.00 / usd 66.00 (expensive) -Maximum watts = 400 450watts -Efficiency = 50% or lower depend on battery voltage. only pro in high robust. Ferrite FT-37 toroid -Price = RM 3.00 / usd 1.00 (cheap) -Maximum watts = 500 600watt depend on switching frequency and high efficiency 80-90%
9W2ZSU = http://qrz.com/db/9w2zsu
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High RPM cooling fans..recycle aluminum SMPS casing fitted my 1200w inverter apply on my small solar system.
9W2ZSU = http://qrz.com/db/9w2zsu
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I have blow dozen of mosfet IRF740 during this research.lucky this mosfet cheaper here. Most of fets blow because unbalance NTC resistor value..un proper cooling system and false frequency switchingnow my inverter well perfect in term robust and power.
NOTE : The two circuit diagram 600w and 1200w just basic heart of inverter..i never put overload protection and low voltage shutdown coz I dont want somebody use my circuit for commercial inverterif you want..you create you self design the two protection overload and low volta ge shutdown..
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PICTURE BELOW IS MY 1ST PROTOTYPE DC-DC CONVERTER 12V TO 320VDC FOR 1000W SMPS 1000W SMPS NEED TWO TORODIAL CORE FT-37.
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PIC BELOW 600W my SMPS portable power pack (very use full) say no to stinky noisy GEN-SET
PIC Below 1200w SMPS for small solar hybrid system. this inverter work every day power up my small electronic workshop, my laptop, soldering iron, kitchen exhaust fan also work as power Backup if grid failure. This small solar system also save my electric bill about rm20.00 per month.
homebrew 1200w inverter + homebrew MPPT 20a solar charger + 120w mono panel + 12v 280ah bank 9W2ZSU = http://qrz.com/db/9w2zsu
9W2ZSU = http://qrz.com/db/9w2zsu
*LEFT PIC -150W PROTOTYPE USING PIC16F628A * RIGHT PIC 250W LINER INVERTER (ANALOG) CIRCUIT DIAGRAM BELOW IS 250-500W LINER ANALOG INVERTER.Actually I like this kind of inverter in term of ROBUST ..you can put this inverter outdoor side.hard to damage..if overload or short circuit this inverter just suck a lot battery amps! And nothing any component part damage..the cons is efficiency is only 50% ,unstable voltage,bulky huge,expensive to build and not suitable application in solar hybrid system
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CONCLUSION
Lastly I suggest who want build inverter in a first step go for liner inverter before build more complicated SMPS inverter and I repeat BUILD SMPS inverter is more COMPLICATED than expected INVERTER most people says BETTER BUY THAN BUILD its costlyyes its true for beginning...but..in my opinion when BUY, you only got ONE..but when you success BUILD..you can build thousand of inverter.. Cheerssorry my poor Englishun finish school..coz my teacher death early.. .thank you By Ags Saleem , HAM callsign 9W2ZSU Malaysian.
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